Hitachi 4HK1 Manuale di istruzioni
EWDCY-EN-004HK1 GB3 EXHAUST EMISSION STANDARDS ENGINE MANUAL WORKSHOP MANUAL
PRINTED IN JAPAN (K) 2015, 06
Service Manual consists of the following sections.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
Engine Manual
EWDCY-EN-00
PART NO.
GB3
EXHAUST EMISSION
STANDARDS
Engine Manual
Workshop Manual
URL:http://www.hitachi-c-m.com
4HK1
FOREWORD
Thismanualdescribestheserviceproceduresforthe4HK1dieselengine(GB3).
Thecontentsofthismanualarecurrentatthedateofissue,butmaydifferslightlyfromyourengineduetospecificationchanges
orothermodificationsmadethereafter.
Thismanualconsistsofthefollowingsub-sections.
PublicationNo. PublicationName Sub-sections
IDE-2820 ENGINE 0 Introduction
14A ServiceInformationGuide
15B MaintenanceInformation
15C FunctionalInspection
15D Symptom
15E DTCInformation
1A EngineControl
1B Mechanical
1C FuelSystem
1D Cooling
1E Lubrication
1F Induction
1H Aux.EmissionControlDevices
1J Electrical
–WiringDiagram
IDE-2820前書450526015.1.283:19AMページ1
FOREWORD
Thismanualdescribestheserviceproceduresforthe4HK1dieselengine(GB3).
Thecontentsofthismanualarecurrentatthedateofissue,butmaydifferslightlyfromyourengineduetospecificationchanges
orothermodificationsmadethereafter.
Thismanualconsistsofthefollowingsub-sections.
PublicationNo. PublicationName Sub-sections
IDE-2820 ENGINE 0 Introduction
14A ServiceInformationGuide
15B MaintenanceInformation
15C FunctionalInspection
15D Symptom
15E DTCInformation
1A EngineControl
1B Mechanical
1C FuelSystem
1D Cooling
1E Lubrication
1F Induction
1H Aux.EmissionControlDevices
1J Electrical
–WiringDiagram
IDE-2820前書450526015.1.283:19AMページ1
The engine specication and description, which is not installed in the machine, may be explained on this manual.
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Introduction
Introduction
(All)
Table of Contents
Introduction........................................................................0-2
safety information..........................................................0-2
Introduction (All) 0-1
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Introduction
safety information
1. Repair work safety information
1. When the engine is unloaded from the machine, use
the engine stand.
When placing the engine, place it in a way that the
oil pan does not interfere.
2. When performing a work with two or more people,
perform while ensuring each other's safety.
3. Do not disconnect the battery cable for approx. 1
minute after turning OFF the ignition switch. If the
power supply to the ECM is cut within approx. 1
minute after turning OFF the ignition switch, failures
to the ECM may be caused.
4. When repairing the electrical system, make sure to
disconnect the negative cable from the battery
terminal before performing the work. When
removing the battery cover, do so away from fire.
5. Do not leave the engine running for an extended
period of time or perform painting in a poorly
ventilated working environment.
6. Make sure to use the special tools if the procedure
requires them for the work. If the procedure is
performed with other tools, the parts may be
damaged or injuries may occur.
7. Always inspect and prepare in advance the
instruments, special tools, and the tools to be used.
Also, do not use tools such as wrenches that have
lost their edge, hammers with frayed edges, or
chipped chisels.
8. When performing work using a device such as a
grinder, crane, or welder, perform the procedure
while paying sufficient attention to the handling
precautions.
Furthermore, for work besides this, carry out work
while wearing safety clothes and equipment.
9. When performing maintenance on the fuel system,
make sure to check that there is no fuel leakage.
10. When handling volatile materials, take care that they
do not catch fire.
Make sure to wipe away any oil that sticks to rubber
parts, as it can cause deterioration.
2. Replacement parts and parts number safety
information
1. Whenever disassembly is performed, make sure to
replace the packing, oil seals, O-rings, crimping lock
nuts, bending lock plates, cotter pins, etc., with new
ones.
2. Make sure to check the supply system and part
numbers in the parts catalog because the part
numbers indicated in this manual may differ from the
supply system and are subject to change.
0-2 Introduction (All)
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Description General Information
Service Information Guide
(All)
Table of Contents
Contents included in service information.....................14A-2
Plastic gauge..................................................................14A-4
Recommended liquid gasket.........................................14A-6
Thread locking adhesive agent......................................14A-8
Term..............................................................................14A-9
Abbreviations .............................................................14A-10
Standard bolts..............................................................14A-13
Service Information Guide (All) 14A-1
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Contents included in service information
1. Contents included in service information
Removal
Includes the removal procedure when repairing parts,
devices, etc.
Installation
Includes the installation procedure when repairing parts,
devices, etc.
Disassembly
Includes the disassembly procedure when overhauling a
unit, assembly part, etc.
Assembly
Includes the assembly procedure when overhauling a
unit, assembly part, etc.
Inspection
Includes inspection items for parts requiring inspection to
ensure continued performance of parts, devices, etc.
Values are listed for parts whose specified values, setting
values, and use conditions have been determined.
Cleaning
Includes the cleaning procedure for parts, devices, etc.
Preparation
Includes the preparatory procedure necessary before
removing parts, devices, etc.
Adjustment
Includes the adjustment procedure if adjustment to the set
or specified values is necessary when performing
assembly or installation.
Measurement
Includes the measurement procedure for determining if
the installation position of parts is correct, etc.
Drain
Includes the draining procedure for oil, etc.
Refill
Includes the refilling procedure for oil, etc.
Air removal
Includes the air removal procedure when air removal is
necessary after changing oil, etc.
Precaution
Includes the maintenance precautions specific to each
item.
Disconnection
Includes the disconnection procedures for wiring, piping,
etc.
Connection
Includes the connection procedures for wiring, piping,
etc.
Writing
Includes the writing procedure necessary when replacing
the ECM or supply pump.
Setting
Includes the setting procedure necessary when replacing
the ECM, etc.
Replacement
Includes the procedure for replacing parts, changing oil,
etc.
Prioritized DTC
Includes DTCs that need to be diagnosed and resolved
before the relevant DTC when multiple DTCs are set.
Diagnosis
Includes the diagnostic procedure for troubleshooting
symptoms.
DTCs are listed in order of priority.
Repair verification
Includes the procedure for verifying resolution of the
symptom by using numerical values, etc., other than the
verification that DTCs are cleared.
Functional description
Includes the detailed functional description related to the
functional inspection.
Symptom description
Includes the detailed symptom descriptions related to a
diagnosis by symptom.
DTC description
Includes the circuit description related to DTCs.
Setting conditions
Includes the conditions and the judgment conditions for
the ECM, etc. to set DTCs.
Action taken when set
Includes the information related to the control actions
taken by the ECM, etc., when DTCs are set.
Items related to ETM
Items related to the ETM are described in the instructions
on how to view the wiring diagram.
2. Arrows and symbols
14A-2 Service Information Guide (All)
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1. Forward
2. Upward
3. Operating section or operating direction
4. Detail of a particular part
5. Detailed view from A
6. Arrow indicating a dimension
7. Arrow indicating a cross-section
8. Outside air or cold air
9. Gas or warm air
10. Mixing of outside air and gas or mixing of cold
air and warm air
11. Rotational direction
12. Apply oil
13. Apply grease
14. Apply liquid gasket
Service Information Guide (All) 14A-3
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Plastic gauge
1. Using the plasti-gauge
Type Measurable range
PG-1 (Green) ： 0.025 to 0.076 mm { 0.00098
to 0.00299 in }
PR-1 (Red) ： 0.051 to 0.152 mm { 0.00201
to 0.00598 in }
PB-1 (Blue) ： 0.102 to 0.229 mm { 0.00402
to 0.00902 in }
Method for measuring clearance between the connecting
rod bearing and the crank pin
Clean the connecting rod and bearing, and assemble the
bearing to the connecting rod.
Cut the PLASTIGAUGE to the width of the crank pin
and lay it parallel avoiding the crank pin oil hole.
Align the markings on the connecting rod and cap, and
assemble them on the crank pin. Apply molybdenum
disulfide to the threaded portion and the seating surface
of the tightening bolts, and tighten the caps alternately to
the specified torque.
Caution：
・Never move the connecting rod when using
PLASTIGAUGE.
Gently remove the cap and the connecting rod, and
measure the width of the flattened PLASTIGAUGE using
the scale printed on the packaging.
Method for measuring clearance between the crank
bearing and the crank journal
Clean the bearing, as well as the cylinder block and
crankcase bearing mounting surfaces, and assemble to the
cylinder block and crankcase.
Gently place the crankshaft on the cylinder block, and
settle it by turning it approximately 30 degrees.
Cut the PLASTIGAUGE to the width of the crank journal
and lay it parallel avoiding the journal oil hole.
Gently place the crankcase on the cylinder block, and
apply molybdenum disulfide to the threaded portion and
the seating surface of the tightening bolts. Tighten to the
specified torque in the specified order .
Caution：
・Never move the connecting rod when using
PLASTIGAUGE.
Gently remove the crankcase, and measure the width of
the flattened PLASTIGAUGE using the scale printed on
the packaging.
14A-4 Service Information Guide (All)
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Indice
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