Hitachi 6HK1 Instruction manual

EWDDN50-EN-016HK1 TIER 4 COMPATIBLE ENGINE MANUAL WORKSHOP MANUAL
PRINTED IN JAPAN (K) 2016, 02
Service Manual consists of the following sections.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
Engine Manual
EWDDN50-EN-01
PART NO.
Tier 4 Compatible
Engine Manual
Workshop Manual
URL:http://www.hitachi-c-m.com
6HK1

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FOREWORD
Thismanualdescribestheserviceproceduresforthe6HK1dieselengine(Tier4/Stage4compatible).
Thecontentsofthismanualarecurrentatthedateofissue,butmaydifferslightlyfromyourengineduetospecificationchanges
orothermodificationsmadethereafter.
Thismanualconsistsofthefollowingsub-sections.
PublicationNo. PublicationName Sub-sections
IDE-2710 ENGINE 0 Introduction
14A ServiceInformationGuide
15B MaintenanceInformation
15C FunctionalInspection
15D Symptom
15E DTCInformation
1A EngineControl
1B Mechanical
1C FuelSystem
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux.EmissionControlDevices
1J Electrical
38B MaintenanceInformation(UreaSCRSystem)
38C FunctionalInspection(UreaSCRSystem)
38D Symptom(UreaSCRSystem)
38E DTCInformation(UreaSCRSystem)
10M EmissionControl(UreaSCRSystem)
–WiringDiagram
IDE-2710前書44051762014.7.10 9:21AM ページ1
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IDE-2710前書44051762014.7.10 9:21AM ページ2
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Introduction
Introduction
(All models)
Table of Contents
Introduction........................................................................0-2
safety information..........................................................0-2
Introduction (All models) 0-1
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Introduction
safety information
1. Repair work safety information
1. Use an engine stand when demounting the engine
from the equipment.
Be sure not to place the engine directly on the
ground or allow the oil pan to come into contact with
the ground.
2. When performing a procedure with two or more
people, make sure to ensure each other's safety.
3. Do not disconnect the battery cable for 3 minutes
after turning OFF the ignition switch.
4. When repairing the electrical system, make sure to
disconnect the cable from the negative (-) battery
terminal before working. Keep fire away when
removing the battery cover.
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 only the special tools if the
procedure requires them for the work. Performing
the procedure using other tools may cause damage to
parts or personal injury.
7. Inspect the tools, instruments, and special tools
regularly, and prepare them before working. Do not
use tools such as a wrench that has lost its edges, a
hammer with frayed edges, or a chipped chisel.
8. When performing work using a device such as a
grinder, crane or welder, make sure to pay sufficient
attention to the handling precautions.
Wear work clothes and safety equipments in the
other operations as well.
9. Be sure to check that there is no fuel leaks when
performing maintenance on fuel systems.
10. When handling volatile materials, be extremely
careful to not let them catch fire.
Also 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 plate, and split pins, etc., with
new ones.
2. Since the part numbers indicated in this manual may
differ from the supply system and are subject to
change, make sure to check the supply system and
part numbers in the parts catalog.
0-2 Introduction (All models)
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Description General Information
Service Information Guide
(All models)
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-14
Service Information Guide (All models) 14A-1
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Contents included in service information
1. Contents included in service information
Removal
Includes the removal procedure for repairing parts and
devices, etc.
Installation
Includes the installation procedure for repairing parts and
devices, etc.
Disassembly
Includes the disassembly procedure for performing an
overhaul of a unit or assembly part, etc.
Assembly
Includes the assembly procedure for performing an
overhaul of a unit or assembly part, etc.
Inspection
Includes the inspection items for the parts that
particularly require inspection to ensure continued
performance of parts and devices.
The standard values, set values, and limits for use of parts
are included if they have these specifications set.
Cleaning
Includes the cleaning procedure for parts and devices, etc.
Preparation
Includes the preparatory procedure necessary before
removing parts and devices, etc.
Adjustment
Includes the adjustment procedure when parts have to be
adjusted to set values or standard values when performing
assembly or installation.
Measurement
Includes the measurement procedure to judge if parts are
installed correctly, etc.
Drain
Includes the draining procedure of oil, etc.
Refill
Includes the refilling procedure of oil, etc.
Air removal
Includes the air removal procedure when air removal is
necessary after replacing oil, etc.
Writing
Includes the writing procedure necessary after replacing
the ECM or supply pump.
Precaution
Includes the maintenance precautions specific to each
item.
Disconnection
Includes the disconnection procedures of wiring, piping,
etc.
Connection
Includes the connection procedures for wiring, piping,
etc.
Setting
Includes the setting procedure necessary after replacing
the ECM, etc.
Replacement
Includes the replacement procedure for parts and oils, etc.
Prioritized DTC
Includes DTCs that need to be diagnosed and resolved
before the relevant DTC when multiple DTCs are
detected.
Diagnosis
Includes the diagnosis procedure for troubleshooting
symptoms.
DTCs are listed in the descending order of priority.
Confirmation of problem resolution
Includes procedures to clear the DTC and any necessary
confirmation steps using numeric values, etc.
Functional description
Includes detailed functional description related to
functional inspection.
Symptom description
Includes detailed symptom descriptions related to
diagnosis by symptom.
DTC description
Includes circuit description related to DTCs.
Setting conditions
Includes the preconditions and judgment conditions
required for the ECU to detect a DTC.
Action upon setting
Includes information related to control actions taken by
the ECU when DTCs are set.
Items related to ETM
Items related to the ETM are included in "Using the
Wiring Diagram".
2. Arrows and symbols
14A-2 Service Information Guide (All models)
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1. Vehicle front
2. Upper
3. Operating section or operating direction
4. Detail on a section
5. Detailed view from the direction of A
6. Arrow indicates measurement
7. Arrow indicates cross-section
8. Outside air or cold air
9. Gas or warm air
10. Mixing of outside air and gas, or cold air and
warm air
11. Rotation direction
12. Oil feeding
13. Lubrication
14. Application area of liquid gasket
Service Information Guide (All models) 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 the gap between the connecting
rod bearing and crank pin
Clean the connecting rod and bearing, and assemble them
on the connecting rod. Cut the plasti-gauge 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 on
the cap to assemble it on the crank pin. Apply
molybdenum disulfide to the threaded portion and seat
surface of the tightening bolts. Alternately tighten them
so that the cap is at the specified torque.
Caution：
・Never move the connecting rod when the
plasti-gauge is in use.
Gently remove the cap and connecting rod and use a scale
printed on the packaging of the plasti-gauge to measure
the flattened plasti-gauge.
Method for measuring the gap between the crank bearing
and crank journal
Clean the installation surfaces of the cylinder block and
crankcase bearing, and assemble them on the cylinder
block and crankcase. Gently place the crankshaft on the
cylinder block, and lock it into place by turning it
approximately 30 degrees. Cut the plasti-gauge 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 seat surface of the tightening bolts.
Tighten in the specified order at the specified torques.
Caution：
・Never move the connecting rod when the
plasti-gauge is in use.
Gently remove the crankcase and use a scale printed on
the packaging of the plasti-gauge to measure the flattened
plastic gauge.
14A-4 Service Information Guide (All models)
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Service Information Guide (All models) 14A-5

Recommended liquid gasket
1. Using the thread liquid gasket
Type Product name Manufacturer
name Area used (reference)
Silicon type
(room temperature
vulcanization
process)
ThreeBond 1207B
ThreeBond 1207C
ThreeBond 1201
ThreeBond 1215
ThreeBond 1216
ThreeBond
ThreeBond
ThreeBond
ThreeBond
ThreeBond
Engine oil seal retainer
Engine oil pan
Timing gear case
Flywheel housing
Cylinder head cover
Fuel pump
Water pump
etc.
Water–soluble ThreeBond 1141 ThreeBond
Solvent type 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
above product name 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 when there is a
gap larger than 0.25 mm {0.0098 in} between
the contact surfaces of metals.
Whenever disassembling, completely remove old liquid
gasket using a scraper, and clean by removing any oil,
moisture, filth, etc. from the locations of parts and the
mating parts where liquid gasket was used by using a rag,
etc. After cleaning, apply the specified liquid gasket to
each location and assemble them.
Note：
・It is better to start the removal operation
approximately 10 minutes after applying when
using gasket remover to make the operation
easier while cleaning.
Caution：
・Do not apply gasket remover to plastic parts
and painted parts.
Apply liquid gasket of the specified bead width to one
side of the contact surface thoroughly.
Caution：
・Be careful to apply a proper amount of the
liquid gasket to avoid an excess or lack in
application.
・Be sure to overlap the beginning and ending of
the liquid gasket application.
・Be careful not to misalign the applied part with
the mating part when assembling.
Note：
・When there is a misalignment, apply again.
・Use the same size studs as a guide when
using with a section which has no positioning
such as a knock pin.
Caution：
・After applying the liquid gasket, assemble
within 15 minutes.
Note：
・When more than 15 minutes have passed after
applying 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 models)

Caution：
・If the workshop manual specifies an
application method, follow that method.
Service Information Guide (All models) 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：
・Remove grime, fluid, oil, and grease off
thoroughly from the bolts, bolt holes, and
screw thread section of nuts to which thread
locking adhesive agent will be applied.
Note：
・Check if the cleaned sections are dry.
Caution：
・After tightening, do not apply excessive torque
or vibrations for at least an hour until the
thread locking adhesive agent hardens.
Apply thread locking adhesive agent to the end 1/3 of the
screw and tighten at the specified torque.
14A-8 Service Information Guide (All models)

Term
1. Term
Nominal dimensions
Refers to standard values for production.
Specified value
Refers to specified values for inspection, adjustment,
assembly, and installation.
Limit
Refers to a maximum or minimum value that should not
be exceeded during maintenance. If this value is
exceeded, replacement or repair must be made.
Warning Refers to something which may cause serious
injuries if it is not performed properly.
CAUTION
Refers to something which may cause physical loss or
damage if it is not performed properly.
NOTE
Instruction, guidance, and usage conditions regarding
usage, operation, and repair in the additional information.
Service Information Guide (All models) 14A-9

Abbreviations
1. Abbreviations
14A-10 Service Information Guide (All models)

Abbreviation Description
A/D Analog/Digital
ABDC After bottom dead center
AC Alternating current
ACC Accessory
ACG Alternating current generator
ACT Actuator
API American Petroleum Industry
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 the top dead center
C/B Circuit breaker
C/U Control unit
CAN A control unit communication method (Control area network)
CKP Crankshaft position
CMP Camshaft position
CO Carbon monoxide
CPU CPU (Central processing unit)
DC Direct current
DI Direct injection type
DLC Data link connector
DPD Diesel particulate diffuser
DTC Self-diagnosis code
DMM Digital multi–meter
ECM Engine control module
ECT Engine coolant temperature
ECU Electronic control unit
EEPROM Electrically erasable/programmable ROM
EGR EGR (Exhaust gas recirculation)
EMI Electromagnetic interference
EVRV Electric vacuum regulating valve
EXH Exhaust
F/B Feedback
F/C Fuel cut
F/L Fusible link
FLW Fusible link wire
FRT Front
FT Fuel temperature
FWD Front
Service Information Guide (All models) 14A-11

GEN Generator
GND Ground
HC Hydrocarbon
HO2S Superheat O2 sensor
IAC Idle air control
IAT Intake air temperature
IC Integrated circuit
ID Plate 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 Electromagnetic valve
MAF Mass air flow
MAP Manifold air pressure
Max Maximum
MIL Warning light (Diagnostic light)
Min Minimum
MPU Micro processing unit
NC Normally closed
NC Normally closed
NO Normally open
NOx Nitrogen oxide
N–TDC Top dead center revolution speed
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 Particle material
PTO Power take–off
PWM Pulse width modulation wave
QOS QOS (Quick on start system)
QWS QWS (Quick warming up system)
14A-12 Service Information Guide (All models)

RH Right side
R/L Relay
RAM RAM (Random access memory)
REF Reference
ROM ROM (Read only memory)
RP Rail pressure
Rr Rear
Rr Rear
RWD Rear
SAE Society of Automotive Engineers
SBF Slow blow fuse
SCV Suction control valve
SIG Signal
SLD Shield
ST Starter/start
STD Standards
SW Switch
TDC Top dead center
TEMP Temperature
TP Throttle position
VB Battery voltage
VGS Turbo Variable geometry system turbo, VGS turbo
W/H Wire/harness
W/L Warning light (Warning light)
W/S Weld splice
WOT Wide open throttle
Service Information Guide (All models) 14A-13

Standard bolts
1. List of standard bolt and nut tightening torques Note：
・The tightening torque values in the following
table apply to locations where tightening
torques are not specified.
14A-14 Service Information Guide (All models)