ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER FRR WT5500 6HK1 TC Diesel Engine & Chassis Service Manual – PDF DOWNLOAD

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ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER FRR WT5500 6HK1 TC Diesel Engine & Chassis Service Manual

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PAGES:636
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ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER FRR WT5500 6HK1 TC DIESEL ENGINE & CHASSIS SERVICE MANUAL – PDF DOWNLOAD:

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ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER FRR WT5500 6HK1 TC Diesel Engine & Chassis Service 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/WS. When used with the Isuzu Commercial Truck Service Manual (Pub. No. FRR97-WSM-C0’I), 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 invehicle damage or malfunction, or possibly personal injury.
• Therefore, fasteners removed from the vehicle should be saved for reuse 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:

ISUZU COMMERCIAL TRUCK FORWARD TILTMASTER FRR WT5500 6HK1 TC Diesel Engine & Chassis Service Manual

INDEX.................................................................................  0
TOP...................................................................................  1
	Sec.0 GENERAL INFORMATION.........................................................  7
	Sec.0A GENERAL INFORMATION........................................................  7
		HANDLING ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS........................  7
		SERVICE PATRS IDENTIFICATION LABEL............................................  8
		RPO (REGULAR PRODUCTION OPTIONS) LIST.........................................  8
		VEHICLE IDENTIFICATION NUMBER (VIN)...........................................  9
		CERTIFICATION LABEL...........................................................  9
		MODEL REFERENCE...............................................................  9
		ENGINE IDENTIFICATION NUMBER..................................................  9
		EMERGENCY STARTING YOUR VEHICLE DUE TO A DISCHARGED BATTERY...................  9
		TOWING PROCEDURE.............................................................. 11
		GRAPHIC SYMBOLS............................................................... 13
		ACTION SYMBOLS................................................................ 13
		COMMON AUOMOTIVE ABBREVIATIONS................................................ 15
	Sec.0B MAINTENANCE AND LUBRICATION................................................ 18
		ENGINE OIL AND VISCOSITY RECOMMENDATIONS...................................... 18
		MAAINTENANCE SCHEDULE......................................................... 19
		SPECIFICATIONS................................................................ 31
		ESSENTIAL SERVICE TOOLS....................................................... 32
	Sec.1 HEATING AND AIR CONDITIONING................................................ 33
	Sec.2 FRAME....................................................................... 34
	Sec.3 STEERING, SUSPENSION, WHEELS AND TIRES...................................... 35
	Sec.3B3 POWER STEERING............................................................ 36
		POWER STEERING SYSTEM ON-VEHICLE SERVICE...................................... 39
		HYDRAULIC PUMP UNIT REPAIR.................................................... 40
		SPECIAL TOOLS................................................................. 43
	Sec.3B4 STEERING COLUMN........................................................... 44
		STEERING COLUMN ON-VEHICLE SERVICE............................................ 45
		STEERING COLUMN UNIT REPAIR................................................... 48
		SPECIFICATIONS................................................................ 49
	Sec.3C FRONT AXLE AND SUSPENSION.................................................. 50
		FRONT HUBS AND BEARINGS ON-VEHICLE SERVICE.................................... 51
	Sec.3E WHEELS AND TIRES........................................................... 52
		SPECIFICATIONS................................................................ 53
	Sec.4 REAR AXLE AND PROPELLER SHAFT............................................... 54
	Sec.4B1A REAR AXLE................................................................ 55
		ON-VEHICLE SERVICE............................................................ 56
	Sec.5 BRAKES (AIR OVER HYDRAULIC BRAKES).......................................... 57
	Sec.5A AIR OVER HYDRAULIC BRAKES.................................................. 57
		INTRODUCTION.................................................................. 58
		DIAGNOSIS OF THE BRAKE SYSTEM................................................. 59
		DIAGNOSIS OF BRAKE SYSTEM..................................................... 60
		DIAGNOSIS OF BRAKE LINING..................................................... 66
		DIAGNOSIS OF BRAKE DRUM....................................................... 67
		PLUMBING SCHEMATIC............................................................ 68
		ON-VEHICLE SERVICE............................................................ 69
	Sec.5A1 HYDRAULIC BRAKE BOOSTER SYSTEM............................................ 78
		INTRODUCTION.................................................................. 78
		ON-VEHICLE SERVICE............................................................ 79
		UNIT REPAIR................................................................... 81
	Sec.5A2 HYDRAULIC FOUNDATION BRAKES............................................... 89
		INTRODUCTION.................................................................. 90
		ON-VEHICLE SERVICE OF BRAKE ASSEMBLY.......................................... 92
		LININGS AND DRUMS............................................................. 98
		SPECIFICATIONS................................................................100
		SPECIAL TOOL..................................................................100
	Sec.5A4 ANTILOCK BRAKE SYSTEM.....................................................101
		SERVICE PRECEAUTION...........................................................103
		GENERAL DESCRIPTION...........................................................104
		GENERAL DIAGNOSIS.............................................................106
		EBCM CONNECTOR PIN-OUT CHECKS.................................................109
		SYMPTOM DIAGNOSIS.............................................................115
		DIAGNOSTIC TROUBLE CODES......................................................118
		DIAGNOSIS BY "ABS" WARNING LIGHT ILLUMINATION PATTERN.........................121
		UNIT INSPECTION PROCEDURE.....................................................151
		WHEEL SPEED SENSOR............................................................156
		MODULATOR.....................................................................158
		SPECIAL TOOLS.................................................................159
	Sec.5B1 AIR BRAKE VALVES..........................................................160
		INTRODUCTION..................................................................161
		ON-VEHICLE SERVICE OF BRAKE VALVES............................................161
		UNIT REPAIR...................................................................164
	Sec.5D AIR COMPRESSOR AND GOVERNOR................................................168
		DESCRIPTION...................................................................168
		DIAGNOSIS OF THE AIR COMPRESSOR AND GOVERNOR..................................169
		ON-VEHICLE SERVICE............................................................170
		AIR COMPRESSOR UNIT REPAIR....................................................172
		SPECIFICATIONS................................................................176
	Sec.5E EXHAUST BRAKE..............................................................177
		DESCRIPTION...................................................................178
		DIAGNOSIS OF EXHAUST BRAKE....................................................179
		EXHAUST BRAKE ON-VEHICLE SERVICE..............................................180
		SPECIFICATIONS................................................................185
	Sec.6 ENGINE......................................................................186
	Sec.6A6B DIESEL ENGINE OVERHAUL...................................................205
		DIESEL ENGINE OVERHAUL........................................................205
		GENERAL DESCRIPTION...........................................................206
		DISASSEMBLY OF THE ENGINE.....................................................208
		CLEANING, INSPECTION, AND REPAIR..............................................212
		ASSEMBLY OF THE ENGINE........................................................231
		SPECIFICATIONS................................................................244
		SPECIAL TOOLS.................................................................248
	Sec.6B1B WATER PUMP OVERHAUL......................................................249
		DISASSEMBLY...................................................................249
		SPECIFICATIONS................................................................253
		SPECIAL TOOLS.................................................................253
	Sec.6A6 DIESEL ENGINE ON-VEHICLE SERVICE..........................................254
		GENERAL DESCRIPTION...........................................................254
		ON-VEHICLE SERVICE............................................................187
		SPECIFICATIONS................................................................203
		SPECIAL TOOLS.................................................................204
	Sec.6C FUEL SYSTEM................................................................255
	Sec.6C2 DIESEL FUEL INJECTION.....................................................256
		GENERAL DESCRIPTION...........................................................257
		FUEL INJECTION SYSTEM.........................................................263
		ON VEHICLE SERVICE............................................................264
		SPECIFICATIONS................................................................270
	Sec.6E ENGINE EMISSION AND ELECTRICAL DIAGNOSIS...................................271
		GENERAL DESCRIPTION...........................................................273
		DIAGNOSIS.....................................................................282
		SYSTEM PARTS DESCRIPTION......................................................301
		ECM SYSTEM WIRING DIAGRAM (1OF4)..............................................306
		LOCATION OF SENSOR AND SWITCH.................................................310
		ENGINE CONTROL MODULE (ECM)...................................................312
		CHART OF ECM INPUT/OUTPUT.....................................................313
		CONNECTOR PIN ASSIGNMENT......................................................313
		TROUBLESHOOTING...............................................................317
		TYPICAL SCAN DATA VALUES......................................................322
		SYMPTOM DIAGNOSIS.............................................................323
		THCHOMETER OUTPUT ERRIR (NO AVAILABLE DTC)....................................324
		ENGINE HUNTING................................................................326
		ENGINE CRANKS BUT DOES NOT RUN................................................327
		ENGINE STARTS AND STALLS......................................................330
		ENGINE STARTS BUT WILL NOT ACCELERATE.........................................331
		EXCESSIVE WHITE OR BLUE SMOKE.................................................332
		EXCESSIVE BLACK SMOKE.........................................................333
		LACK OF POWER.................................................................334
		SURGING, HESITATION...........................................................336
		ENGINE STALL..................................................................338
		ENGINE DOES NOT STOP..........................................................339
		IDLE CONTROL ERROR............................................................340
		HIGH IDLE ENGINE SPEED........................................................341
		EXHAUST BRAKE ERROR (NO DTC SET)..............................................342
	Sec.6J TURBOCHARGER...............................................................471
		GENERAL DESCRIPTION...........................................................471
		ON-VEHICLE SERVICE............................................................472
		SPECIFICATIONS................................................................475
		SPECIAL TOOLS.................................................................475
	Sec.7 TRANSMISSION AND CLUTCH.....................................................476
	Sec.8 CAB AND CHASSIS ELECTRICAL..................................................477
		GENERAL DESCRIPTION...........................................................478
		MAIN DATA AND SPECIFICATIONS..................................................491
		SYSTEM REPAIR.................................................................500
	Sec.10 CAB........................................................................574
		1. DISMOUNTING OF CAB.........................................................576
		2. MOUNTING OF CAB............................................................578
		3. DISASSEMBLING OF FRONT PART................................................581
		4. ASSEMBLING OF FRONT PART...................................................582
		5. DISASSEMBLING OF FENDER AND ITS ASSOCIATED PARTS...........................583
		6. ASSEMBLING OF FENDER AND ITS ASSOCIATED PARTS..............................584
		7. DISASSEMBLING OF FRONT DOOR (LEFT-HAND SIDE)...............................585
		8. ASSEMBLING OF FRONT DOOR (LEFT-HAND SIDE)..................................587
		9. DISASSEMBLING OF FRONT DOOR (RIGHT-HAND SIDE)..............................589
		10. ASSEMBLING OF FRONT DOOR (RIGHT-HAND SIDE)................................591
		11. DISASSEMBLING OF FRONT WINDSHIELD GLASS...................................594
		12. ASSEMBLING OF FRONT WINDSHIELD GLASS......................................596
		13. DISASSEMBLING OF QUARTER WINDOW GLASS.....................................598
		14. ASSEMBLING OF QUARTER WINDOW GLASS........................................600
		15. DISASSEMBLING OF BACKLIGHT GLASS..........................................602
		16. ASSEMBLING OF BACKLIGHT GLASS.............................................604
		17. DISASSEMBLING OF OUTSIDE MIRROR...........................................606
		18. ASSEMBLING OF OUTSIDE MIRROR..............................................607
		19. DISASSEMBLING OF INSTRUMENT PANEL AND ITS ASSOCIATED PARTS................608
		20. ASSEMBLING OF INSTRUMENT PANEL AND ITS ASSOCIATED PARTS...................610
		21. DISASSEMBLING OF FRONT SEATS AND THEIR ASSOCIATED FLOOR PARTS.............612
		22. ASSEMBLING OF FRONT SEATS AND THEIR ASSOCIATED FLOOR PARTS................614
		23. DISASSEMBLING OF HEAD LINING AND ITS ASSOCIATED PARTS.....................616
		24. ASSEMBLING OF HEAD LINING AND ITS ASSOCIATED PARTS........................618
		25. DISASSEMBLING OF INTERIOR TRIMS...........................................620
		26. ASSEMBLING OF INTERIOR TRIMS..............................................622
		27. DISASSEMBLING AND INSPECTION OF CAB TILTING MECHANISM (STANDARD MODEL)....623
		28. ASSEMBLING OF CAB TILTING MECHANISM (STANDARD MODEL)......................626
		29. DISASSEMBLING AND INSPECTION OF CAB LOCK..................................629
		30. ASSEMBLING OF CAB LOCK....................................................631

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