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6wg1-E-0112 (Part1) TroubleDiagnosis
6wg1-E-0112 (Part1) TroubleDiagnosis
6wg1-E-0112 (Part1) TroubleDiagnosis
ECM control
DTC
Sensor output
V
V
RPM
RPM
Snapshot V
V
%
TSWG0121
Electronic Control Fuel Injection System (Common Rail Type) 1E-13
Trouble diagnostic procedure
Step 1 Confirm the user’s complaint
• Organize the trouble conditions using a check list.
TSWG0156
TSWG0155
TSWG0160
Name
1. Trouble symptom
2. Frequency of trouble occurrence / trouble condi-
tions
Because:
• It may be impossible to reproduce the trouble
symptom at a service shop.
• All of complaints from customers do not always
mean troubles.
Electronic Control Fuel Injection System (Common Rail Type) 1E-15
TSWG0155
1E-16 Electronic Control Fuel Injection System (Common Rail Type)
Pre-inspection Trouble diagnosis
Visual inspection of engine compartment Basic knowledge for required tools
Visual inspection of engine compartment should be Important:
carefully when performing the diagnostic procedure. If performing the diagnostic procedure, no basic
This inspection can often solve the trouble with no extra knowledge on this powertrain may lead to faulty
steps. If performing visual inspection, follow the guide- diagnosis or damage to powertrain components. If
line below. you do not have basic knowledge, do not perform
• Check all the air hoses etc. for punch hole, cut, dis- the diagnosis of the trouble relating to powertrain.
connection or improper routing. Basic understanding on hand tools, such as scan
tools, is required to utilize service manual effec-
• Inspect the hoses hidden behind other compo-
tively.
nents.
• Check if all the harnesses of the engine compart- About on-board diagnosis test
ment are properly connected, if there are any burn-
out parts or worn parts, if harnesses are pinched, if Types of trouble diagnosis results are the following.
there are any contacts with sharp edges, or an 1. History trouble
exhaust manifold or pipes in high temperature, etc. Trouble codes which occurred under the following
conditions are called “History trouble”.
Machine maintenance result check • Diagnostic test was completed at previous igni-
If the maintenance of the machine is not properly per- tion cycle.
formed, the diagnosis lamp comes on. Clogging in oil • Diagnosis test has accepted at current ignition
filter or fuel filter caused by insufficient oil change or cycle.
improper oil viscosity and deposit in crankcase may • Faults found by the diagnostic test do not cur-
cause troubles on the machine, which were not found rently exist.
before on-board diagnosis (OBD) system check.
2. Present trouble
Though improper maintenance of the machine is not
Trouble codes which occurred under the following
classified as “The trouble caused by other than a
conditions are called “Present trouble”.
machine”, a maintenance schedule should be more
strictly followed because of high sensitivity of the on- • Diagnostic test was completed at previous igni-
board diagnosis (OBD) system check. tion cycle.
• The faults detected by the diagnostic test cur-
Non-OEM parts rently exist.
All the on-board diagnosis system checks are adjusted • The faults exist at current ignition cycle.
to be operated by genuine parts. Therefore, if a com-
mercial general sensor or switch is installed, the diag- Description of terms
nosis lamp comes on due to faulty diagnosis. Diagnostic trouble code (DTC)
If commercial electronic devices, such as mobile Every time turning the key switch to ON, the ECM per-
phone, stereo, antitheft device, etc. are installed and forms self-test of most wiring and components and
their installation is not proper, EMI (electromagnetic stores the detected faults in memory. For some DTCs,
interference) may be discharged to the control system. it also performs the back-up control. If the fault which
That leads to the generation of fault sensor information affects operation occurs, the diagnosis lamp comes on
and the diagnosis lamp comes on. When performing to notify an operator.
trouble diagnosis, turn the power of all commercial
parts to “OFF” or remove those parts, and check for Ignition cycle
faults again. Ignition cycle is defined as Key ON, Run and Key OFF
so that the machine can be operated under the speci-
Information: fied diagnostic standard.
At code [23]
Goes off
At code [413]
ON
Goes off
TSWG0023
Note:
• Refer to the machine’s manual for the locations of
memory clear switch and diagnosis switch.
• Perform the same procedure to clear memory
regardless of forms of switches (switches, connec-
tors). (ON = Connection, OFF = Disconnection)
Electronic Control Fuel Injection System (Common Rail Type) 1E-21
Value
TSWG0182
Name
1. Tech2 and scan tool with KW communication
2. Scan tool with CAN communication
ECM control
DTC
Sensor output
V
V
RPM
RPM
Snapshot V
V
%
TSWG0121
Function of Tech2
Data display
This displays conditions recognized and controlled by
ECM at each items.
The values of display items is described in typical data V
of Tech2 data list. V
The contents of display items describe about data. RPM
RPM
V
V
%
MPa
TSWG0098
Snapshot
To find the cause of trouble, perform this snapshot to
review the data.
• The snapshot can record the data list menu and
plot a graph.
• Utilizing this mode, reproduce and record the con-
ditions claimed by the customer to identify the data
fault.
• The trigger type allows to record the data of the
time when DTC is displayed.
• The stored data can be replayed with a domestic
power supply.
Programming
Confirm the data history before replacement of ECM.
(Data confirmation) Then, upload the data to the
Tech2. After replacement of ECM, download data from
Tech2 to new ECM.
Actuator test
Perform each test to check the operation or function of
appropriate parts for faults.
When giving instruction to ECM from test screen, set
the select switch of the Tech2 adapter to “2” position.
Caution:
Each test may not performed if the machine, engine
operation status, coolant temperature, vehicle
speed, switch status, gear position, etc. does not
meet conditions or if DTC is detected.
Electronic Control Fuel Injection System (Common Rail Type) 1E-25
1 5
3 4
TSWG0148
Name
1. PCMCIA card 4. DLC cable
2. SAE 16/19 adapter 5. Tech2
3. Power cable
1E-26 Electronic Control Fuel Injection System (Common Rail Type)
Each part of Tech2
Name
1. Softkeys 10. Fastening bar of VCI module
2. Selection keys (Arrow keys) 11. Connector of DLC cable connection
3. Action keys (YES, NO, ENTER, EXIT) 12. Connector for AC adapter connection
4. Function keys (F0 — F9) 13. PCMCIA card insertion slot with cover
5. Help key (?) 14. PCMCIA card release button
6. Control keys (PWR / SHIFT) 15. Connector for external communication (RS-232
7. Wide stand port)
8. Display area (LCD) 16. Connector for external communication (RS-485
9. Machine communication interface (VCI) module port)
TSWG0115
TSWG0116
Note:
Use of the external power (AC power) does not allow to
utilize the applications.
TSWG0117
Connection of power
TSWG0162
Name
1. Battery cable 2. Power socket cable (AC/DC adapter)
Battery cable
This cable should be used, in the case where no power
is supplied even when the Tech2 is connected to the
machine through the machine DLC cable, or where the
machine works with a higher voltage than the operating
voltage of the unit. When connecting the cable, pay
heed to the polarities of the clamps. (The black clip of
the cable is to be connected to the negative terminal of
the battery and the red clip to the positive terminal.)
Caution:
In the case of a 24-V machine, connect to battery
on the body ground side to take out 12 V.
1E-30 Electronic Control Fuel Injection System (Common Rail Type)
How to connect Tech2
1. Insert the PCMCIA Card with the latest version of
ISUZU system into the Tech2.
2. Connect the SAE 16/19 adapter to the DLC cable.
3. Connect the DLC cable to the Tech2.
4. Make sure that the key switch is OFF.
5. Connect the SAE 16/19 adapter of Tech2 to the
machine DLC.
Caution:
Connecting method varies depending on each
machine. Refer to the machine’s manual. The fol-
lowing description is for the machine with DLC.
TSWG0141
Caution:
Be sure to use the power socket cable adapted to
local standards. Otherwise, it may result in failure
of Tech2 or power socket cable due to different
voltage and current depending on regions.
PCMCIA Card
Check to see whether the slot (upper side) has this
card inserted with its “Tech2” label side up.
Caution:
If the card is not inserted properly and the unit is
switched on, “NO PCMCIA CARD INSERTED” will
appear. If that is the case, turn off the power and
redo the insertion of the PCMCIA Card.
Connection
Check to see whether the DLC cable is fitted with an
adapter compatible with the machine.
TSHK0144
Note: 6. Turn the ignition switch to ON and press the
Before connecting the cable to the machine, verify that “PWR” key of the Tech2.
the key switch is in the “OFF” position.
7. Check the display of the Tech2.
Caution:
In the case of a 24-V machine, connect to battery
on the body ground side to take out 12 V.
Electronic Control Fuel Injection System (Common Rail Type) 1E-31
Note:
• If the LED fails to come on, it means a malfunction
of the LED, not a malfunction of the SHIFT key.
• Absence of sound means a malfunction of the
Sound Transducer*1, but the unit can be used as
is, without any problem.
*1. Sound Transducer: The sound is intended to
indicate the completion of a data setup or an error
in a setup.
TSWG0110
Caution:
Be sure to turn off the power of Tech2 when install-
ing/removing the PCMCIA card.
Start-up
The Tech2 is designed to automatically conduct a self-
function test every time it is started. Immediately after
the unit has been switched on, the “SYSTEM INITIAL-
IZING” message will appear. During this period, POST TSGW0085
(Power-On Self Test) is carried out, and if the test ends Pass: Normal, Fail: Abnormal
normally, a sound will be issued at the completion of
the test. Simultaneously, the LED of the SHIFT key will Note:
momentarily come on. This is also meant to check the Only for UART, SCI, RTC, and CLKMEM in particular,
normality of the LED. the test result may appear as “Fail” without this mean-
ing any trouble. For “Fail” above, refer to 1E-46, “Tool
option menu, Tech2, How to Use Trouble Diagnosis-
related Tool”.
TSWG0084
Note:
Except industrial engine.
WARNING:
Press [ENTER] While this function is under execution, do not con-
nect the unit to the machine!
TSWG0086
F0: Diagnostics
Allows the user to check data, including Tech2-compat-
ible DTC (Diagnostics Trouble Codes), Data Display,
Snapshot, Miscellaneous Tests, etc., by selecting a
machine ID and System.
• DTC: Shows the contents and situation of DTC
stored in the controller of the system.
Electronic Control Fuel Injection System (Common Rail Type) 1E-33
TITLE AREA
Shows the item currently selected.
MESSAGE AREA
Shows a supplementary explanation or instruction.
V DISPLAY AREA
V Displays data parameters and values (9 lines x 23
RPM characters)
RPM
V FULL TEXT AREA
V Shows details of the parameter under the highlight bar.
%
MPa SOFT KEY AREA
The softkeys below the function item display boxes are
valid.
TSWG0087
Name
1. TITLE AREA
2. MESSAGE AREA
3. DISPLAY AREA
4. highlight bar
5. FULL TEXT AREA
6. SOFT KEY AREA
TSWG0161
1E-34 Electronic Control Fuel Injection System (Common Rail Type)
Diagnostic procedure
1. When the Tech2 is switched on, the software ver-
sion and the model year applicable to the software
will also be shown. Confirm the display and press
[ENTER].
TSWG0089
TSWG0110
TSWG0090
TSWG0088
Note:
Select the model year of the relevant machine by
checking VIN of each machine.
Electronic Control Fuel Injection System (Common Rail Type) 1E-35
TSWG0091 TSWG0093
6. Select Powertrain (Eng. name) on the “Vehicle 8. The following illustration shows the state in which
Identification” screen and press the [ENTER] key. the Tech2 is waiting for communication with the
machine controller. If the softkey “Next” is pressed
with the ignition key in “OFF”, this display will stay
forever. (State of communication disabled) How-
ever, turning the ignition key “ON” to “START” in
this condition will place the unit in the waiting state
for communication.
TSWG0092
d
TSWG0094
DTC check
1. Select “F0: Diagnostic Trouble Codes” on the
“Engine” screen.
TSWG0123
If DTC stored
TSWG0095
TSWG0098
V V
V V
RPM RPM
RPM RPM
V V
V V
% %
MPa MPa
TSWG0099
1E-38 Electronic Control Fuel Injection System (Common Rail Type)
Snapshot About trigger type:
1. Select “F2: Snapshot” on the “Engine” screen. Choosing the Trigger Type Menu allows to check the
cause that triggered [Snapshot]. [Snapshot] is exe-
cuted when there is one of the three causes of occur-
rence.
F0: Manual Trigger:
Pressing the softkey “Trigger” saves data.
F1: Any Code:
Data is saved in case any trouble code is issued.
F2: Single Code:
Data is saved in case the specified trouble code is
issued.
TSWG0102 TSWG0104
Plot
Snapshot can also be replayed in “View Captured
Data.”
Plot setup procedure
1. Pressing the softkey “Plot” switches the “Data Dis-
play” screen.
RPM
MPa
TSWG0105
V Plot cancel
V
To close the graph display screen, press the [ENTER]
RPM
key and you will be returned to the “Data Display”
V
V screen.
%
TSWG0103
Select frame
C
TSWG0106 1. Press softkey “Select Frame.”
Name
A. Maximum values of selected parameters
B. Minimum values of selected parameters
C. Values of selected parameters at Center Point
(E) in frame RPM
D. Number of frames/time MPa
E. Center point of graph indication
V
V
RPM
V
V
%
1
TSWG0103
TSWG0124
Softkey functions
Choose the “More” on the snapshot graph display
screen.
• Move m: Allows to view changes of data preceding TSWG0125
the display screen.
Electronic Control Fuel Injection System (Common Rail Type) 1E-41
• First Frame: First frame No. and data acquisi- 2. Start the engine and run it at idle.
tion time from Trigger Point (calculated back- 3. Select the Common Rail System.
ward).
• Last Frame: Last frame No. and data acquisi-
tion time from Trigger Point (integrated).
• Go To Frame: Entering a frame No. allows to
view its data.
• +/-: Only the “-” sign is displayed.
3. “1” entered via keys in the “Go To Frame” area.
V
V
RPM
RPM
V
V TSWG0128
TSWG0107
Actuator test
TSWG0130
TSWG0127
V
V
RPM RPM
MPa RPM
V
V
%
TSWG0139
TSWG0131
V
V
RPM
RPM
V
V
%
TSWG0132 TSWG0133
6. If the operation sound is heard, electrical circuit of 5. Send the instruction to glow plug relay and check
that injector is judged as normal. whether the lamp on the machine operates.
If the operation sound is not heard, electrical circuit
of that injector or injector body is judged as faulty.
Note:
After injector control test, the key switch must be turned
to OFF once to restart.
TSWG0134
TSWG0137
TSWG0140 TSWG0110
5. Send the instruction to EGR valve and check the 2. Press [ENTER].
data list.
%
%
%
TSWG0108
off.
Set units
Tech2 self test menu Operation procedure:
F0: Automated Main PCB and VCI 1. Choose the “F2: Tool Options” and press
Automatically executes function tests on the Main PCB [ENTER].
and VCI modules. 2. Choose the “F2: Set Unit” and press [ENTER].
F1: Automated Main PCB 3. Display the “Set Unit” screen, and move the cursor
Automatically executes function tests on the Main PCB to the item you want changed by operating the
module. selection keys (▲▼), and press [ENTER] key.
F2: Automated VCI
Automatically executes function tests on the VCI mod- 4. When the setup is complete, press the [EXIT] key
ule. to save the current setting.
F3: Selectable Main PCB
Note:
Allows to check detailed information on the PCB mod-
It will take effect next time the Tech2 is switched on.
ule test items.
F4: Selectable VCI
Allows to check detailed information on the VCI module
test items.
F5: Power On Self Test Results
Displays POST test results again.
Set clock
Operation procedure:
1. Choose the “F2: Tool Options” and press
[ENTER].
2. Choose the “F1: Set Clock” and press [ENTER].
3. Display the “Set Real-Time Clock” screen. Move
the cursor to the item you want changed by operat-
ing the selection keys (▲▼), and press the
[ENTER] key.
Electronic Control Fuel Injection System (Common Rail Type) 1E-47
Rewriting of Q adjust correction data by
Tech2
“Q adjust, Injector code label” is attached to the cylin-
der head cover. It is used for rewriting and registering
the ID.
1 2 3 4
TSWG0145
*Metric
Temperature: qC Speed: km/h
*English
Temperature: qF Speed: MPH
TSHK0098
Name
1. Engine number
2. Typical engine model
3. Q adjust information
4. Injector information
Step 1
• Press [ENTER].
TSWG0110
1E-48 Electronic Control Fuel Injection System (Common Rail Type)
Step 2
• Choose the menu F0: Diagnostics with ▲, ▼ (up/
down) keys or F0 (function) key, and press
[ENTER].
TSWG0090
Step 5
• Choose F0: Engine in Menu with ▲, ▼ (up/down)
TSWG0088 keys or F0 (function), and press [ENTER].
Step 3
• Choose the menu (5) 2005 with ▲, ▼ (up/down)
keys, and press the [ENTER] key.
* Applicable for 2000MY or later.
TSWG0091
Step 6
• Choose 6HK1-TC (C/Rail_TIER3) with ▲, ▼ (up/
down) keys, and press [ENTER].
TSWG0089
Step 4
• Choose the menu (Off-Road) Industrial Engine
with ▲, ▼ (up/down) keys, and press the [ENTER]
key.
Electronic Control Fuel Injection System (Common Rail Type) 1E-49
Step 7-1
TSWG0092
TSWG0122
Step 7
• Press the softkey “Confirm”. Step 8
• The ignition is ON at this time. • Press the softkey “Confirm”.
• This displays the ECU ID information.
TSWG0093
TSWG0094
Step 9
• Choose the menu F4: Programming with ▲, ▼ (up/
down) keys or F4 (function) key, and press
[ENTER].
1E-50 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0050 TSHK0052
Step 10 Step 12
• Choose the menu F0: Q adjust with ▲, ▼ (up/ • Password input screen
down) keys or F0 (function) key, and press • This procedure will end automatically if the regis-
[ENTER]. tration is not completed within 120 seconds.
The message “Time Over” appears.
TSHK0051
TSHK0053
Step 11
• Choose the menu F2: Service mode with ▲, ▼ Step 12-1
(up/down) keys or F2 (function) key, and press • After entering the password, press the [ENTER]
[ENTER]. key.
F0: Uploads the three-point Q adjust data stored in the • The password for 4/6HK1 is “SLNPTL4”.
ECM to the Tech2. • The password for 6WG1 is “SLNPTL6”.
* Registers the data when replacing ECM.
• Entering wrong password will return to the previ-
F1: Writes the three-point Q adjust data temporarily
ous menu.
stored in the Tech2 to the ECM.
* Registers to the ECM after replacing ECM.
F2: Any data can be written. However, password and
ID are required.
Electronic Control Fuel Injection System (Common Rail Type) 1E-51
Note:
The ID code you have entered will appear on the
screen, suffixed with “0”.
The clock of Tech2 must be correctly set.
• After entering, press [ENTER] key.
TSHK0054
Step 12-2
• If the password you have entered is correct, press
the softkey [Okay].
• Enter the password within 120 seconds. Failure to TSHK0057
TSHK0055
Step 13
• After completing the password registration, pro-
ceed to ID registration.
TSHK0058
Step 13-1
Step 15
The numbers will appear on the screen. Obtain the ID
code from Hitachi Construction Machinery service • Displays the three-point Q adjust data in the ECM.
center by using this number (6855 in this case). 1. To modify the Q adjust data, press the softkey
Enter the obtained ID code (2495 in this case). At this “Change”.
time, the suffix “0” will be added to the end of it on the
Tech2 screen. Press the [ENTER] key.
1E-52 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0059 TSHK0099
Note:
Q adjust information in the label attached to the cylin-
der head cover is given in hexadecimal number. Enter
it into Tech2 in decimal number as below.
6 6
Step 15-3
7 7
• If the Q adjust data you have entered is off the set
8 8
value, the message shown as Step 15-4 appears.
9 9
A 10
B 11
C 12
D 13
E 14
F 15
Electronic Control Fuel Injection System (Common Rail Type) 1E-53
TSHK0101 TSHK0103
TSHK0102
Step 15-5
• If the entered values meet the conditions in Step TSHK0104
1 2 3 4
TSHK0105
TSHK0098
Name
1. Engine number
2. Typical engine model
3. Q adjust information
4. Injector information
Note:
Do not enter the six figures “0”, indicated with
strikethrough in the illustration, of ID code on the injec-
tor ID plate. Also, do not enter the letters at the end
with double strikethrough.
Electronic Control Fuel Injection System (Common Rail Type) 1E-55
TSWG0088
Name
1. Injector ID plate Step 3
2. Injector ID code • Choose the menu (5) 2005 with ▲, ▼ (up/down)
3. Injector keys, and press the [ENTER] key.
Step 1
• Press [ENTER].
TSWG0089
Step 4
• Choose the menu (Off-Road) Industrial Engine
with ▲, ▼ (up/down) keys, and press the [ENTER]
key.
TSWG0110
Step 2
• Choose the menu F0: Diagnostics with ▲, ▼ (up/
down) keys or F0 (function) key, and press
[ENTER].
1E-56 Electronic Control Fuel Injection System (Common Rail Type)
TSWG0090 TSWG0092
Step 5 Step 7
• Choose F0: Engine in Menu with ▲, ▼ (up/down) • Press the softkey “Confirm”.
keys or F0 (function), and press [ENTER]. • The ignition is ON at this time.
TSWG0091
TSWG0093
Step 6
• Choose 6HK1-TC (C/Rail_TIER3) with ▲, ▼ (up/
down) keys, and press [ENTER].
Electronic Control Fuel Injection System (Common Rail Type) 1E-57
Step 7-1
TSHK0050
TSWG0122
Step 10
Step 8 • Choose the menu F1: Injector ID code with ▲, ▼
• Press the softkey [Confirm]. (up/down) keys or F1 (function) key, and press
[ENTER].
• This displays the ECU ID information.
TSHK0108
TSWG0094
Step 11
Step 9
• Choose the menu F1: ID code registration with ▲,
• Choose the menu F4: Programming with ▲, ▼ (up/ ▼ (up/down) keys or F1 (function) key, and press
down) keys or F4 (function) key, and press [ENTER].
[ENTER].
F0: Displays the Injector ID codes (hereinafter called ID
code) of Cyl.1-Cyl.6.
Allows you to confirm the ID code after registration.
F2: Uploads (transfers) the ID code (No. 1 cylinder
No. 6 cylinder) registered in the ECM to Tech2 to
store in its memory.
F3: Allows you to download (batch registration) the
uploaded ID codes from Tech2 to the ECM.
1E-58 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0067 TSHK0069
TSHK0070
Step 12-3
• You need to enter the ID on the following display.
TSHK0068 ID code is number of year. The following condi-
tions must be met.
Step 12-1 Conditions:
• The following display appears while checking if the 1. The time setting of Tech2 matches with the cal-
engine speed is 0 rpm. endar.
When the engine speed is 0 rpm, it will take you to 2. Press the function keys (F0 —F9) to enter.
Step 13.
Electronic Control Fuel Injection System (Common Rail Type) 1E-59
TSHK0071 TSHK0073
Step 13 Step 15
• Choose the cylinder (No. 1 cylinder No. 6 cylin- ID code registration (data entry)
der) you want to register the ID code with ▲, ▼ 1. The cursor is positioned at M (model code) in the
(up/down) keys, and press the [ENTER] key. default setting.
• As an example, this describes about No. 1 cylin- MCD0 D1D2
der. 2. At this point, enter the model code (MC) and ID
code (D0) in this order.
• Entering with the function keys (F0 F9) will
automatically move the cursor to the right. How-
ever, if you enter with ▲, ▼ (up/down) keys,
you need to move the cursor with the arrow
(left/right) keys.
3. Data must be entered within $00 $FF.
• You can enter 0 through 9 with the function
keys (F0 F9), or 0 through Z with ▲, ▼ (up/
down) keys.
4. For VC17 (China), BCC code needs to be entered.
NK3 request
• Tech2 calculates the entered data and displays
the following message.
When entered ID code (QR) is off the set value:
Writing unable
TSHK0072
When entered BCC code is off the set value:
Writing unable
Step 14 When the ID code (QR) does not correspond to
BCC code: Writing unable
• To register the ID code, press the softkey
[Change].
• The ID code for Cylinder1 (No. 1 cylinder) selected
at Step 13 is shown here.
1E-60 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0074 TSHK0076
TSHK0075
Step 15-2
• If the ID code you have entered is correct, press
the softkey [Program]. TSHK0077
If you want to quit the program (registration), press
the softkey [Abort] or press [EXIT] key. Step 16
• Quitting the registration or pressing [EXIT] key • If the entered values meet the conditions in Step
returns you to Step 11. 15-1 and 15-3, the status display of data registra-
tion (writing) from the Tech2 to ECM as shown
below will appear.
Electronic Control Fuel Injection System (Common Rail Type) 1E-61
TSHK0078 TSHK0080
Step 17 Step 18
• When the ID code entered in Steps 15-1 and 15-3 • Pressing [EXIT] key returns you to Step 11.
corresponds to that registered in the ECM, the fol-
lowing message will appear. Also, if you want to
register ID again, press the softkey [Yes]. This
returns you to Step 13, and allows you make regis-
tration as before. Pressing the softkey [No] will
take you to Step 18.
This completes the ID code registration.
TSHK0081
TSHK0079
Step 17-1
• When the ID code entered in Steps 15-1 and 15-3
does not correspond to that registered in the ECM,
the following message will appear.
Pressing the softkey [End] returns you to Step 11.
1E-62 Electronic Control Fuel Injection System (Common Rail Type)
ID code upload (Tech2)
Step 1
• Press [ENTER].
TSWG0089
Step 4
• Choose the menu (Off-Road) Industrial Engine
TSWG0110
with ▲, ▼ (up/down) keys, and press the [ENTER]
key.
Step 2
• Choose the menu F0: Diagnostics with ▲, ▼ (up/
down) keys or F0 (function) key, and press
[ENTER].
TSWG0090
Step 5
• Choose F0: Engine in Menu with ▲, ▼ (up/down)
TSWG0088
keys or F0 (function), and press [ENTER].
Step 3
• Choose the menu (5) 2005 with ▲, ▼ (up/down)
keys, and press the [ENTER] key.
Electronic Control Fuel Injection System (Common Rail Type) 1E-63
TSWG0091 TSWG0093
TSWG0122
TSWG0092 Step 8
• Press the softkey [Confirm].
Step 7
• This displays the ECU ID information.
• Press the softkey “Confirm”.
• The ignition is ON at this time.
1E-64 Electronic Control Fuel Injection System (Common Rail Type)
TSWG0094 TSHK0108
Step 9 Step 11
• Choose the menu F4: Programming with ▲, ▼ (up/ • Choose the menu F2: ID code upload (Tech2) with
down) keys or F4 (function) key, and press ▲, ▼ (up/down) keys or F2 (function) key, and
[ENTER]. then press the [ENTER] key.
TSHK0050 TSHK0060
Step 10
• Choose the menu F1: Injector ID code with ▲, ▼
(up/down) keys or F1 (function) key, and press
[ENTER].
Electronic Control Fuel Injection System (Common Rail Type) 1E-65
Step 11-1 Step 12-1
TSHK0061 TSHK0061
TSHK0063
TSHK0062
Step 12-3
• When the ID code registered in the ECM does not
correspond to that uploaded to the Tech2, the fol-
lowing message will appear.
Pressing the softkey [Confirm] returns you to Step
11.
• In this case, the uploaded ID code will be erased.
Therefore, perform upload again. The message
shown in Step 12-4 will appear.
1E-66 Electronic Control Fuel Injection System (Common Rail Type)
TSHK0064
Step 12-4
• Pressing the softkey [Confirm] returns you to Step
11.
TSHK0065
Electronic Control Fuel Injection System (Common Rail Type) 1E-67
ID code download (ECM)
Step 1
• Press [ENTER].
TSWG0089
Step 4
• Choose the menu (Off-Road) Industrial Engine
TSWG0110
with ▲, ▼ (up/down) keys, and press the [ENTER]
key.
Step 2
• Choose the menu F0: Diagnostics with ▲, ▼ (up/
down) keys or F0 (function) key, and press
[ENTER].
TSWG0090
Step 5
• Choose F0: Engine in Menu with ▲, ▼ (up/down)
TSWG0088
keys or F0 (function), and press [ENTER].
Step 3
• Choose the menu (5) 2005 with ▲, ▼ (up/down)
keys, and press the [ENTER] key.
1E-68 Electronic Control Fuel Injection System (Common Rail Type)
TSWG0091 TSWG0093
TSWG0122
TSWG0092 Step 8
• Press the softkey [Confirm].
Step 7
• This displays the ECU ID information.
• Press the softkey “Confirm”.
• The ignition is ON at this time.
Electronic Control Fuel Injection System (Common Rail Type) 1E-69
TSWG0094 TSHK0108
Step 9 Step 11
• Choose the menu F4: Programming with ▲, ▼ (up/ • Choose the menu F3: ID code download (ECM)
down) keys or F4 (function) key, and press with ▲, ▼ (up/down) keys or F2 (function) key, and
[ENTER]. then press the [ENTER] key.
TSHK0050 TSHK0088
Step 10
• Choose the menu F1: Injector ID code with ▲, ▼
(up/down) keys or F1 (function) key, and press
[ENTER].
1E-70 Electronic Control Fuel Injection System (Common Rail Type)
Step 11-1
TSHK0091
TSHK0089
Step 12-2
Step 12 • The following display appears when the engine
• Press the softkey “Confirm”. speed is not 0 rpm.
In this case, stop the engine as instructed in the
• As an example, the vehicle will be checked message, and try again from Step 1.
whether it is in the condition (engine stopped) that
the ECM requests during ID registration.
TSHK0092
TSHK0090
Step 13
Step 12-1 • Pressing the softkey [Yes] downloads (registers)
the uploaded ID codes (Cyl.1-Cyl.6) to the ECM.
• The following display appears while checking if the Pressing the softkey [No] returns you to Step 11.
engine speed is 0 rpm.
When the engine speed is 0 rpm, it will take you to • Download is the function to register (write) the
Step 13. stored (uploaded) ID codes (No. 1 cylinder No. 6
cylinder) in the Tech2 to the ECM. ID is registered
from No. 1 cylinder to No. 6 cylinder in the order.
Electronic Control Fuel Injection System (Common Rail Type) 1E-71
TSHK0093 TSHK0095
TSHK0096
TSHK0094
Step 13-2
• When the downloaded ID code corresponds to that
registered (written) in the ECM, the following mes-
sage will appear. Download (registration) is com-
pleted.
Pressing the softkey [Confirm] returns you to Step
11.
1E-72 Electronic Control Fuel Injection System (Common Rail Type)
TIS2000
TIS 2000 installation procedure
(Time needed: 30 minutes)
8. On the “Set HARDWARE_KEY” screen, select the 10. On the “TIS 2000 installation mode”, select the
“LPT” and click the “Next”. “Standalone” and click the “Next”.
9. On the “Salesmake” screen, select either the 11. On the “TIS 2000 Update” screen, click the “OK”.
“Isuzu - General Export (General Export VIN)” or
“Isuzu US (US VIN)” and click the “Next”.
[Example (UBS 6VE1 engine)]
General VIN: JACUBS26GY7100001
US VIN: JACDJ58X3Y7100001
1E-74 Electronic Control Fuel Injection System (Common Rail Type)
12. If the installation is completed, the “TIS 2000” icon a. Startup TIS 2000.
is displayed on the desktop. b. Choose the “Snapshot Upload/Display” on the
• An error message may appear when restarting initial screen of TIS 2000.
the PC at Step 12. c. Either select the “Upload from diagnostic tool”
In this case, install the following file in the CD- or click the appropriate icon on the tool bar.
ROM.
d. Select the “Tech2” and transmit the saved
~cosids¥Diag¥Mdac_type.ex_
snapshot data.
Copy this file on your hard disk, change the file
name into “mdac.exe”, and double-click e. Select the “Transmitted Snapshot”.
“mdac.exe”. f. When the snapshot data transmission is com-
After this work, install TIS 2000 again. pleted, the data parameter list will appear on
the screen.
How to display snapshot
Icons to be displayed
The following icons are used for data display.
Uploads the snapshot data from the floppy disk or hard disk.
Displays the data parameters in graph and list (up to 3 parameter items for graph display).
Trigger of record: Moves to the trigger position and displays the snapshot.
Regeneration in forward direction: Replays all the snapshot in the forward direction.
Graph display
Numeric value and graph (up to 3 for graph display):
1. Clicking the icon for graph display opens “Graph
Parameters.” window.
2. Click the 1st graph icon in the top of the window,
and select one parameter from the list in the bot-
tom of the window. Selected parameter is shown
next to the graph icon. Graph category can be
selected with the field located in the right hand of
the parameter.
3. Perform the same procedure for the 2nd and 3rd
graph icons.
4. After selecting all the parameters (up to 3 parame-
ters) you wish to view, click the [OK] button.
[TIS2000 end]: Quits all TIS 2000 applications to return to the Windows desktop screen.
[Select page]: Returns to the initial page of TIS 2000 without quitting applications currently used. The
applications currently used run in the background.
[Vehicle data]: Starts [Vehicle data display] function. This displays all the vehicle information.
[Executed applications end]: Quits the application currently used to return to the initial page of TIS 2000.
[TIS2000 end]: Quits all TIS 2000 applications to return to the Windows desktop screen.
[Select page]: Returns to the initial page of TIS 2000 without quitting applications currently used. The
applications currently used run in the background.
[Vehicle data]: Starts [Vehicle data display] function. This displays all the vehicle information.
[Executed applications end]: Quits the application currently used to return to the initial page of TIS 2000.
TSWG0211
Name
1. Injector checker body 3. Test harness for 4-cylinders
2. Test harness for 6-cylinders
• To prevent wrong connection, the end of corrugate tube of connection harness for 6-cylinders is wrapped by
identification tape (red) for 4-5-6 cylinder side harness.
Electronic Control Fuel Injection System (Common Rail Type) 1E-83
Each part of injector checker • Do not turn the selection switch excessively after it
is turned to stopper.
Start switch
This is used to stop the cylinder selected by the cylin-
der selection switch. Injection of selected cylinder stops
4
approx. 2.4 seconds.
Operation lamp
This comes on while injector is checked (approx. 2.4
seconds) after starting button is pressed.
3 5
Note:
Do not use any switches and operate the machine
2
while the lamp comes on. Otherwise, diagnosis result is
not correct.
Holder
1
Holders are used to hang or fix the body. They are
tightened on the body. To use the holders, loosen the
TSWG0212 screws to move.
Name
Note:
1. Main switch
2. Battery lamp • When using or storing holders, be sure to tighten
3. Operation lamp them to fix.
4. Cylinder selection switch • Be careful not to tighten screws excessively. This
5. Start button may damage the body.
Main switch
This is used to switch ON and OFF of injector checker
function.
Note:
Be sure to turn it to OFF before removing/installing har-
ness.
Battery lamp
This comes on when the battery (9V) in the body gets
low (7.2V or less).
If the battery lamp comes on, replace the battery as
soon as possible. (Refer to 1E-85, “Battery Replace-
ment, How to use injector checker, How to Inspect
Injector”.)
Note:
When using the main switch, it comes on momentarily TSWG0221
due to voltage change. If the battery lamp does not
come on when using the main switch, check the bat- Precautions on handling the body
tery. Replace it if it gets low (7.2V or less).
• The body is a precision equipment. Do not
Cylinder selection switch drop it or make a high impact on it.
This is used to switch a cylinder to be checked. Turn it • The body is drip-proof type. However, avoid
left fully before check, and then start to check clockwise using it in rainy day or operating with wet
(1 o 2 o 3 o 4 o 5 o 6). hands to prevent water from entering through
connector connection.
Note: • Power for the body must be supplied from
• One rotation of cylinder selection switch allow to internal battery, not from external one.
check twice for each cylinder. At the third time or • Prevent foreign matter from entering into the
later, turn the selection switch left back to the origi- body while replacing battery.
nal position and start to check.
1E-84 Electronic Control Fuel Injection System (Common Rail Type)
• Do not use screws to tighten battery holder Note:
except original ones. This may cause body • Be careful not to let the metal parts of test harness
damage or battery damage and electric leak- and connector contact glow plug connector. Protect
age. it with cloth to prevent short during operation of key
• Do not disassemble the body in any circum- switch.
stances. Contact Hitachi Construction • Do not connect wrong connector. (Confirm the iden-
Machinery. if it is faulty. tification tape (red) before connecting.)
• DTC will be detected if disconnecting or connecting
the harness with the key switch to ON. Turn it to
Injector test OFF during work.
1. Check the DTC.
• If DTC unrelated to injector is detected, repair
or check to eliminate the faults before test.
2. Turn the key switch to OFF.
3. Disconnect the injector connector from engine on
the machine. (4-cylinder: one, 6-cylinder: two)
4HK1
TSWG0215
Note:
Be careful not to let the metal parts of connector con-
tact glow plug connector while connecting the harness.
TSWG0213
6HK1
#4,5,6
#1,2,3
TSWG0216
TSWG0214
Note:
Do not operate the body and the machine while the
operation lamp comes on.
10. Confirm that the lamp goes off and repeat check of
the remaining cylinders as steps 8 and 9.
11. Replace the injector in the cylinder of which engine
vibration level and exhaust noise did not change.
Note:
TSWG0218
For work procedure, refer to “Engine section” in the ser-
vice manual. 3. Remove the battery from the holder.
12. Turn the key switch to OFF, remove the test har-
ness, and restore the injector harness.
Note:
DTC will be detected if disconnecting or connecting the
harness with the key switch to ON. Turn it to OFF dur-
ing work.
13. Start the engine and return the idle speed at speci-
fied one.
14. Clear the DTC.
15. Refer to the machine’s manual for how to clear
DTCs.
16. Perform a test drive, and check that there are no
faults.
1E-86 Electronic Control Fuel Injection System (Common Rail Type)
Method to identify using non-contact
infrared thermometer
There are three methods to identify injectors as follows.
Since the method varies depending on the necessary
tools you have, and/or the judgment difficulty of each
machine, refer to the section of Hitachi Construction
Machinery.
Method to identify
1. Method of judgment by an injector balance test
using a diagnostic tool with KW or CAN communi-
cation such as Tech2.
• For the procedure of a balance test, refer to 1E-
42, “Injector balance test, Tech2, How to Use
Trouble Diagnosis-related Tool”.
2. Method of judgment by such an injector balance
TSWG0219
test that the injector power line is broken for a short
4. Disconnect the connector from battery, and time using an injector checker without communica-
replace the battery. tion with the ECM.
• Refer to 1E-82, “How to use injector checker,
How to Inspect Injector”.
3. Method of judgment by measuring and comparing
the rising trend of the exhaust temperature using a
non-contact infrared thermometer.
Depending on machine types, proficiency may be
required to judge only using an injector checker when a
diagnostic tool is not available. If it is difficult to judge,
we recommend the method of measuring and compar-
ing the rising trend of exhaust pipe temperature using a
non-contact infrared thermometer.
Method to measure
Use a non-contact infrared thermometer capable of
measuring 500qC (932qF), and continuously measure
at a rated point (for excavators, the points on two pump
relief) on the engine which you can stably measure.
TSWG0220 Measuring period should be 3 to 5 minutes after the
5. Restore in the reverse order. engine stabilized. Measure and compare the exhaust
pipe temperature of each cylinder, and judge as faulty
Note: cylinder if the temperature of certain cylinder is signifi-
cantly lower than others.
• Prevent foreign matter from entering in while remov-
ing the battery.
Comparing exhaust pipe temperature of
• Do not tighten the battery holder screws exces-
engine unit alone
sively.
Note:
• Do not replace the battery holder screws with other
than original ones. • Reference for test on engine unit. Test results will
show similar tendency when trouble occurs
• Be sure to use specified battery.
although variation may differ depending on
machine type and measuring conditions.
• Be careful not to continue the test condition for a
long time. Otherwise the test result may be incor-
rect due to heat conduction of the exhaust pipe.
Electronic Control Fuel Injection System (Common Rail Type) 1E-87
Changes in the temperature in the normal condition Changes in the temperature when injection in one
of No. 2 to No. 5 cylinders stops
500
(932) 500
(932)
400
400 (752)
(752)
300
C ( F)
(572)
C ( F)
#2 - #5
300 200
#6
(572) (392)
100
(212)
200
(392) 0
TSHK0135 (32)
TSHK0137
In the normal condition, the temperature of the No. 6
cylinder keeps lower than others. When injection in one of No. 2 to No. 5 cylinders stops,
the temperature of the stopped cylinder keeps lower
Changes in the temperature when injection in 1st
than normal cylinders.
or No. 6 cylinder stops
Note:
500 Refer to the relevant section for the reference value of
(932)
Hitachi Construction Machinery.
400
(752) Injector balance test (Tech2)
Refer to 1E-42, “Injector balance test, Tech2, How to
300
(572) Use Trouble Diagnosis-related Tool” for injector bal-
C ( F)
ance by Tech2.
200
(392)
100
(212) #1/#6
0
(32)
TSHK0136
Cautions
For your safety, read the following cautions.
1. Always turn the POWER switch of EMPS selector
to OFF before connecting/disconnecting the
cables. Before turning on the POWER switch of
EMPS selector, make sure that the cables are con-
nected securely.
11
5 4 3 2 1
6 7 8 9 10
Name
1. Selector 7. ECM connector
2. ECM POWER switch 8. Fuse
3. DATA SELECT switch 9. POWER switch
4. READY lamp 10. ECM connection cable
5. POWER lamp 11. Battery cable
6. RS-232C connector
Caution:
Power supply: You can use an AC adapter, however, AC adapter is not provided in the component parts.
Prepare an AC adapter that meets the specification. Available DC plug model number is MP-121C (outer
diameter: 5.5 mm u inner diameter: 2.1 mm, DC 12 V – 0.5 A).
Note:
If your PC has no RS-232C port, you can use a USB to RS-232C converter (optional) to connect.
However, error may occur during reflashing with some converters.
The converter shown below was verified for operation.
Voltage Specifications
Remarks
12 V specifications 24 V specifications
4HK1 4HK1
6HK1 6HK1
Eng Model 6WG1 6WG1
ECM (hardware) for 6WG1 and 6U is the same.
6U 6U
4J 4J
• Using EMPS can reflash the ECM of industrial common rail engine only.
• Using EMPS cannot reflash the ECM of industrial engine (RED – 4 type injection system) that meets Phase 2
Emission Standards.