Case 4HK1-6HK1 Manuale utente
SERVICE MANUAL
Revised 05-2006
Issued 02-2006
9-44061 NA
Replaces 9-44060 NA
4HK1-6HK1
ISUZU ENGINES
9-44061 NA4HK1- 6HK1 ISUZU ENGINES
05-2006Revision 1
9-44060 NA4HK1- 6HK1 ISUZU ENGINES02-2006First Edition
REVISION HISTORY
RemarksIssue Issue Date Applicable Machines
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America, LLC. Racine, WI 53403 U.S.A..
CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not
necessarily show products in standard condition.For exact information about any particular product, please consult your Dealer
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1
9-44061Issued 02-06
INDEX OF CHAPTERS
GENERAL INFORMATION .................................................................................................................................... 0A
ENGINE MECHANICAL ......................................................................................................................................... 1A
COOLING SYSTEM ............................................................................................................................................... 1B
FUEL SYSTEM....................................................................................................................................................... 1C
ENGINE ELECTRICAL........................................................................................................................................... 1D
EXHAUST SYSTEM AND TURBOCHARGER........................................................................................................1F
NOTE: CNH Company reserves the right to make changes in the specification and design of the machine with-
out prior notice and without incurring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in accordance with the technical specifica-
tions known as of the date of design of this document.
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IN-2 Introduction
UNITS OF MEASURE
This manual adopts the units of measure based on International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 MPa (250 kgf/cm2)
The following table converts the International System units of measure in some of the main units belonging to other
system.
Quantity To convert
from (IS)
Into
(Others) Multiply by Quantity To convert
from (IS)
Into
(Others) Multiply by
Lenght mm in 0.03937 Pressure MPa kgf/cm210.197
mm ft 0.003281 MPa psi 145.0
Volume
L US gal 0.2642 Power kW CV-PS 1.360
L US qt 1.057 kW HP 1.341
m3yd31.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Speed km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Capacity L/min US gpm 0.2642
Torqu e N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
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General Information 0A-1
GENERAL INFORMATION
General Information
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2
Reading the model . . . . . . . . . . . . . . . . . . . . . . . 0A-6
General information . . . . . . . . . . . . . . . . . . . . . . 0A-7
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0A-2 General Information
General Information
Service Precautions
In order to carry out work safely
1. Always use an engine stand when taking the
engine down from the vehicle.
Do not place the engine directly onto the ground,
or place in a manner that interferes with the oil
pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical
system, always remove the minus side cable from
the battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.
4. Do not perform painting work or leave the engine
running for long periods of time in an enclosed or
badly ventilated indoor workshop.
5. Always use the correct specialized tool indicated in
the instructions. Using the incorrect tool may
cause damage to the parts or injury to the person
using the tool.
6. All regular tools, gauges and special tools should
be regularly inspected, and prepared before
starting work. Do not use bent spanners, hammers
with damaged edges, chipped chisels, or any other
faulty or damaged tools.
7. Always pay close attention to safety and handling
requirements when using grinders, cranes,
welders, and other such equipment.
Moreover, always wear the correct protective
garments and use the necessary safety tools for
the job in hand.
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General Information 0A-3
8. Always check that there are no fuel leaks when
performing maintenance work on the fuel system.
(It may cause a fire.)
9. Pay close attention to the risk of ignition if you are
handling parts that carry a high voltage.
Furthermore, any oil or fat spilt onto rubber parts
must be wiped off immediately, as it will cause
deterioration of the rubber.
Replacement parts and part numbers.
1. Always replace packing, oil seals, o-rings, caulking
lock nuts, folding lock plates, split pins and other
such parts with brand new parts.
2. The parts numbers contained in this manual may
not represent the supply condition of the parts, and
the part numbers may be changed due to
revisions. Therefore, parts should always be
checked against a parts catalogue before use.
Liquid gasket
1. Each time you disassemble parts that use liquid
gasket, completely remove the old gasket residue
from each of the parts and matching sections using
a scraper, then clean each of the parts to
completely remove oil, water, and dirt etc. from the
various surfaces. Using the specified type of liquid
gasket, apply new liquid gasket to each of the
surfaces before reassembling the parts.
2. In order to make it easier to clean liquid gasket
surfaces, apply gasket remover liquid (Pando-
391D made by Three Bond Co., Ltd.) and leave
the part to stand for approximately 10 minutes,
after which the old liquid gasket residue will be
easier to remove.
However, this should not be used on resin
components or painted components.
3. Please take care not to apply too much or too little
liquid gasket.
Also, you should always re-apply the liquid gasket
upon itself when you start and finish application.
4. Make sure that there are no gaps when re-
installing the liquid gasket parts to each other. If
there are gaps between the two parts, re-apply the
liquid gasket. Some parts, especially the oil pan,
use the same size studs as a guide to eliminate the
need for knock pin positioning etc.
5. Re-install these parts within 7 minutes of applying
the liquid gasket.
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0A-4 General Information
If more than 7 minutes passes, remove the
previous liquid gasket and re-apply it.
6. Please wait for at least 30 minutes since the last
part is installed before starting the engine.
Liquid gasket
• Always use the liquid gasket products listed above,
or a liquid gasket identical to the ones listed above.
• Use the correct quantity of liquid gasket. Always
follow the handling instructions for each product.
Application procedure
1. Wipe the contact surfaces clean of all water, fat or
oil. The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one
of the contact surfaces. Make sure that the bead
does not break at this point.
Notes:
If there are special regulations concerning the
application procedure in the repair document, please
follow those regulations.
Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and
screw thread section clean of water, fat, and oil.
The contact surfaces should be dry.
2. Apply Loctite to the top 1/3 of the screw.
3. Tighten the bolt to the correct tightening torque.
Important:
After tightening the bolt, do not apply excessive torque
or try to rotate the bolt until at least one hour has
passed, and the Loctite has hardened.
Procedure for using the Plastiguage
Example: Procedure for measuring the clearance
between the connecting rod bearing and crank pin.
• Clean the connecting rod and bearing, and install
the bearing to the rod.
• Cut the plastiguage to the same width as the crank
pin, and while avoiding the oil pore of the crank pin
lay the gauge parallel to the pin.
Seal section Product name Manufacturer's name
Between cylinder block and – Flywheel housing 1207B Three Bond
Between cylinder block and – Flywheel housing and –
Crankcase 1207B Three Bond
Between cylinder block and – Crank case 1207B Three Bond
Between cylinder block and – Front cover 1207B Three Bond
Cylinder block, head plug nipple, unit, switches 262 Loctite
Type Measurable range mm (in)
PG-1 (Green) 0.025 – 0.076 (0.001 – 0.003)
PR-1 (Red) 0.051 – 0.152 (0.002 – 0.006)
PB-1 (Blue) 0.102 – 0.229 (0.004 – 0.009)
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General Information 0A-5
• Line up the marks on the connecting rod and cap
and install the crank pin, apply molybdenum
disulphide to the thread section and bearing
surface of the fastening bolt, and rotate both cap
and bolt to the correct torque.
Important:
Do not move the connecting rod while using the
plastiguage.
• Gently remove the cap and connecting rod, and
measure the crushed width of the plastiguage
(clearance between rod and pin) using the scale
printed on the bag.
Example: Measuring the clearance between the crank
bearing and crank journal
• Clean the clamp face of the cylinder block and
crankcase bearing, and also the bearing, and
install the cylinder block to the crankcase.
• Gently rest the crankshaft on the cylinder block,
and rotate it approximately 30 degree to stabilize it.
• Cut the plastiguage to the same size as the journal
width, and while avoiding the oil pore of the journal
lay the gauge parallel to the journal.
• Gently rest the crank case on the cylinder block,
apply molybdenum disulphide to the thread section
and bearing surface of the fastening bolt, and
tighten in sequence to the correct torque.
Important:
Do not rotate the crankshaft while using the
plastiguage.
• Gently remove the crankcase, and measure the
crushed width of the plastiguage (clearance
between bearing and journal) using the scale
printed on the bag.
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