Case 6HK1-6WG1 Engine Troubleshooting Manual 87528730 – PDF DOWNLOAD

Description

Case 6HK1-6WG1 Engine Troubleshooting Manual 87528730 – PDF DOWNLOAD

DESCRIPTION:

Case 6HK1-6WG1 Engine Troubleshooting Manual 87528730 – PDF DOWNLOAD

Precautions on Service Work:
Use of tools for circuit test :
If there are no special instructions test lights must not be used in the diagnosis of system.
Commercial electrical equipment :

• Commercial electrical equipment means that commercial electrical components installed to a machine after shipment from factory. Be careful that no special consideration for this equipment is taken in the design process of the machine.
• Commercial electrical equipment may cause malfunction of the electronic control system even if they are installed properly. They include devices which are not connected to the electrical systems on the machine, such as mobile phones or radios. Therefore, in trouble diagnosis of powertrain, first check if this commercial electrical equipment is installed, and if so, remove it from the machine. If the trouble has not been solved after the removal, diagnose it in usual procedures.

Welding work on the machine :
If performing welding on the machine, remove the battery in advance. Otherwise, the current during welding may cause system trouble or damage.

TABLE OF CONTENTS:

Case 6HK1-6WG1 Engine Troubleshooting Manual 87528730 – PDF DOWNLOAD

List of error codes …………………………………………………….3
6HK1 Engine error codes …………………………………………………….3
6WG1 Engine error codes ………………………………………………….11
About recovery from failure…………………………………………………20
How to use this manual ……………………………………………21
Table of abbreviation …………………………………………………………22
List of parts according to engine control specifications …………..23
About colors of wirings……………………………………………………….24
About wiring diagrams ……………………………………………………….25
How to read Error Code diagnosis section ……………………………26
Precautions on Service Work……………………………………28
Procedure of trouble diagnosis with an interview ……..29
Information……………………………………………………………………….29
Interview ………………………………………………………………………….29
Pre-inspection…………………………………………………………………..32
Confirmation after repair …………………………………………………….33
List of final check items………………………………………………………34
How to use breaker box ……………………………………………35
Injector inspection procedure using thermo gun……….38
Engine Control System …………………………………………….40
Description of function and operation …………………………………..40
Engine Control Module (ECM)…………………………………………….47
Pin arrangement of engine control module (ECM) …………………49
Engine component location diagram (6HK1) …………………………52
Engine component location diagram (6WG1)………………………..52
Supply pump (6HK1) …………………………………………………………53
Supply pump (6WG1) ………………………………………………………..53
SCV (suction control valve) (6HK1) ……………………………………..53
PCV (pressure control valve) (6WG1) ………………………………….54
Fuel temperature (FT) sensor (B3) ………………………………………54
G sensor (B50) (W6G1)……………………………………………………..54
Common rail …………………………………………………………………….55
Flow damper …………………………………………………………………….55
Pressure limiter…………………………………………………………………55
Common rail pressure sensor (B52)…………………………………….55
Injector …………………………………………………………………………….56
Engine coolant temperature (ECT) sensor (B1) …………………….56
Crankshaft position (CKP) sensor (B49)……………………………….56
Camshaft position (CMP) sensor (6HK1) ……………………………..57
Engine oil pressure sensor (B21) ………………………………………..57
Accelerator position (AP) sensor …………………………………………57
Barometric pressure sensor (B48)……………………………………….58
Intake air temperature (IAT) sensor (B6) ……………………………..58
EGR position sensor (B53) ………………………………………………..58
Boost pressure sensor (B47) ……………………………………………..58
Boost temperature sensor (B51) …………………………………………59
Description of components shown on the wiring diagram and electrical
circuits of engine ………………………………………………………60
Wiring diagram of engine control module (ECM) (6WG1) ……….61
Wiring diagram of engine control module (ECM) (6HK1) ……….62
Circuit diagram………………………………………………………………….63
Connector list……………………………………………………………………79
Trouble Shooting……………………………………………………..83
Diagnosis of Service and support ………………………………………..84
Starting circuit system check ………………………………………………85
Starting system check………………………………………………………..89
Fuel system check …………………………………………………………….91
Intake system check ………………………………………………………….94
Exhaust system check ……………………………………………………….95
EGR control system check …………………………………………………96
QOS system check ……………………………………………………………98
Error Code: 0087 (6WG1)…………………………………………………106
Error Code: 0088 …………………………………………………………….112
Error Code: 0089 …………………………………………………………….116
Error Code: 0090 (6HK1)………………………………………………….120
Error Code: 0090/1291 (6WG1)…………………………………………125
Error Code: 0092/1292 (6WG1)…………………………………………130
Error Code: 0107 …………………………………………………………….134
Error Code: 0108 …………………………………………………………….139
Error Code: 0112 …………………………………………………………….143
Error Code: 0113 …………………………………………………………….148
Error Code: 0117 …………………………………………………………….153
Error Code: 0118 …………………………………………………………….158
Error Code: 0182 …………………………………………………………….163
Error Code: 0183 …………………………………………………………….167
Error Code: 0192 …………………………………………………………….171
Error Code: 0193 …………………………………………………………….176
Error Code: 0201 …………………………………………………………….180
Error Code: 0202 …………………………………………………………….185
Error Code: 0203 …………………………………………………………….190
Error Code: 0204 …………………………………………………………….195
Error Code: 0205 …………………………………………………………….200
Error Code: 0206 …………………………………………………………….205
Error Code: 0219 …………………………………………………………….210
Error Code: 0237 …………………………………………………………….212
Error Code: 0238 …………………………………………………………….217
Error Code: 0335 …………………………………………………………….222
Error Code: 0336 …………………………………………………………….227
Error Code: 0340 (6HK1) ………………………………………………….231
Error Code: 0340 (6WG1)…………………………………………………237
Error Code: 0341 (6HK1) ………………………………………………….243
Error Code: 0341 (6WG1)…………………………………………………248
Error Code: 0380 …………………………………………………………….253
Error Code: 0487 …………………………………………………………….257
Error Code: 0488 …………………………………………………………….262
Error Code: 0522 …………………………………………………………….267
Error Code: 0523 …………………………………………………………….272
Error Code: 0601 …………………………………………………………….277
Error Code: 0603 …………………………………………………………….278
Error Code: 0606 …………………………………………………………….279
Error Code: 0611 …………………………………………………………….281
Error Code: 0612 …………………………………………………………….284
Error Code: 1093 (6WG1)…………………………………………………287
Error Code: 1095 …………………………………………………………….293
Error Code: 1112 …………………………………………………………….300
Error Code: 1113 …………………………………………………………….306
Error Code: 1173 …………………………………………………………….311
Error Code: 1261 …………………………………………………………….316
Error Code: 1262 …………………………………………………………….323
Error Code: 1345 …………………………………………………………….330
Error Code: 1630 …………………………………………………………….333
Error Code: 1631 …………………………………………………………….334
Error Code: 1632 …………………………………………………………….337
Error Code: 1633 …………………………………………………………….340
Error Code: 1634 …………………………………………………………….343
Error Code: 1635 …………………………………………………………….346
Error Code: 2104 …………………………………………………………….349
Error Code: 2106 …………………………………………………………….353
List of trouble symptom………………………………………… 357
Engine start failure …………………………………………………………..358
Engine stall …………………………………………………………………….361
Engine hunting, rough idling ……………………………………………..364
Engine output shortage…………………………………………………….367
Exhaust gas contains a lot of white smoke ………………………….371
Exhaust gas contains a lot of black smoke ………………………….373
Special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

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CASE 6HK1-6WG1 ENGINE TROUBLESHOOTING MANUAL 87528730 – PDF DOWNLOAD:

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