Hitachi 4HK1 Instruction manual
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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Service Information Guide (All) 14A-5
Recommended liquid gasket
1. Using the thread liquid gasket
Type Product name Manufacturer Location of use (Reference)
Silicon type
(Room-
temperature
vulcanized)
ThreeBond 1207B
ThreeBond 1207C
ThreeBond 1215
ThreeBond 1216
ThreeBond
ThreeBond
ThreeBond
ThreeBond
Engine oil seal retainer
Engine oil pan
Timing gear case
Cylinder head cover
Fuel pump
Water pump
etc.
Water soluble ThreeBond 1141 ThreeBond
Solvent based ThreeBond 1104
ThreeBond 1194
ThreeBond
ThreeBond
Anaerobic
Loctite 515
Loctite 518
FMD127
（Loctite 5127）
Loctite 271
Loctite
Loctite
Loctite
Loctite
Loctite
Engine oil seal retainer
Water pump
Plug
etc.
Caution：
・Make sure to use a liquid gasket with the
product name above or equivalent.
・Use an appropriate amount of liquid gasket.
・Follow the handling precautions for the
product.
・Do not use LOCTITE 515, 518, or FMD 127
(Loctite 5127) as they are anaerobic and do
not provide sufficient effect if there is a gap
larger than 0.25 mm {0.0098 in} between the
contact surfaces of metals.
Whenever disassembling, completely remove the old
liquid gasket on the parts and the mating parts where the
liquid gasket was used using a scraper, and clean using a
waste cloth, etc., so that any oil, moisture, dirt, etc., is
removed. After cleaning, apply the specified liquid gasket
to each location and assemble.
Note：
・If a gasket remover is used to make the
operation during cleaning easier, it is better to
wait approximately 10 minutes after applying
before starting the removal operation.
Caution：
・Do not apply a gasket remover to the plastic
parts and the painted parts.
Thoroughly apply a liquid gasket with the specified bead
width to one side of the contact surface.
Caution：
・Be careful not to excessively or insufficiently
apply liquid gasket.
・Be sure to overlap the start and end of the
liquid gasket application.
・Be careful not to misalign the part with the
mating part when assembling applied parts.
Note：
・Apply again if there is a misalignment.
・Use the same size studs as a guide when
using for a section which has no positioning
such as a dowel pin.
Caution：
・After applying a liquid gasket, assemble within
15 minutes.
Note：
・When more than 15 minutes have passed after
applying a liquid gasket, remove the liquid
gasket and apply it again.
Caution：
・Wait at least 30 minutes before starting the
engine after assembling each part.
14A-6 Service Information Guide (All)
Caution：
・If the workshop manual specifies an
application method, follow that method.
Service Information Guide (All) 14A-7
Thread locking adhesive agent
1. Using the thread locking adhesive agent
Type Color
Loctite 242 Blue
Loctite 262 Red
Loctite 271 Red
Caution：
・Thoroughly remove grime, moisture, oil, and
grease from the bolts, bolt holes, and screw
thread portion of the nuts to which thread
locking adhesive agent will be applied.
Note：
・Verify that the cleaned sections are dry.
Caution：
・After tightening, do not apply excessive torque
or vibration for at least 1 hour until the thread
locking adhesive agent hardens.
Apply the thread locking adhesive agent to the end 1/3 of
the bolt and tighten to the specified torque.
14A-8 Service Information Guide (All)
Term
1. Term
Nominal dimension
Refers to standard values during production.
Specified value
Refers to specified values for inspection, adjustment,
assembly, and installation.
Limit
Refers to maximum or minimum values that should not
be exceeded during maintenance.
Parts exceeding these values must be repaired or
replaced.
Warning
Refers to a precaution which may lead to injury if not
observed.
Caution
Refers to a precaution which may lead to equipment
damage if not observed.
Note
Refers to special notes that give instruction, guidance, or
use conditions related to use, operation, repair, etc.
Service Information Guide (All) 14A-9
Abbreviations
1. Abbreviations
Abbreviation
A- E Description
A/D Analog/Digital
ABDC After bottom dead center
AC Alternating current
ACC Accessory
ACG Alternating current generator
ACT Actuator
API American Petroleum Institute
ASM Assembly
ATDC After top dead center
ATF Automatic transmission fluid
B+ Battery + terminal
BAT Battery
BBDC Before bottom dead center
BKT Bracket
BRG Bearing
BTDC Before top dead center
C/B Circuit breaker
C/U Control unit
CAN Control unit communication method (Controller area network)
CKP Crankshaft position
CMP Camshaft position
CO Carbon monoxide
CPU Central processing unit
DC Direct current
DI Direct injection type
DLC Data link connector
DPD Diesel particulate defuser
DTC Diagnostic trouble code
DMM Digital multimeter
ECM Engine control module
ECT Engine coolant temperature
ECU Electronic control unit
EEPROM Electrically erasable/programmable ROM
EGR Exhaust gas recirculation
EMI Electromagnetic interference
ETM Wiring diagram (Electrical trouble shooting manual)
EVRV Electric vacuum regulating valve
EXH Exhaust
14A-10 Service Information Guide (All)
Abbreviation
F - N Description
F/B Feedback
F/C Fuel cut
F/L Fusible link
FLW Fusible link wire
FRT Front
FT Fuel temperature
FWD Forward
GEN Generator
GND Ground
HC Hydrocarbon
HO2S Superheat O2 sensor
IAC Idle air control
IAT Intake air temperature
IC Integrated circuit
ID Plate Name plate
IDSS ISUZU Diagnostic Service System
IMT Intake manifold temperature
INL Intake
INJ Injection
ISO International Organization for Standardization
ISP Intake shutter position
ITP Intake throttle position
J/C Joint connector
JIS Japan Industrial Standard
KW A communication method (Keyword)
LH Left side
LLC Long life coolant
M/V Magnetic valve
MAF Mass air flow
MAP Manifold air pressure
Max Maximum
MIL Malfunction indicator light (Diagnostic light)
Min Minimum
MPU Microprocessing unit
NC Normally closed
NC Normally closed
NO Normally open
NOx Nitrogen oxide
N-TDC Top dead center revolution speed
Service Information Guide (All) 14A-11
Abbreviation
O - W Description
O2S O2 sensor
OBD On-board diagnosis
OEM Original equipment manufacturer
OPT Option
OT Oil temperature
P/L Pilot light
PCV Pump control valve / Positive crankcase ventilation
P-I Proportion-integration
PM Particulate matter
PTO Power take-off
PWM Pulse width modulation wave
QOS Quick on start system
QWS Quick warming up system
RH Right side
R/L Relay
RAM Random access memory
REF Reference
ROM Read-only memory
RP Rail pressure
RR Rear
Rr Rear
RWD Rearward
SAE Society of Automotive Engineers
SBF Slow blow fuse
SCV FRP regulator
SIG Signal
SLD Shield
ST Starter/Start
STD Standard
SW Switch
TDC Top dead center
TEMP Temperature
TP Throttle position
VB Battery voltage
VGS Turbo Variable geometry system turbo
W/H Wire/Harness
W/L Warning light
W/S Weld splice
WOT Wide open throttle
14A-12 Service Information Guide (All)
Standard bolts
1. List of standard bolt and nut tightening torques
The tightening torque values in the following table apply
to locations where no tightening torque is specified.
Note：
・Those indicated with an asterisk (*) are used
for the internal threaded portion of soft
materials such as castings.
Strength
category
4.8
4T 7T
Bolt head
shape
M6 - M16
Hex bolt Flange bolt Hex bolt Flange bolt
M6 x 1
： 3.9 to 7.8 N・m { 0.4 to
0.8 kgf・m / 35 to 69 lb・
in }
： 4.6 to 8.5 N・m { 0.5 to
0.9 kgf・m / 41 to 75 lb・
in }
： 4.9 to 9.8 N・m { 0.5 to
1.0 kgf・m / 43 to 87 lb・
in }
： 5.7 to 10.6 N・m { 0.6
to 1.1 kgf・m / 50 to 94
lb・in }
M8 x 1.25
： 7.8 to 17.7 N・m { 0.8
to 1.8 kgf・m / 69 to 157
lb・in }
： 10.5 to 19.6 N・m { 1.1
to 2.0 kgf・m / 93 to 173
lb・in }
： 11.8 to 22.6 N・m { 1.2
to 2.3 kgf・m / 9 to 17 lb・
ft }
： 13.5 to 25.0 N・m { 1.4
to 2.5 kgf・m / 10 to 18
lb・ft }
M10 x 1.25
： 20.6 to 34.3 N・m { 2.1
to 3.5 kgf・m / 15 to 25
lb・ft }
： 23.1 to 38.5 N・m { 2.4
to 3.9 kgf・m / 17 to 28
lb・ft }
： 27.5 to 46.1 N・m { 2.8
to 4.7 kgf・m / 20 to 34
lb・ft }
： 31.0 to 51.7 N・m { 3.2
to 5.3 kgf・m / 23 to 38
lb・ft }
*M10 x 1.5
： 19.6 to 33.3 N・m { 2.0
to 3.4 kgf・m / 14 to 25
lb・ft }
： 22.3 to 37.2 N・m { 2.3
to 3.8 kgf・m / 16 to 27
lb・ft }
： 27.5 to 45.1 N・m { 2.8
to 4.6 kgf・m / 20 to 33
lb・ft }
： 30.3 to 50.4 N・m { 3.1
to 5.1 kgf・m / 22 to 37
lb・ft }
M12 x 1.25
： 49.0 to 73.5 N・m { 5.0
to 7.5 kgf・m / 36 to 54
lb・ft }
： 54.9 to 82.3 N・m { 5.6
to 8.4 kgf・m / 40 to 61
lb・ft }
： 60.8 to 91.2 N・m { 6.2
to 9.3 kgf・m / 45 to 67
lb・ft }
： 68.1 to 102.1 N・m
{ 6.9 to 10.4 kgf・m / 50
to 75 lb・ft }
*M12 x 1.75
： 45.1 to 68.6 N・m { 4.6
to 7.0 kgf・m / 33 to 51
lb・ft }
： 51.0 to 76.5 N・m { 5.2
to 7.8 kgf・m / 38 to 56
lb・ft }
： 56.9 to 84.3 N・m { 5.8
to 8.6 kgf・m / 42 to 62
lb・ft }
： 62.7 to 94.0 N・m { 6.4
to 9.6 kgf・m / 46 to 69
lb・ft }
M14 x 1.5
： 76.5 to 114.7 N・m
{ 7.8 to 11.7 kgf・m / 56
to 85 lb・ft }
： 83.0 to 124.5 N・m
{ 8.5 to 12.7 kgf・m / 61
to 92 lb・ft }
： 93.2 to 139.3 N・m
{ 9.5 to 14.2 kgf・m / 69
to 103 lb・ft }
： 100.8 to 151.1 N・m
{ 10.3 to 15.4 kgf・m / 74
to 111 lb・ft }
*M14 x 2
： 71.6 to 106.9 N・m
{ 7.3 to 10.9 kgf・m / 53
to 79 lb・ft }
： 77.2 to 115.8 N・m
{ 7.9 to 11.8 kgf・m / 57
to 85 lb・ft }
： 88.3 to 131.4 N・m
{ 9.0 to 13.4 kgf・m / 65
to 97 lb・ft }
： 94.9 to 142.3 N・m
{ 9.7 to 14.5 kgf・m / 70
to 105 lb・ft }
M16 x 1.5
： 104.0 to 157.0 N・m
{ 10.6 to 16.0 kgf・m / 77
to 116 lb・ft }
： 115.6 to 173.3 N・m
{ 11.8 to 17.7 kgf・m / 85
to 128 lb・ft }
： 135.3 to 204.0 N・m
{ 13.8 to 20.8 kgf・m /
100 to 150 lb・ft }
： 150.1 to 225.2 N・m
{ 15.3 to 23.0 kgf・m /
111 to 166 lb・ft }
*M16 x 2
： 100.0 to 149.1 N・m
{ 10.2 to 15.2 kgf・m / 74
to 110 lb・ft }
： 109.4 to 164.2 N・m
{ 11.2 to 16.7 kgf・m / 81
to 121 lb・ft }
： 129.4 to 194.2 N・m
{ 13.2 to 19.8 kgf・m / 95
to 143 lb・ft }
： 142.5 to 213.8 N・m
{ 14.5 to 21.8 kgf・m /
105 to 158 lb・ft }
Service Information Guide (All) 14A-13
Strength
category
4.8
4T 7T
Bolt head
shape
M18 - M24
Hex bolt Flange bolt Hex bolt Flange bolt
M18 x 1.5
： 151.0 to 225.6 N・m
{ 15.4 to 23.0 kgf・m /
111 to 166 lb・ft }
―
： 195.2 to 293.2 N・m
{ 19.9 to 29.9 kgf・m /
144 to 216 lb・ft }
―
*M18 x 2.5
： 151.0 to 225.6 N・m
{ 15.4 to 23.0 kgf・m /
111 to 166 lb・ft }
―
： 196.1 to 294.2 N・m
{ 20.0 to 30.0 kgf・m /
145 to 217 lb・ft }
―
M20 x 1.5
： 206.0 to 310.0 N・m
{ 21.0 to 31.6 kgf・m /
152 to 229 lb・ft }
―
： 269.7 to 405.0 N・m
{ 27.5 to 41.3 kgf・m /
199 to 299 lb・ft }
―
*M20 x 2.5
： 190.2 to 286.4 N・m
{ 19.4 to 29.2 kgf・m /
140 to 211 lb・ft }
―
： 249.1 to 374.6 N・m
{ 25.4 to 38.2 kgf・m /
184 to 276 lb・ft }
―
M22 x 1.5
： 251.1 to 413.8 N・m
{ 25.6 to 42.2 kgf・m /
185 to 305 lb・ft }
―
： 362.8 to 544.3 N・m
{ 37.0 to 55.5 kgf・m /
268 to 401 lb・ft }
―
*M22 x 2.5
： 217.7 to 327.5 N・m
{ 22.2 to 33.4 kgf・m /
161 to 242 lb・ft }
―
： 338.3 to 507.0 N・m
{ 34.5 to 51.7 kgf・m /
250 to 374 lb・ft }
―
M24 x 2
： 358.9 to 539.4 N・m
{ 36.6 to 55.0 kgf・m /
265 to 398 lb・ft }
―
： 430.5 to 711.0 N・m
{ 43.9 to 72.5 kgf・m /
318 to 524 lb・ft }
―
*M24 x 3
： 338.3 to 507.0 N・m
{ 34.5 to 51.7 kgf・m /
250 to 374 lb・ft }
―
： 406.0 to 608.0 N・m
{ 41.4 to 62.0 kgf・m /
299 to 448 lb・ft }
―
14A-14 Service Information Guide (All)
Table of contents
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