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2002 FRR WT5500 ISUZU Commercial Truck FORWARD TILTMASTER – Service Workshop Manual – PDF DOWNLOAD
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2002 FRR WT5500 ISUZU Commercial Truck FORWARD TILTMASTER – Service Workshop Manual
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Description
2002 FRR WT5500 ISUZU Commercial Truck FORWARD TILTMASTER – Service Workshop Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:506
DOWNLOADABLE:YES
FILE TYPE:PDF
2002 FRR WT5500 ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER – SERVICE WORKSHOP MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
2002 FRR WT5500 ISUZU Commercial Truck FORWARD TILTMASTER – Service Workshop Manual
FOREWORD:
This service supplemental manual contains diagnosis, on-vehicle service, wiring diagrams, and component unit repair for Medium Duty Steel Tilt Cab Vehicles FRR/WTSSOO. When used with the Isuzu Commercial Truck Service Manual: Pub. No. FRR97-WSM-CO1, FRROO—WSM-CSl, and FSEO1-ESM-CO‘l, complete service coverage is provided. Keep this manual in a handy place for ready reference. If properly used, it will enable the technician to serve the owners of these vehicles.
- This service manual is intended for use by professional, qualified technicians. Attempting repairs or service without the appropriate training, tools, and equipment could cause injury to you or others and damage to your vehicle that may cause it not to operate properly. These vehicles contain parts dimensioned in the metric system as well as in the customary system.
- Some fasteners are metric and are very close in dimension to familiar customary fasteners in the inch system. It is important to note that, during any vehicle maintenance procedures, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. (Numbers on the heads of metric bolts and on surfaces of metric nuts indicate their strength.
- Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings.) Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possibly personal injury. Therefore, fasteners removed from the vehicle should be saved for re-use in the same location whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. For information and assistance, see your authorized dealer.
TABLE OF CONTENTS:
2002 FRR WT5500 ISUZU Commercial Truck FORWARD TILTMASTER – Service Workshop Manual
INDEX................................................................................................... 0 TOP..................................................................................................... 1 Sec.0 GENERAL INFORMATION........................................................................... 8 GENERAL INFORMATION............................................................................. 8 MAINTENANCE AND LUBRICATION..................................................................... 20 Sec.0A GENERAL INFORMATION.......................................................................... 8 HANDLING ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS.......................................... 8 SERVICE PARTS IDENTIFICATION LABEL.............................................................. 9 RPO (REGULAR PRODUCTION OPTIONS) LIST........................................................... 9 VEHICLE IDENTIFICATION NUMBER (VIN)............................................................. 10 CERTIFICATION LABEL............................................................................. 10 MODEL REFERENCE................................................................................. 10 ENGINE IDENTIFICATION NUMBER.................................................................... 10 EMERGENCY STARTING YOUR VEHICLE DUE TO A DISCHARGED BATTERY..................................... 10 TOWING PROCEDURE................................................................................ 12 GRAPHIC SYMBOLS................................................................................. 14 ACTION SYMBOLS.................................................................................. 14 COMMON AUTOMOTIVE ABBREVIATIONS................................................................. 16 Sec.0B MAINTENANCE AND LUBRICATION.................................................................. 20 ENGINE OIL AND VISCOSITY RECOMMENDATIONS........................................................ 20 MAINTENANCE SCHEDULE........................................................................ 21 MAINTENANCE SCHEDULE AND LOG................................................................ 21 EXPLANATION OF VEHICLE MAINTENANCE AND LOG.................................................. 26 EXPLANATION OF MAINTENANCE ITEM............................................................. 26 GREASING POINTS FOR FRR/WT5500 MODEL........................................................ 28 OWNER SAFETY AND ROUTINE MAINTENANCE........................................................ 28 NOISE EMISSION CONTROL...................................................................... 30 RECOMMENDED FLUIDS AND LUBRICANTS........................................................... 31 LUBRICATION CHART........................................................................... 32 SPECIFICATIONS.................................................................................. 33 CAPACITIES.................................................................................. 33 COOLING SYSTEM.............................................................................. 33 REAR AXLE................................................................................... 33 AIR CLEANERS ELEMENT........................................................................ 33 OIL FILTERS ELEMENT......................................................................... 33 FUEL FILTER ELEMENT......................................................................... 33 ESSENTIAL SERVICE TOOLS......................................................................... 34 Sec.1 HEATING AND AIR CONDITIONING.................................................................. 36 HEATING AND VENTILATION......................................................................... 34 AIR CONDITIONING................................................................................ 46 Sec.2 FRAME......................................................................................... 38 FRAME AND BODY MOUNTS........................................................................... 86 Sec.3 STEERING, SUSPENSION, WHEELS AND TIRES........................................................ 40 FRONT END ALIGNMENT.............................................................................114 STEERING LINKAGE................................................................................120 POWER STEERING.................................................................................. 40 STEERING COLUMN................................................................................. 40 FRONT AXLE AND SUSPENSION.......................................................................156 REAR SUSPENSION.................................................................................182 WHEELS AND TIRES................................................................................ 40 Sec.4 REAR AXLE AND PROPELLER SHAFT................................................................. 42 PROPELLER SHAFT.................................................................................214 REAR AXLE....................................................................................... 42 Sec.5 BRAKES (AIR OVER HYDRAULIC BRAKES)............................................................ 44 HYDRAULIC BRAKES................................................................................ 44 HYDRAULIC BRAKE BOOSTER SYSTEM.................................................................. 44 HYDRAULIC FOUNDATION BRAKES..................................................................... 44 ANTI-LOCK BRAKE SYSTEM.......................................................................... 44 AIR BRAKE VALVES................................................................................ 44 PARKING BRAKE................................................................................... 46 AIR COMPRESSOR AND GOVERNOR..................................................................... 44 EXHAUST BRAKE................................................................................... 52 Sec.5C PARKING BRAKE................................................................................ 46 DESCRIPTION..................................................................................... 46 ON-VEHICLE SERVICE.............................................................................. 47 BRAKE SHOE ADJUSTMENT....................................................................... 47 SHOE REPLACEMENT............................................................................ 48 DRUM REPLACEMENT............................................................................ 49 COVER REPLACEMENT........................................................................... 49 LEVER ADJUSTMENT............................................................................ 50 BRAKE LEVER REPLACEMENT..................................................................... 50 SPECIFICATIONS.................................................................................. 51 Sec.5E EXHAUST BRAKE................................................................................ 52 DESCRIPTION..................................................................................... 53 DIAGNOSIS OF EXHAUST BRAKE...................................................................... 54 EXHAUST BRAKE ON-VEHICLE SERVICE................................................................ 55 EXHAUST BRAKE ASSEMBLY REPLACEMENT.......................................................... 55 EXHAUST BRAKE VALVE UNIT REPAIR............................................................. 56 AIR CYLINDER PARTS UNIT REPAIR.............................................................. 58 CLUTCH PEDAL SWITCH REPLACEMENT............................................................. 60 SPECIFICATIONS.................................................................................. 61 Sec.6 ENGINE........................................................................................ 62 DIESEL ENGINE ON-VEHICLE SERVICE................................................................ 62 DIESEL ENGINE OVERHAUL.......................................................................... 62 WATER PUMP OVERHAUL............................................................................. 62 FUEL SYSTEM..................................................................................... 62 DIESEL FUEL INJECTION........................................................................... 64 ENGINE ELECTRICAL............................................................................... 82 DIESEL ELECTRICAL............................................................................... 62 EMISSIONS....................................................................................... 94 TURBOCHARGER.................................................................................... 62 Sec.6C2 DIESEL FUEL INJECTION....................................................................... 64 GENERAL DESCRIPTION............................................................................. 65 COMMON RAIL SYSTEM.......................................................................... 65 SYSTEM OUTLINE.............................................................................. 65 SYSTEM COMPOSITION.......................................................................... 65 SYSTEM DESCRIPTION AND OPERATION............................................................ 67 VARIOUS CONTROLS............................................................................ 68 FUEL INJECTION RATE CONTROL................................................................. 69 FUEL INJECTION SYSTEM........................................................................... 71 SYSTEM OPERATION............................................................................ 71 ON VEHICLE SERVICE.............................................................................. 72 FUEL SUPPLY PUMP, REMOVAL................................................................... 72 FUEL SUPPLY PUMP, INSTALLATION.............................................................. 73 FUEL INJECTOR, Removal...................................................................... 74 FUEL INJECTOR, Installation................................................................. 74 Bleeding Fuel System........................................................................ 75 COMMON RAIL ASSEMBLY........................................................................ 77 FUEL PRESSURE SENSOR........................................................................ 77 FUEL PRESSURE LIMITER....................................................................... 77 FUEL FLOW DAMPER............................................................................ 79 SPECIFICATIONS.................................................................................. 80 Fastener Tightening Specifications.......................................................... 80 Sec.6D ENGINE ELECTRICAL............................................................................ 82 CHARGING SYSTEM................................................................................. 82 DESCRIPTION................................................................................. 82 DIAGNOSIS OF CHARGING SYSTEM.................................................................... 83 UNDERCHARGED BATTERIES...................................................................... 83 OVERCHARGED CONDITION....................................................................... 83 NOISY GENERATOR............................................................................. 83 CHARGING SYSTEM TEST........................................................................ 83 ON-VEHICLE SERVICE.............................................................................. 85 GENERATOR REPLACEMENT....................................................................... 85 UNIT REPAIR..................................................................................... 86 BENCH TEST.................................................................................. 86 DISASSEMBLY................................................................................. 87 INSPECTION AND REPAIR....................................................................... 91 REASSEMBLY.................................................................................. 92 Sec.6E ENGINE EMISSION AND ELECTRICAL DIAGNOSIS..................................................... 94 GENERAL DESCRIPTION............................................................................. 96 HOW TO PROCEED WITH TROUBLESHOOTING......................................................... 96 CUSTOMER PROBLEM ANALYSES CHECK............................................................. 97 FUEL SYSTEM OUTLINE......................................................................... 98 CONSTRUCTION AND OPERATION SUPPLY PUMP......................................................102 WORKING ON ELECTRICAL ITEMS.................................................................104 NOTES FOR WORKING ON ELECTRICAL ITEMS.......................................................104 SYMBOLS AND ABBREVIATIONS...................................................................109 PARTS FOR ELECTRICAL CIRCUIT................................................................111 Diagnosis.......................................................................................113 Strategy Based Diagnostics..................................................................113 General Service Information.................................................................113 On Board Diagnostic (OBD)...................................................................114 Reading Diagnostic Trouble Codes Using A Tech 2 or Other Scan Tool..........................115 System Parts Description........................................................................133 ECM System Wiring Diagram.......................................................................138 Location Of Sensor And Switch...................................................................143 Engine Control Module (ECM).....................................................................146 Appearance Of ECM...........................................................................146 Detail Of 40 Pins Connector For Engine Harness..............................................146 Detail Of 80 Pins Connector For Engine Harness..............................................146 Chart Of ECM Input/Output...................................................................147 Connector Pin Assignment....................................................................147 Diagnostic Indication...........................................................................152 Contents Of Diagnostic Indication...........................................................152 Diagnostic Lamp Patterns In User Mode.......................................................152 Diagnostic Code Outputting In Dealer Mode...................................................152 How To Read Flashing Of The Indicator Lamp..................................................153 Clearing Method Of Diagnosis Trouble Code...................................................154 Typical Scan Data Values........................................................................155 Engine Data Definitions.........................................................................157 Symptom Diagnosis...............................................................................162 Hard Start Symptom..............................................................................163 Engine Stall....................................................................................164 Engine Hunting..................................................................................165 Surging, Hesitation.............................................................................166 High Idle Engine Speed/Engine Starts But Will Not Accelerate....................................167 Excessive White Smoke Or Blue Smoke.............................................................168 Excessive Black Smoke...........................................................................169 Lack Of Power...................................................................................170 TACHOMETER OUTPUT ERROR (Not Available DTC).....................................................171 EXHAUST BRAKE ERROR (No DTC Set)................................................................173 PTO (POWER TAKE OFF) ERROR (No DTC Set).........................................................175 VEHICLE SPEED SENSOR ERROR (Not DTC Set)........................................................177 COMMON RAIL SYSTEM CHECK........................................................................180 OBD SYSTEM CHECK DIAGNOSIS CHART............................................................181 NO MIL DIAGNOSIS CHART......................................................................184 MIL WILL NOT FLASH DIAGNOSIS CHART..........................................................187 ENGINE WILL NOT START DIAGNOSIS CHART.......................................................189 CHECK FUEL INJECTION AND TIMING RELATION (ENGINE OFF) DIAGNOSIS CHART.......................191 CHECK SUPPLY PUMP (ENGINE OFF) DIAGNOSIS CHART..............................................193 CHECK INJECTOR (ENGINE OFF) DIAGNOSIS CHART.................................................196 CHECK FUEL PRESSURE IN COMMON RAIL (ENGINE OFF) DIAGNOSIS CHART.............................198 SYSTEM OPERATION DIAGNOSIS CHART............................................................200 CHECK FUEL INJECTION AND TIMING RELATION (ENGINE RUNNING) DIAGNOSIS CHART...................202 CHECK SUPPLY PUMP (ENGINE RUNNING) DIAGNOSIS CHART..........................................204 CHECK FUEL PRESSURE IN COMMON RAIL (ENGINE RUNNING) DIAGNOSIS CHART.........................206 CHECK INJECTOR (ENGINE RUNNING) DIAGNOSIS CHART.............................................208 CHECK FUEL SYSTEM DIAGNOSIS CHART...........................................................210 MULTIPLE DTCS STORED DIAGNOSIS CHART........................................................212 ECM Diagnosis Trouble Codes.....................................................................215 Diagnosis Trouble Code List.................................................................215 DTC 0014 Pump Position Sensor Error (CAM Sensor)................................................219 DTC 0015 Crank Position Sensor Error (CKP Sensor)...............................................223 DTC 0022 Ambient Air Temperature Sensor Error...................................................227 DTC 0023 Engine Coolant Temperature Sensor Error................................................231 DTC 0024 Accelerator Pedal Position Sensor Error 1 And 2 .......................................235 Procedure Acceleration Sensor Adjustment...................................................237 DTC 0025 Vehicle Speed Sensor Error.............................................................241 DTC 0028 PTO Accelerator Position Sensor Error..................................................244 DTC 0032 Boost Pressure Sensor Error............................................................247 DTC 0034 Fuel Rate Data Error (No History Recorded).............................................252 DTC 0035 Analog Digital Conversion Error, CPU Monitoring IC Error And Charging Circuit Error....253 DTC 0042, 0032 High Boost Pressure Abnormal.....................................................255 DTC 0065 Low Boost Pressure Abnormal............................................................259 DTC 0071 BARO Sensor Error......................................................................263 DTC 0115 Common Rail Pressure Sensor Output Fixed...............................................265 DTC 0118 Common Rail Pressure Abnormal (Control System) 1st And 2nd Stage.......................270 DTC 0151 Common Rail Pressure Abnormal (Pump Over Pressure Supply)..............................275 DTC 0158 TWV Driving System Error (Common 1)....................................................280 DTC 0159 TWV Driving System Error (Common 2)....................................................285 DTC 0211 Fuel Temperature Sensor Error..........................................................290 DTC 0217 PCV 1 (Coil Or Harness) B+ Shortage....................................................294 DTC 0218 PCV 2 (Coil Or Harness) B+ Shortage....................................................297 DTC 0226 Supply Pump Non Pressure Supply Or Pressure Limiter Activation.........................300 DTC 0227 Supply Pump Non Pressure Supply........................................................303 DTC 0245 Abnormal Common Rail Pressure (PC Sensor System).......................................306 DTC 0247 PCV 1 (Coil Or Harness) Disconnect Or GND Shorted......................................311 DTC 0248 PCV 2 (Coil Or Harness) Disconnect Or GND Shorted......................................315 DTC 0261 (Cylinder No. 1) Flow Damper Activated.................................................319 DTC 0262 (Cylinder No. 2) Flow Damper Activated.................................................321 DTC 0263 (Cylinder No. 3) Flow Damper Activated.................................................323 DTC 0264 (Cylinder No. 4) Flow Damper Activated.................................................325 DTC 0265 (Cylinder No. 5) Flow Damper Activated.................................................327 DTC 0266 (Cylinder No. 6) Flow Damper Activated.................................................329 DTC 0271 (Cylinder No. 1) TWV Side Disconnected.................................................331 DTC 0272 (Cylinder No. 2) TWV Side Disconnected.................................................334 DTC 0273 (Cylinder No. 3) TWV Side Disconnected.................................................337 DTC 0274 (Cylinder No. 4) TWV Side Disconnected.................................................340 DTC 0275 (Cylinder No. 5) TWV Side Disconnected.................................................343 DTC 0276 (Cylinder No. 6) TWV Side Disconnected.................................................346 DTC 0416 Main Relay System Error (No History Records)...........................................349 DTC 0417 Starter Switch Abnormal................................................................351 DTC 0421 PCV Relay (R/L) System Error...........................................................354 DTC 0543 Over Speed Condition (Not Turn On MIL).................................................357 ENGINE CONTROL MODULE (ECM) DESCRIPTION.........................................................358 ON-VEHICLE SERVICE..............................................................................359 SPECIAL TOOLS...................................................................................365 Sec.7 TRANSMISSION AND CLUTCH.......................................................................366 AUTOMATIC TRANSMISSION..........................................................................366 MANUAL TRANSMISSION.............................................................................366 CLUTCH..........................................................................................366 Sec.7A AUTOMATIC TRANSMISSION (S1000 TRANSMISSION)..................................................368 DESCRIPTION.....................................................................................369 ELECTRONIC CONTROL SYSTEM...................................................................369 TORQUE CONVERTER............................................................................369 PLANETARY GEARS AND CLUTCHES................................................................369 COOLER CIRCUIT..............................................................................370 LUBRICATION DETAILS.........................................................................370 INSPECTION......................................................................................370 TRANSMISSION FLUID..........................................................................370 FLUID LEVEL.................................................................................370 GENERAL TROUBLESHOOTING INFORMATION.............................................................372 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS...............................................373 ON-VEHICLE SERVICE..............................................................................382 DRAIN AND FILL..............................................................................382 FILTER......................................................................................382 SHIFT CABLE.................................................................................383 FLUSHING THE TRANSMISSION COOLER AND LINES..................................................384 TRANSMISSION REPLACEMENT....................................................................385 TRANSMISSION CONTROL MODULE (TCM)...........................................................389 SPECIFICATIONS..................................................................................390 FASTENER TORQUE.............................................................................390 LUBRICATION.................................................................................390 Sec.8 CAB AND CHASSIS ELECTRICAL....................................................................392 GENERAL DESCRIPTION.............................................................................392 NOTES FOR WORKING ON ELECTRICAL ITEMS.......................................................392 SYMBOLS AND ABBREVIATIONS...................................................................392 SYMBOLS.................................................................................392 ABBREVIATIONS...........................................................................392 PARTS FOR ELECTRICAL CIRCUIT................................................................392 WIRING..................................................................................392 CIRCUIT BREAKER, FUSIBLE LINK WIRE AND SLOW BLOW FUSE...................................392 RELAY...................................................................................392 CONNECTOR...............................................................................392 DIODE...................................................................................392 MAIN DATA AND SPECIFICATIONS....................................................................394 BULB SPECIFICATIONS.........................................................................394 CIRCUIT BREAKER AND SLOW BLOW FUSE LOCATION.................................................396 FUSE BLOCK CIRCUIT..........................................................................398 REFERENCE TABLE OF CIRCUIT BREAKER..........................................................400 RELAY LOCATION..............................................................................402 SYSTEM REPAIR...................................................................................403 START AND CHARGING..........................................................................403 ENGINE CONTROL MODULE (ECM).................................................................408 HEADLIGHT...................................................................................412 MARKER LIGHT, TAILLIGHT, LICENSE PLATE LIGHT AND STOPLIGHT..................................417 TURN SIGNAL LIGHT AND HAZARD WARNING LIGHT..................................................421 HORN AND BACKUP LIGHT.......................................................................425 DOME LIGHT..................................................................................431 POWER WINDOW................................................................................434 WINDSHIELD WIPER AND WASHER.................................................................436 CIGARETTE LIGHTER AND CONSENT...............................................................439 METER AND WARNING/INDICATOR LIGHT...........................................................442 SPEEDOMETER.................................................................................451 HEATER, VENTILATION AND AIR CONDITIONING....................................................457 RADIO.......................................................................................459 POWER TAKE OFF (PTO)........................................................................462 DRAIN HEATER................................................................................466 ANTI-LOCK BRAKE SYSTEM (ABS)................................................................469 TRANSMISSION CONTROL MODULE.................................................................472 WIRING DIAGRAM..............................................................................476 Sec.9 METRIC AND FASTENER INFORMATION...............................................................498 METRIC FASTENERS................................................................................498 REPLACEMENT FASTENERS.......................................................................498 FASTENER STRENGTH IDENTIFICATION................................................................498 PREVAILING TORQUE FASTENERS.....................................................................498 RECOMMENDATIONS FOR REUSE...................................................................498 SIX-LOBED SOCKET HEAD FASTENERS.................................................................498 DECIMAL AND METRIC EQUIVALENTS..................................................................498 CONVERSION TABLE................................................................................498 Sec.10 CAB..........................................................................................500 STEEL TILT CAB..................................................................................500
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