Isuzu 6WG1 6WG1T 6WG1-TC 6WF1-TC 6SD1T 6RB1 6RB1T AH-6UZ1 AA-6SD1T Engine Workshop Repair Service Manual PDF - MISZ6RB6SD6UZ6WG.zip
A full factory-style service guide covering the Isuzu Engines 6WF1-TC, 6WG1, 6WG1T, 6WG1-TC, 6SD1T, 6RB1, 6RB1T, AH-6UZ1, and AA-6SD1T models — packed with every technical detail needed to keep, troubleshoot, overhaul, and service these engines just as skilled technicians would.
This workshop service & repair manual for the Isuzu Engine 6WF1-TC, 6WG1, 6WG1T, 6WG1-TC, 6SD1T, 6RB1, 6RB1T, AH-6UZ1, and AA-6SD1T Models covers:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MANUAL LIST:
6WG1E00 - Isuzu 6WG1 Engine Service Manual (Hitachi).pdf
9-54850 - Isuzu 6WG1T Engine Service Manual (CNH Case).pdf
9-54870_EN - Isuzu Engines 6SD1T Service Manual.pdf
9806-2166 - Isuzu 6RB1, 6RB1T Model Industrial Diesel Engine Workshop Manual.pdf
IDE-2392 - Isuzu AA-6SD1T Model Industrial Diesel Engine Workshop Manual.pdf
IDE-2440 - Isuzu AH-6UZ1 Model Industrial Diesel Engine Workshop Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,483 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
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6WFGCEDG2-WE-0661 - Isuzu C&E SERIES ENGINE CONTROL SYSTEM (6WF1-TC, 6WG1-TC (Common Rail) models) WORKSHOP MANUAL................1
TOP................0
Engine Control System (6WF1-TC,6WG1-TC(Common Rail))................5
Engine Control System................6
Precautions for servicing................6
Explanation of Functions and Operations................8
Parts layout diagram................35
Circuit Diagram................40
Connector List................62
Fault diagnosis process................73
Breakdown diagnosis using the scan tool.................79
Function Inspection List................92
Oral consultation................93
On-Board Diagnosis (OBD) System Check................95
Checking the MIL (check engine lamp) lighting circuit system (MIL does not turn ON)................98
Checking the MIL (check engine lamp) flashing control system (MIL does not flashing)................101
Checking the Scan Tool Circuit System................104
Checking the starting system................107
Checking the fuel system................110
Checking the intake air system................114
Checking the exhaust system................116
Checking the EGR................120
Checking the engine control module (ECM) power supply and ground circuit................123
Checking the PTO................126
Table of diagnostics codes................130
DTC P0014 (Flash code 14)................141
DTC P0015 (Flash code 15)................145
DTC P0022 (Flash code 22)................149
DTC P0023 (Flash code 23)................153
DTC P0024 (Flash code 24)................157
DTC P0025 (Flash code 25)................161
DTC P0032 (Flash code 32)................166
DTC P0033 (Flash code 33)................170
DTC P0035 (Flash code 35)................172
DTC P0042 (Flash code 42)................174
DTC P0051 (Flash code 51)................177
DTC P0071 (Flash code 71)................179
DTC P0072 (Flash code 72)................181
DTC P0115 (Flash code 115)................183
DTC P0118 (Flash code 118)................187
DTC P0151 (Flash code 151)................193
DTC P0158 (Flash code 158)................199
DTC P0159 (Flash code 159)................203
DTC P0211 (Flash code 211)................207
DTC P0217 (Flash code 217)................210
DTC P0218 (Flash code 218)................213
DTC P0226 (Flash code 226)................216
DTC P0227 (Flash code 227)................221
DTC P0242 (Flash code 242)................226
DTC P0245 (Flash code 245)................230
DTC P0247 (Flash code 247)................234
DTC P0248 (Flash code 248)................237
DTC P0271 (Flash code 271)................240
DTC P0272 (Flash code 272)................244
DTC P0273 (Flash code 273)................248
DTC P0274 (Flash code 274)................252
DTC P0275 (Flash code 275)................256
DTC P0276 (Flash code 276)................260
DTC P0277 (Flash code 277)................264
DTC P0278 (Flash code 278)................267
DTC P0411 (Flash code 411)................270
DTC P0412 (Flash code 412)................274
DTC P0413 (Flash code 413)................278
DTC P0416 (Flash code 416)................282
DTC P0418 (Flash code 418)................285
DTC P0421 (Flash code 421)................288
DTC P0424 (Flash code 424)................290
DTC P0441 (Flash code 441)................293
DTC P0442 (Flash code 442)................297
DTC P0446 (Flash code 446)................301
DTC P0447 (Flash code 447)................306
DTC P0448 (Flash code 448)................311
DTC P0449 (Flash Code 449)................316
DTC P0518(Flash Code 518)................321
DTC P0543(Flash Code 543)................323
Symptom List................325
Engine Stall................326
Engine hunting, rough idle................329
Lack of power, slugginess or hesitation................333
Excessive white smoke................336
Excessive black smoke................338
Idling revolutions cannot be adjusted................341
Idling revolutions cannot be adjusted down................343
Special tool................346
Programming................347
Explanation of Functions and Operations................347
Programming................348
Special tool................358
6WG1E00 - Isuzu 6WG1 Engine Service Manual (Hitachi)................361
Engine Manual(1/2)................361
Introduction................362
General Contents................364
Control System................366
Engine Control (Electronic control fuel injection system (Common rail type))................366
How to use this manual................368
Table of abbreviation................369
List of parts according to engine control specifications................370
About colors of wirings................371
About wiring diagrams................372
How to read trouble diagnosis section................373
Precautions on Service Work................375
Procedure of trouble diagnosis................376
Information:................377
Interview................378
Pre-inspection................380
Information:................380
Trouble Diagnosis................380
Description of terms................380
How to read DTC................381
Confirmation after repair................383
List of final check items................383
How to clear DTC................384
Trouble diagnosis with scan tool................385
About scan tool display................386
How to use trouble diagnosis-related tool................390
How to use Tech2................390
Components of Tech2................390
Each part of Tech2................391
Precautions on handling Tech2................392
Power supply................394
Check items before use................395
How to connect Tech2................395
Operation procedure................396
List of functions of Tech2................398
Diagnostic procedure................399
DTC application menu display screen................401
Data Display................402
Snapshot................403
Actuator test................407
Injector balance test................408
View captured data.................410
Tool options................412
Rewrite setting of Q adjust correction data by Tech2................413
Injector ID code (No. 1 cylinder - No. 6 cylinder) registration setting using Tech2................420
ID code upload (Tech2)................428
ID code download (Tech2)................430
How to use TIS 2000................433
TIS 2000 installation procedure................433
How to display snapshot................435
Software download................440
How to Inspect Injector................443
How to use injector checker................443
Components of injector checker................443
Method to identify using non-contact infrared thermometer................447
How to use flash tool................449
Refer to related document.................449
How to use breaker box................450
Breaker box inspection procedure................450
How to connect breaker box................450
Example of use for breaker box................451
Engine Control System................453
Description of function and operation................453
About engine control (common rail) system................453
System control schematic diagram................453
Table of Input/Output................455
Electronic control fuel injection system (Common rail type)................455
System schematic diagram................456
Fuel system................457
EGR (Exhaust gas recirculation)................457
Idling control................459
Speed limit control................459
Engine speed output to tachometer................460
Preheating control................461
Engine Control Module (ECM)................461
Engine component location diagram................463
Supply pump................464
PCV (pressure control valve)................464
Fuel temperature (FT) sensor................465
G sensor................465
Common rail................466
Flow damper................466
Pressure limiter................467
Common rail pressure sensor................467
Injector................468
Engine coolant temperature (ECT) sensor................468
Crankshaft position (CKP) sensor................469
Engine oil pressure sensor................469
Accelerator position (AP) sensor................470
Intake air temperature (IAT) sensor................470
EGR position sensor................470
Boost pressure sensor................471
Boost temperature sensor................472
Diagnosis lamp................472
DLC (data link connector)................472
Diagnostic switch................472
Memory clear switch................472
Mode selector switch (1, 2, 3)................472
Wiring diagram of engine control module (ECM)................473
Pin arrangement of engine control module (ECM)................474
Circuit diagram................478
Main relay circuit................478
Starter for ECM control, glow circuit................479
Starter for safety relay, glow circuit................480
CAN, GND, DLC circuits................481
Indicator lamp, tachometer circuit................482
Injector circuit................483
PCV circuit................484
CKP sensor, vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil pressure sensor circuit................485
Boost temperature sensor, boost pressure sensor circuit................486
G sensor, common rail pressure sensor, EGR circuit................487
Accelerator position sensor, barometric pressure sensor, intake air temperature sensor circuit................488
Idling selector switch, idle up switch, idle down switch, mode map switch circuit................489
Memory clear switch, engine stop switch circuit................490
Engine harness location................491
H94/H95 connector................496
Connector list................497
List of function checks................500
OBD system check................501
Diagnosis lamp illumination circuit system check................503
Diagnosis lamp blinking circuit system check................505
Scan tool power supply circuit system check................508
Scan tool communication circuit system check................510
Starting circuit system check................513
Starting system check................519
Fuel system check................522
Intake system check................525
Exhaust system check................526
EGR control system check................527
QOS system check................530
List of diagnostic trouble code................535
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)................548
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump)................553
DTC: P0091/P1291 (Flash code 247/248) PCV circuit fault (PCV1 open circuit or GND short circuit / PCV2 open circuit or GND short circuit)................558
DTC: P0092/P1292 (Flash code 217/218) PCV circuit fault (PCV1+B short circuit / PCV2+B short circuit / PCV2+B short circuit)................564
DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short)................569
DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short)................576
DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short, short circuit)................583
DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)................589
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit)................597
DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply)................603
DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short)................611
DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)................617
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit)................625
DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault, open circuit)................631
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system................638
DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system................643
DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system................648
DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system................653
DTC: P0205 (Flash code 275) Open circuit in injection nozzle #5 drive system................658
DTC: P0206 (Flash code 276) Open circuit in injection nozzle #6 drive system................663
DTC: P0219 (Flash code 543) Overrun................668
DTC: P0237 (Flash code 32) Boost sensor pressure fault (low voltage fault, open circuit)................670
DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit)................677
DTC: P0335 (Flash code 15) Crank sensor fault (no signal)................684
DTC: P0336 (Flash code 15) Crank sensor fault (signal fault)................690
DTC: P0340 (Flash code 14) G sensor fault (no signal)................696
DTC: P0341 (Flash code 14) G sensor fault (signal fault)................702
DTC: P0380 (Flash code 66) Glow relay circuit fault................708
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault................713
DTC: P0487 (Flash code 44) EGR position sensor fault................718
DTC: P0488 (Flash code 45) EGR valve control fault................724
DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short)................730
DTC: P0523 (Flash code 295) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short)................736
DTC: P0601 (Flash code 53) ROM fault................744
DTC: P0603 (Flash code 54) EEPROM fault................746
DTC: P0606 (Flash code 51/52) CPU fault................748
DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)................750
DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)................753
DTC: P0615 (Flash code 19) Starter cut relay circuit fault................756
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault................762
DTC: P1093 (Flash code 227) No pump pressure feed (2nd stage)................767
DTC: P1094 (Flash code 226) No pump pressure feed (1st stage)................776
DTC: P1095 (Flash code 225) Pressure limiter open................785
DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short)................794
DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit)................802
DTC: P1173 (Flash code 542) Overheat................809
DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault................815
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault................819
DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault................829
DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault................839
DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault)................845
DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault)................850
DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault)................855
DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault)................860
DTC: P1345 (Flash code 16) Cam sensor out of phase................865
DTC: P1625 (Flash code 416) Main relay fault................870
DTC: P1630 (Flash code 36) A/D conversion fault................877
DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1................879