This workshop manual covers detailed service and repair information, maintenance and overhauls instructions, description of routine maintenance for the Isuzu Diesel Engine 6HK1 model, that is installed on JCB machines.
Also, this service repair manual includes lots of illustrations, pictures and diagnosis charts. These diagnosis charts are an organized approach to identifying a condition that causes the status for when an engine does not start. The appropriate system diagnosis can be performed with diagnostic charts, which are presented in this manual.
The service manual comes in PDF format. To work with PDF book, you should use Adobe PDF Reader (or any analog). Working in the application, you can print the necessary pages of the manual or its entirety and use it as a book.
It is easy to study the content of this manual. You should study the screenshots and list of "Contents", that is below. Or you can go to the link in the description of the manual "Isuzu pdf manual instant preview" and preview it.
Models:
Diesel Engine 6HK1 Interim Tier 4 Compatible
Contents:
- 0 Introduction
- Introduction
- Safety Information
- 14A Service Information Guide
- Contents included in service information
- Plastic gauge
- Recommended liquid gasket
- Thread locking adhesive agent
- Term
- Abbreviations
- Standard bolts
- 15B Maintenance Information
- Primary specifications
- Function, Structure, Operation
- Maintenance precautions
- Introduction to the trouble diagnosis
- 15C Functional Inspection
- Starting system check
- Fuel system check
- Air intake system check
- Exhaust system check
- EGR control system check
- Glow control system check
- DPD control system check
- OBD system check
- Inspection of the diagnostic light warning light illumination circuit system
- Inspection of the diagnostic light warning light blinking circuit system
- Inspection of the starter circuit system
- Engine compression pressure inspection
- Lubrication system check
- 15D Symptom
- DPD system manual regeneration frequently
- DPD system regeneration long time
- Engine start failure
- Engine stalling
- Engine hunching, rough idling
- Excessive white smoke in the exhaust gas
- Excessive black smoke in the exhaust gas
- Abnormal noise
- Large fuel consumption
- Large oil consumption
- Insufficient engine output
- 15E DTC Information
- DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation
- DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
- DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low
- DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High
- DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance
- DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
- DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High
- DTC P0093 (Flash Code 227) Fuel System Leak Detected
- DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
- DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
- DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
- DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
- DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low
- DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High
- DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low
- DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High
- DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
- DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
- DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
- DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High
- DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1
- DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2
- DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3
- DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4
- DTC P0205 (Flash Code 275) Injector Circuit - Cylinder 5
- DTC P0206 (Flash Code 276) Injector Circuit - Cylinder 6
- DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition
- DTC P0219 (Flash Code 543) Engine Overspeed Condition
- DTC P0234 (Flash Code 42) Turbocharger Overboost Condition
- DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low
- DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High
- DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit
- DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance
- DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit
- DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance
- DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit
- DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High
- DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low
- DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
- DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
- DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1
- DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
- DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
- DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2
- DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low
- DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High
- DTC P0560 (Flash Code 155) System Voltage
- DTC P0563 (Flash Code 35) System Voltage High
- DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
- DTC P0602 (Flash Code 154) Control Module Programming Error
- DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error
- DTC P0606 (Flash Code 51) ECM/PCM Processor
- DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance
- DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
- DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit
- DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL) Control Circuit
- DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit
- DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open
- DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
- DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
- DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low
- DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
- DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
- DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1
- DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
- DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low
- DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High
- DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance
- DTC P1455 (Flash Code 132) PM Over Accumulation
- DTC P1471 (Flash Code 149) DPD Insufficient Regeneration
- DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance
- DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit
- DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
- DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input
- DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input
- DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input
- DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input
- DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation
- DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit
- DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit
- DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low
- DTC P2229 (Flash Code 71) Barometric Pressure Circuit High
- DTC P242F (Flash Code 131) DPD Restriction
- DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
- DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance
- DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low
- DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
- DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position
- DTC P2458 (Flash Code 139) DPD Regeneration Duration
- DTC U0001 (Flash Code 84) CAN-Bus Malfunction.15E-92
- DTC U0073 (Flash Code 84) Control Module Communication Bus Off
- DTC U0101 (Flash Code 85) Lost Communication with TCM
- DTC U0110 (Flash Code 87) Lost Communication with VNT System
- DTC mapping table
- 1A Engine Control
- DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation
- DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
- DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low
- DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High
- DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance
- DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
- DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High
- DTC P0093 (Flash Code 227) Fuel System Leak Detected
- DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
- DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
- DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
- DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
- DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low
- DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High
- DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low
- DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High
- DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
- DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
- DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
- DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High
- DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1
- DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2
- DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3
- DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4
- DTC P0205 (Flash Code 275) Injector Circuit - Cylinder 5
- DTC P0206 (Flash Code 276) Injector Circuit - Cylinder 6
- DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition
- DTC P0219 (Flash Code 543) Engine Overspeed Condition
- DTC P0234 (Flash Code 42) Turbocharger Overboost Condition
- DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low
- DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High
- DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit
- DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance
- DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit
- DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance
- DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit
- DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High
- DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low
- DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
- DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
- DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1
- DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
- DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
- DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2
- DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low
- DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High
- DTC P0560 (Flash Code 155) System Voltage
- DTC P0563 (Flash Code 35) System Voltage High
- DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
- DTC P0602 (Flash Code 154) Control Module Programming Error
- DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error
- DTC P0606 (Flash Code 51) ECM/PCM Processor
- DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance
- DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
- DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit
- DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL) Control Circuit
- DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit
- DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open
- DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
- DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
- DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low
- DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
- DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
- DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1
- DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
- DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low
- DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High
- DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance
- DTC P1455 (Flash Code 132) PM Over Accumulation
- DTC P1471 (Flash Code 149) DPD Insufficient Regeneration
- DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance
- DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit
- DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
- DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input
- DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input
- DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input
- DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input
- DTC P2138 (Flash Code 124) Pedal Position Sensor 1 - 2 Voltage Correlation
- DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit
- DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit
- DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low
- DTC P2229 (Flash Code 71) Barometric Pressure Circuit High
- DTC P242F (Flash Code 131) DPD Restriction
- DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
- DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance
- DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low
- DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
- DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position
- DTC P2458 (Flash Code 139) DPD Regeneration Duration
- DTC U0001 (Flash Code 84) CAN-Bus Malfunction 1A-117
- DTC U0073 (Flash Code 84) Control Module Communication Bus Off
- DTC U0101 (Flash Code 85) Lost Communication with TCM
- DTC U0110 (Flash Code 87) Lost Communication with VNT System
- 1B Mechanical
- Cylinder headcover
- Cylinder head assembly
- Idle gear
- Inlet cover
- Cylinder block
- Camshaft
- Rocker arm shaft
- Valve spring
- Crankshaft
- Flywheel
- Piston
- Crankshaft front oil seal
- Cover of gear case cover
- CKP sensor
- Crankshaft rear oil seal
- Intake throttle valve
- Exhaust manifold
- CMP sensor
- Supplementary Information
- 1C Fuel System
- Fuel supply pump
- Injector
- Common rail assembly
- Suction control valve
- Relief valve
- Fuel filter
- Fuel filter element
- Fuel filter pressure sensor
- Supplementary Information
- 1D Cooling
- Water pump assembly
- Drive belt
- Thermostat
- Overheat switch
- Engine coolant temperature sensor
- Coolant
- Radiator
- Supplementary Information
- 1E Lubrication
- Oil pan
- Oil cooler assembly
- Oil level switch
- Oil port cover
- Oil pressure sensor
- Oil pump assembly
- Engine oil
- Supplementary Information
- 1F Induction
- Boost temperature sensor
- Turbocharger assembly
- IMT sensor
- Boost sensor
- Intercooler
- Air cleaner element
- Supplementary Information
- 1G Exhaust
- DPD assembly
- Exhaust differential pressure sensor
- Exhaust gas temperature sensor
- Supplementary Information
- 1H Aux. Emission Control Devices
- EGR valve
- Supplementary Information
- 1J Electrical
- Glow plug
- Starter assembly
- Generator
- ECM
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