Kawasaki KCM 4HK1 Isuzu Diesel Engine For 62Z7 67Z7 Wheel Loader Shop Manual PDF
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KCM 60Z7 Wheel Loader(Operational Performance Test Troubleshooting)DEUTZ TCD36 Engine Shop Manual – PDF DOWNLOAD (Section 4&5)
Description
Kawasaki KCM 4HK1 Isuzu Diesel Engine(General Information Troubleshooting Information) For 62Z7 67Z7 Wheel Loader Shop Manual – PDF DOWNLOAD
FILE DETAILS:
Kawasaki KCM 4HK1 Isuzu Diesel Engine(General Information Troubleshooting Information) For 62Z7 67Z7 Wheel Loader Shop Manual – PDF DOWNLOAD
Language : English
Pages : 381
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KCM 60Z7 Wheel Loader(Operational Performance Test Troubleshooting)DEUTZ TCD36 Engine Shop Manual – PDF DOWNLOAD (Section 4&5)
ETDCA-EN-010
FOREWORD2
0 Introduction (All)4
Introduction 5
safety information 5
14A Service Information Guide (All)6
Contents included in service information7
Plastic gauge9
Recommended liquid gasket 11
Thread locking adhesive agent13
Term 14
Abbreviations 15
Standard bolts19
15B Maintenance Information (4HK1) 26
Maintenance precautions27
Primary specifications 30
Function,Structure,Operation 32
Introduction to the trouble diagnosis 84
15C Functional Inspection (4HK1) 94
Engine compression pressure inspection95
Fuel system check97
Lubrication system check 98
Air intake system check99
Exhaust system check 100
DPD control system check101
EGR control system check104
Starting system check105
Glow control system check 106
OBD system check 108
Inspection of the diagnostic light warning light illumination circuit system 109
Inspection of the diagnostic light warning light blinking circuit system110
Inspection of the starter circuit system 111
15D Symptom (4HK1) 112
Engine start failure 113
Engine stalling115
Engine hunching,rough idling 117
Excessive white smoke in the exhaust gas 118
Excessive black smoke in the exhaust gas 119
Abnormal noise 120
Large fuel consumption 121
Large oil consumption123
Insufficient engine output 124
DPD system manual regeneration frequently 126
DPD system regeneration long time127
15E DTC Information (4HK1) 128
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation 130
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit131
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low 132
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High 133
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance 134
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low 135
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High 136
DTC P0093 (Flash Code 227) Fuel System Leak Detected 137
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input138
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input 139
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low 140
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High 141
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low 142
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High143
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low 144
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High145
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low 146
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High147
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low 148
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High 149
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1 150
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2 151
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3 152
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4 153
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition 154
DTC P0219 (Flash Code 543) Engine Overspeed Condition 155
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition 156
DTC P0237 (Flash Code 32) Turbocharger Boost Sensor Circuit Low157
DTC P0238 (Flash Code 32) Turbocharger Boost Sensor Circuit High 158
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit159
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance160
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit 161
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance162
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit 163
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High 164
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low165
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 166
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1 167
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1168
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 169
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 170
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2171
DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low 172
DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High 173
DTC P0560 (Flash Code 155) System Voltage 174
DTC P0563 (Flash Code 35) System Voltage High175
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error176
DTC P0602 (Flash Code 154) Control Module Programming Error 177
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error 178
DTC P0606 (Flash Code 51) ECM/PCM Processor 179
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance 180
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance181
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit182
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit 183
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit184
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open 185
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High 186
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit187
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP)Too Low 188
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low189
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High 190
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1191
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2192
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low193
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High 194
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance195
DTC P1455 (Flash Code 132) PM Over Accumulation 196
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration 197
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance198
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit199
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit 200
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input 201
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input202
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input 203
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input204
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation 205
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit 206
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit 207
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low208
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High 209
DTC P242F (Flash Code 131) DPD Restriction210
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit 211
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance 212
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low 213
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High 214
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position215
DTC P2458 (Flash Code 139) DPD Regeneration Duration 216
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN) 217
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939) 218
DTC U0101 (Flash Code 85) Lost Communication with TCM 219
DTC U0110 (Flash Code 87) Lost Communication with VNT System220
DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction 221
DTC mapping table 222
1A Engine Control (4HK1) 226
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation 228
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit229
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low 231
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High 234
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance 237
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low 239
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High 240
DTC P0093 (Flash Code 227) Fuel System Leak Detected 241
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input244
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input 245
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low 246
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High 247
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low 248
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High249
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low 250
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High251
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low 252
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High253
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low254
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High 255
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1 256
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2 258
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3 260
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4 262
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition 264
DTC P0219 (Flash Code 543) Engine Overspeed Condition 265
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition 266
DTC P0237 (Flash Code 32) Turbocharger Boost Sensor Circuit Low267
DTC P0238 (Flash Code 32) Turbocharger Boost Sensor Circuit High 268
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit269
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance271
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit 272
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance274
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit 275
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High 277
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low278
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 279
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1 280
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1281
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 282
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 283
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2284
DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low 286
DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High 287
DTC P0560 (Flash Code 155) System Voltage 288
DTC P0563 (Flash Code 35) System Voltage High289
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error290
DTC P0602 (Flash Code 154) Control Module Programming Error 291
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error 292
DTC P0606 (Flash Code 51) ECM/PCM Processor 293
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance 294
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance295
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit296
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit 298
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit299
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open 300
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High 301
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit302
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP)Too Low 304
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low307
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High 308
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1309
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2310
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low311
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High 312
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance313
DTC P1455 (Flash Code 132) PM Over Accumulation 314
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration 316
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance318
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit319
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit 321
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input 322
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input323
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input 324
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input325
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation 326
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit 327
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit 329
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low331
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High 332
DTC P242F (Flash Code 131) DPD Restriction333
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit 335
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance 337
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low 339
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High 340
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position341
DTC P2458 (Flash Code 139) DPD Regeneration Duration 342
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN) 344
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939) 345
DTC U0101 (Flash Code 85) Lost Communication with TCM 347
DTC U0110 (Flash Code 87) Lost Communication with VNT System348
DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction 349
Wiring Diagram 350
Using the Wiring Diagram352
Structure and Content of This Document353
1Wiring Diagram354
2Location Diagram 357
3Connector Information 357
4Terminal Name 357
5Circuit Symbols 358
6Abbreviations 359
Engine360
Engine Control361
Location Diagram 366
Connector Location Diagram367
Connector List 370
T โฆ๏ผConnector List ๏ผ371
H โฆ๏ผConnector List ๏ผ373
S โฆ๏ผConnector List ๏ผ374
Terminal Name 376
Terminal Name 377
SERVICE MANUAL REVISION REQUEST FORM 0
DESCRIPTION:
KCM 60Z7 Wheel Loader(Operational Performance Test Troubleshooting)DEUTZ TCD36 Engine Shop Manual – PDF DOWNLOAD (Section 4&5)
This manual describes the service procedures for the 4HK1 diesel engine (Interim Tier 4 compatible).
The contents of this manual are current at the date of issue, but may differ slightly from your engine due to specification changesor other modifications made thereafter.
G.B 31/01/25
