Isuzu Hitachi 6WG1 Engine Manual KM-6WG1-E-00 – PDF DOWNLOAD 

Description

Isuzu Hitachi 6WG1 Engine Manual KM-6WG1-E-00 – PDF DOWNLOAD

FILE DETAILS:

Isuzu Hitachi 6WG1 Engine Manual KM-6WG1-E-00 – PDF DOWNLOAD

Language : English
Pages : 846
Downloadable : Yes
File Type : PDF 

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Isuzu Hitachi 6WG1 Engine Manual KM-6WG1-E-00 – PDF DOWNLOAD 

Engine Manual(1/2) 1
Introduction 2
General Contents 4
Control System 6
Engine Control (Electronic control fuel injection system (Common rail type)) 6
How to use this manual 8
Table of abbreviation 9
List of parts according to engine control specifications 10
About colors of wirings 11
About wiring diagrams 12
How to read trouble diagnosis section 13
Precautions on Service Work 15
Procedure of trouble diagnosis 16
Information: 17
Interview 18
Pre-inspection 20
Information: 20
Trouble Diagnosis 20
Description of terms 20
How to read DTC 21
Confirmation after repair 23
List of final check items 23
How to clear DTC 24
Trouble diagnosis with scan tool 25
About scan tool display 26
How to use trouble diagnosis-related tool 30
How to use Tech2 30
Components of Tech2 30
Each part of Tech2 31
Precautions on handling Tech2 32
Power supply 34
Check items before use 35
How to connect Tech2 35
Operation procedure 36
List of functions of Tech2 38
Diagnostic procedure 39
DTC application menu display screen 41
Data Display 42
Snapshot 43
Actuator test 47
Injector balance test 48
View captured data 50
Tool options 52
Rewrite setting of Q adjust correction data by Tech2 53
Injector ID code (No 1 cylinder – No 6 cylinder) registration setting using Tech2 60
ID code upload (Tech2) 68
ID code download (Tech2) 70
How to use TIS 2000 73
TIS 2000 installation procedure 73
How to display snapshot 75
Software download 80
How to Inspect Injector 83
How to use injector checker 83
Components of injector checker 83
Method to identify using non-contact infrared thermometer 87
How to use flash tool 89
Refer to related document 89
How to use breaker box 90
Breaker box inspection procedure 90
How to connect breaker box 90
Example of use for breaker box 91
Engine Control System 93
Description of function and operation 93
About engine control (common rail) system 93
System control schematic diagram 93
Table of Input/Output 95
Electronic control fuel injection system (Common rail type) 95
System schematic diagram 96
Fuel system 97
EGR (Exhaust gas recirculation) 97
Idling control 99
Speed limit control 99
Engine speed output to tachometer 100
Preheating control 101
Engine Control Module (ECM) 101
Engine component location diagram 103
Supply pump 104
PCV (pressure control valve) 104
Fuel temperature (FT) sensor 105
G sensor 105
Common rail 106
Flow damper 106
Pressure limiter 107
Common rail pressure sensor 107
Injector 108
Engine coolant temperature (ECT) sensor 108
Crankshaft position (CKP) sensor 109
Engine oil pressure sensor 109
Accelerator position (AP) sensor 110
Intake air temperature (IAT) sensor 110
EGR position sensor 110
Boost pressure sensor 111
Boost temperature sensor 112
Diagnosis lamp 112
DLC (data link connector) 112
Diagnostic switch 112
Memory clear switch 112
Mode selector switch (1, 2, 3) 112
Wiring diagram of engine control module (ECM) 113
Pin arrangement of engine control module (ECM) 114
Circuit diagram 118
Main relay circuit 118
Starter for ECM control, glow circuit 119
Starter for safety relay, glow circuit 120
CAN, GND, DLC circuits 121
Indicator lamp, tachometer circuit 122
Injector circuit 123
PCV circuit 124
CKP sensor, vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil pressure sensor circuit 125
Boost temperature sensor, boost pressure sensor circuit 126
G sensor, common rail pressure sensor, EGR circuit 127
Accelerator position sensor, barometric pressure sensor, intake air temperature sensor circuit 128
Idling selector switch, idle up switch, idle down switch, mode map switch circuit 129
Memory clear switch, engine stop switch circuit 130
Engine harness location 131
H94/H95 connector 136
Connector list 137
List of function checks 140
OBD system check 141
Diagnosis lamp illumination circuit system check 143
Diagnosis lamp blinking circuit system check 145
Scan tool power supply circuit system check 148
Scan tool communication circuit system check 150
Starting circuit system check 153
Starting system check 159
Fuel system check 162
Intake system check 165
Exhaust system check 166
EGR control system check 167
QOS system check 170
List of diagnostic trouble code 175
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage) 188
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump) 193
DTC: P0091/P1291 (Flash code 247/248) PCV circuit fault (PCV1 open circuit or GND short circuit / PCV2 open circuit or GND short circuit) 198
DTC: P0092/P1292 (Flash code 217/218) PCV circuit fault (PCV1+B short circuit / PCV2+B short circuit / PCV2+B short circuit) 204
DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short) 209
DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short) 216
DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short, short circuit) 223
DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit) 229
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit) 237
DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply) 243
DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short) 251
DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit) 257
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit) 265
DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault, open circuit) 271
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system 278
DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system 283
DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system 288
DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system 293
DTC: P0205 (Flash code 275) Open circuit in injection nozzle #5 drive system 298
DTC: P0206 (Flash code 276) Open circuit in injection nozzle #6 drive system 303
DTC: P0219 (Flash code 543) Overrun 308
DTC: P0237 (Flash code 32) Boost sensor pressure fault (low voltage fault, open circuit) 310
DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit) 317
DTC: P0335 (Flash code 15) Crank sensor fault (no signal) 324
DTC: P0336 (Flash code 15) Crank sensor fault (signal fault) 330
DTC: P0340 (Flash code 14) G sensor fault (no signal) 336
DTC: P0341 (Flash code 14) G sensor fault (signal fault) 342
DTC: P0380 (Flash code 66) Glow relay circuit fault 348
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault 353
DTC: P0487 (Flash code 44) EGR position sensor fault 358
DTC: P0488 (Flash code 45) EGR valve control fault 364
DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short) 370
DTC: P0523 (Flash code 295) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short) 376
DTC: P0601 (Flash code 53) ROM fault 384
DTC: P0603 (Flash code 54) EEPROM fault 386
DTC: P0606 (Flash code 51/52) CPU fault 388
DTC: P0611 (Flash code 34) Charge circuit fault (bank 1) 390
DTC: P0612 (Flash code 34) Charge circuit fault (bank 2) 393
DTC: P0615 (Flash code 19) Starter cut relay circuit fault 396
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault 402
DTC: P1093 (Flash code 227) No pump pressure feed (2nd stage) 407
DTC: P1094 (Flash code 226) No pump pressure feed (1st stage) 416
DTC: P1095 (Flash code 225) Pressure limiter open 425
DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short) 434
DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit) 442
DTC: P1173 (Flash code 542) Overheat 449
DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault 455
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault 459
DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault 469
DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault 479
DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault) 485
DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault) 490
DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault) 495
DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault) 500
DTC: P1345 (Flash code 16) Cam sensor out of phase 505
DTC: P1625 (Flash code 416) Main relay fault 510
DTC: P1630 (Flash code 36) A/D conversion fault 517
DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1 519
DTC: P1632 (Flash code 55) Voltage fault in 5-V power supply 2 522
DTC: P1633 (Flash code 55) Voltage fault in 5-V power supply 3 525
DTC: P1634 (Flash code 55) Voltage fault in 5-V power supply 4 528
DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5 531
DTC: U2104 (Flash code 84) CAN Bus fault 534
DTC: U2106 (Flash code 85) CAN timeout fault 539
List of trouble symptom 544
Engine start failure 545
Engine stall 549
Engine hunting, rough idling 553
Engine output shortage 557
Exhaust gas contains a lot of white smoke 562
Exhaust gas contains a lot of black smoke 565
Noise 568
Fuel consumption deteriorates 570
Oil consumption deteriorates 573
Special tool 575
Difference by each machine manufacturer 576
Hitachi Construction Machinery Co , Ltd 576
List of DTC 576
About wiring diagrams 579
Engine Manual(2/2) 584
Introduction 585
General Contents 586
Disassemble and Assemble Engine 587
General Information 587
General Information 590
Service Precautions 590
Reading the model 594
General information 594
Engine mechanical (6WG1 (Common rail)) 601
6WG1-TC Engine 604
Service Precautions 604
Reading the model 605
Explanation of functions and operations 606
Functional check: 609
Main data and specifications 612
Engine accessories 614
Component parts 614
Removal 614
Installation 615
Engine exterior equipment 618
Component parts 618
Removal 621
Inspection 632
Installation 632
Torque specifications 646
Cylinder head 648
Component parts 648
Removal 648
Disassembly 652
Inspection 655
Assembly 658
Installation 663
Torque specifications 671
Special tools 672
Rocker arm 673
Component parts 673
Disassembly 673
Inspection 674
Assembly 675
Camshaft 676
Component parts 676
Disassembly 676
Inspection 677
Assembly 679
Torque specifications 679
Timing gear 680
Component parts 680
Removal 680
Inspection 682
Disassembly 683
Assembly 684
Installation 684
Torque specifications 688
Special tools 689
Flywheel, flywheel housing 690
Component parts 690
Removal 691
Disassembly 691
Inspection 692
Assembly 692
Installation 692
Torque specifications 695
Special tools 696
Piston, connecting rod 697
Component parts 697
Removal 697
Disassembly 698
Inspection 699
Assembly 702
Installation 705
Torque specifications 708
Special tools 709
Crankshaft 710
Component parts 710
Removal 710
Disassembly 711
Inspection 712
Assembly 715
Installation 715
Special tools 717
Cylinder block 718
Component parts 718
Disassembly 718
Inspection 719
Assembly 719
Torque specifications 722
Cooling system (6WG1 (Common rail)) 723
Cooling system 726
Service Precautions 726
Explanation of functions and operations 726
Trouble shooting 728
Engine overheats 729
Engine overcools 730
Main data and specifications 730
Thermostat 731
Component parts 731
Removal 731
Inspection 732
Installation 732
Torque specifications 734
Special tools 735
Water pump 736
Component parts 736
Disassembly 736
Inspection 738
Assembly 738
Torque specifications 741
Special tools 742
Fuel system (6WG1 (Common rail)) 743
Fuel system 746
Service Precautions 746
Explanation of functions and operations 746
Functional check: 749
Main data and specifications 751
Fuel filter 752
Component parts 752
Disassembly 752
Inspection 753
Assembly 754
Electrical system (6WG1 (Common rail)) 757
Starting system 760
Service Precautions 760
Explanation of functions and operations 760
Trouble shooting 761
Even if the starter switch is switched on, the starter does not function 762
The pinion advances but does not engage the ring gear 763
The pinion engagement motor turns but the engine does not turn 764
The pinion engages but the engine does not turn 765
After starting the engine, the starter doesn’t stop when the starter switch is turned off 766
Main data and specifications 766
Starter 767
Component parts 767
Disassembly 768
Inspection 770
Assembly 774
Torque specifications 777
Charging system 778
Service Precautions 778
Trouble shooting 780
Does not charge at all 781
Lack of electrical charge 782
Overcharged 783
Charging current is unstable 784
Abnormal noises come from the generator 785
Main data and specifications 785
Generator 786
Component parts 786
Disassembly 787
Inspection 788
Assembly 790
Functional check: 791
Torque specifications 792
Lubricating system (6WG1 (Common rail)) 793
Lubricating system 796
Service Precautions 796
Explanation of functions and operations 796
Main data and specifications 797
Oil filter 799
Component parts 799
Disassembly 799
Assembly 799
Special tools 801
Oil pan, oil jet 802
Component parts 802
Removal 803
Installation 803
Torque specifications 806
Oil pump 807
Component parts 807
Disassembly 807
Inspection 808
Assembly 809
Torque specifications 811
Oil cooler 812
Component parts 812
Disassembly 812
Inspection 813
Assembly 813
Torque specifications 815
Intake system (6WG1 (Common rail)) 817
Turbocharging system 820
Service Precautions 820
Explanation of functions and operations 820
Trouble shooting 821
If faults or vibrations occur 822
When the turbocharger is thought to be mainly fine but output power is low 823
Oil is leaking in the exhaust pipe or intake pipe, exhaust gas is white 824
Main data and specifications 824
Turbocharger 825
Component parts 825
Disassembly 825
Inspection 829
Assembly 832
Preheating system (6WG1 (Common rail)) 837
Preheating system 840
Service Precautions 840
Explanation of functions and operations 840
Functional check 841
Trouble shooting 842
Glow indicator lamp doesn’t light 843
Preheating doesn’t function 844
Preheating time is either too long or too short 845
Main data and specifications 845

DESCRIPTION:

Isuzu Hitachi 6WG1 Engine Manual KM-6WG1-E-00 – PDF DOWNLOAD 

Introduction:

This Manual describes the structure and the troubleshooting of electronic control fuel injection system (common rail type) in 6WG1 industrial engines. Use this manual sufficiently to perform service work properly and quickly.

How to use this manual:

• This manual describes about engine-related trouble diagnosis, and is closely related
  to the machine trouble diagnosis. Always refer to both manuals for the trouble
  diagnosis.
• This manual consists of the following contents. This section “How to use this manual”
  describes about abbreviations and instructions to use this manual. Therefore, if you
  are familiar with manuals, start with Precautions on service work and Basic
  procedure of trouble diagnosis.

How to use this manual
• Table of abbreviation
• List of parts according to engine control specifications
• Wiring color code
• How to use wiring diagram

S.V 05/01/2025