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Hitachi 4HK1 Workshop Manual
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Hitachi 4HK1 Workshop Manual

Hitachi 4HK1 Workshop Manual

Gb3 exhaust emission standards
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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (K) 2015, 06
PART NO.
EWDCY-EN-00
Engine Manual
Workshop Manual
4HK1
GB3
EXHAUST EMISSION
STANDARDS
Service Manual consists of the following sections.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
Engine Manual

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Summary of Contents for Hitachi 4HK1

  • Page 1 PART NO. EWDCY-EN-00 Engine Manual Workshop Manual 4HK1 EXHAUST EMISSION STANDARDS URL:http://www.hitachi-c-m.com Service Manual consists of the following sections. Technical Manual (Operational Principle) Technical Manual (Troubleshooting) Workshop Manual PRINTED IN JAPAN (K) 2015, 06 Engine Manual...
  • Page 2 Find manuals at https://best-manuals.com Find manuals at https://best-manuals.com...
  • Page 3 FOREWORD FOREWORD This manual describes the service procedures for the 4HK1 diesel engine (GB 3). The contents of this manual are current at the date of issue, but may differ slightly from your engine due to specification changes This manual describes the service procedures for the 4HK1 diesel engine (GB 3). or other modifications made thereafter. 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. The engine specification and description, which is not installed in the machine, may be explained on this manual. This manual consists of the following sub-sections. This manual consists of the following sub-sections. Publication No. Publication Name Sub-sections IDE-2820 ENGINE Introduction Publication No. Publication Name Sub-sections Service Information Guide IDE-2820 ENGINE Introduction Maintenance Information...
  • Page 4 Find manuals at https://best-manuals.com Find manuals at https://best-manuals.com...
  • Page 5 Introduction (All) 0-1 Introduction Introduction (All) Table of Contents Introduction................0-2 safety information............0-2 Find manuals at https://best-manuals.com Find manuals at https://best-manuals.com...
  • Page 6 0-2 Introduction (All) Introduction safety information while paying sufficient attention to the handling precautions. Repair work safety information Furthermore, for work besides this, carry out work while wearing safety clothes and equipment. When the engine is unloaded from the machine, use the engine stand.

  • Page 7: Table Of Contents

    Service Information Guide (All) 14A-1 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 Find manuals at https://best-manuals.com Find manuals at https://best-manuals.com...

  • Page 8: Contents Included In Service Information

    14A-2 Service Information Guide (All) Contents included in service information Contents included in service information Connection Includes the connection procedures for wiring, piping, Removal etc. Includes the removal procedure when repairing parts, devices, etc. Writing Includes the writing procedure necessary when replacing Installation the ECM or supply pump.
  • Page 9 Service Information Guide (All) 14A-3 1. Forward 9. Gas or warm air 2. Upward 10. Mixing of outside air and gas or mixing of cold 3. Operating section or operating direction air and warm air 4. Detail of a particular part 11.

  • Page 10: Plastic Gauge

    14A-4 Service Information Guide (All) Plastic gauge Using the plasti-gauge Type Measurable range ： 0.025 to 0.076 mm { 0.00098 PG-1 (Green) to 0.00299 in } ： 0.051 to 0.152 mm { 0.00201 PR-1 (Red) to 0.00598 in } ： 0.102 to 0.229 mm { 0.00402 PB-1 (Blue) to 0.00902 in } Method for measuring clearance between the connecting...
  • Page 11 Service Information Guide (All) 14A-5...

  • Page 12: Recommended Liquid Gasket

    14A-6 Service Information Guide (All) Recommended liquid gasket Using the thread liquid gasket Type Product name Manufacturer Location of use (Reference) Silicon type ThreeBond 1207B ThreeBond Engine oil seal retainer (Room- ThreeBond 1207C ThreeBond Engine oil pan temperature ThreeBond 1215 ThreeBond Timing gear case vulcanized)
  • Page 13 Service Information Guide (All) 14A-7 Caution： ・ If the workshop manual specifies an application method, follow that method.

  • Page 14: Thread Locking Adhesive Agent

    14A-8 Service Information Guide (All) Thread locking adhesive agent Using the thread locking adhesive agent Type Color Loctite 242 Blue Loctite 262 Loctite 271 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.

  • Page 15: Term

    Service Information Guide (All) 14A-9 Term 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.

  • Page 16: Abbreviations

    14A-10 Service Information Guide (All) Abbreviations Abbreviations Abbreviation Description A- E Analog/Digital ABDC After bottom dead center Alternating current Accessory Alternating current generator Actuator American Petroleum Institute Assembly ATDC After top dead center Automatic transmission fluid Battery + terminal Battery BBDC Before bottom dead center Bracket...
  • Page 17 Service Information Guide (All) 14A-11 Abbreviation Description F - N Feedback Fuel cut Fusible link Fusible link wire Front Fuel temperature Forward Generator Ground Hydrocarbon HO2S Superheat O2 sensor Idle air control Intake air temperature Integrated circuit ID Plate Name plate IDSS ISUZU Diagnostic Service System Intake manifold temperature...
  • Page 18 14A-12 Service Information Guide (All) Abbreviation Description O - W O2 sensor On-board diagnosis Original equipment manufacturer Option Oil temperature Pilot light Pump control valve / Positive crankcase ventilation Proportion-integration Particulate matter Power take-off Pulse width modulation wave Quick on start system Quick warming up system Right side Relay...

  • Page 19: Standard Bolts

    Service Information Guide (All) 14A-13 Standard bolts List of standard bolt and nut tightening torques Note： ・ Those indicated with an asterisk (*) are used The tightening torque values in the following table apply for the internal threaded portion of soft to locations where no tightening torque is specified.
  • Page 20 14A-14 Service Information Guide (All) Strength category Bolt head shape Hex bolt Flange bolt Hex bolt Flange bolt M18 - M24 ： 151.0 to 225.6 N・m ： 195.2 to 293.2 N・m M18 x 1.5 { 15.4 to 23.0 kgf・m / ―...
  • Page 21 Service Information Guide (All) 14A-15 Strength category Bolt head shape Hex bolt Flange bolt Hex bolt Flange bolt M6 - M16 ： 5.6 to 11.2 N・m { 0.6 ： 6.6 to 12.2 N・m { 0.7 M6 x 1 to 1.1 kgf・m / 50 to 99 to 1.2 kgf・m / 58 to 108 ―...
  • Page 22 14A-16 Service Information Guide (All) Strength category Bolt head shape Hex bolt Flange bolt Hex bolt Flange bolt M18 - M24 ： 222.5 to 334.3 N・m ： 229.5 to 345.2 N・m M18 x 1.5 { 22.7 to 34.1 kgf・m / ―...
  • Page 23 Service Information Guide (All) 14A-17 1. Hex bolt (4.8, 4T) 10. Hex bolt (Non-thermally refined 8.8) 2. Hex bolt (4.8, 4T) 11. Flange bolt (8.8) 3. Flange bolt (4.8, 4T) 12. Flange bolt (8.8) 4. Flange bolt (4.8, 4T) 13. Hex bolt (9.8, 9T) 5.
  • Page 24 14A-18 Service Information Guide (All) Connector (Brass tapered screws) Screw size PT（R）1/8 PT（R）1/4 PT（R）3/8 PT（R）1/12 ： 2.0 to 14.7 N・m ： 4.9 to 15.7 N・m ： 9.8 to 16.7 N・m ： 9.8 to 17.7 N・m ― { 0.20 to 1.50 kgf・m / { 0.5 to 1.6 kgf・m / 43 { 1.0 to 1.7 kgf・m / 87 { 1.0 to 1.8 kgf・m / 87...
  • Page 25 Mechanical (4HK1) 1B-1 Engine Mechanical (4HK1) Table of Contents Cylinder head cover............1B-2 installation...............1B-256 removal...............1B-2 Flywheel..............1B-262 installation..............1B-3 removal..............1B-262 Cylinder head assembly...........1B-4 inspection..............1B-264 removal...............1B-4 installation...............1B-265 disassembly...............1B-13 Crankshaft front oil seal..........1B-267 inspection..............1B-19 removal..............1B-267 reassembly..............1B-25 installation...............1B-269 installation..............1B-34 Crankshaft rear oil seal..........1B-272 Idle gear.................1B-49 removal..............1B-272 removal..............1B-49...

  • Page 26: Cylinder Head Cover

    1B-2 Mechanical (4HK1) Cylinder head cover removal Ventilation hose disconnect Remove the air leak pipe from the EGR cooler and bracket. Note： ・ The existence or nonexistence of the equipment varies depending on the machine manufacturer. Remove the bracket from the cylinder head cover.

  • Page 27: Installation

    Mechanical (4HK1) 1B-3 installation Connect the oil level gauge guide tube to the cylinder head cover. Cylinder head cover installation tightening torque： 19 N・m { 1.9 kgf・m / 14 lb・ft } Align the head cover gasket to the cylinder head Install the bracket to the cylinder head cover.

  • Page 28: Cylinder Head Assembly

    1B-4 Mechanical (4HK1) Cylinder head assembly removal Turbocharger assembly removal Remove the exhaust pipe from the turbocharger Battery ground cable disconnect assembly. Disconnect the battery ground cable from the battery. Remove the air cleaner duct from the air cleaner Caution：...
  • Page 29 Mechanical (4HK1) 1B-5 Disconnect the water return pipe from the 13. Remove the turbocharger assembly from the exhaust turbocharger assembly. manifold. Remove the water return pipe from the water pump. Note： ・ The turbocharger specification varies Note： depending on the machine manufacturer.
  • Page 30 1B-6 Mechanical (4HK1) Caution： Disconnect the harness connector from the EGR valve. ・ After removing the EGR pipe, seal to prevent intrusions of foreign material. Remove the EGR valve from EGR pipe C. Caution： ・ After removing the EGR valve, seal to prevent intrusions of foreign material.

  • Page 31: Inlet Cover

    Mechanical (4HK1) 1B-7 3. Fan guide bracket 2. Gasket 3. Inlet pipe Disconnect the radiator upper hose from the water 4. Boost pressure/boost temperature sensor outlet pipe. 10. Oil level gauge guide tube removal Remove the EGR cooler water pipe from the engine assembly.
  • Page 32 1B-8 Mechanical (4HK1) Remove the fuel pipe from the fuel supply pump and the common rail assembly. Note： ・ Remove the clip. Caution： ・ Do not reuse the gasket. 14. Fuel leak off pipe assembly removal Disconnect the fuel leak-off pipe from the cylinder head assembly.
  • Page 33 Mechanical (4HK1) 1B-9 Disconnect the injector harness from the injector. Caution： ・ Be careful not to damage the injector side stud bolts. Remove the injector harness from the cylinder head assembly. Note： ・ Remove the bracket tightening bolts and then remove the injector harness together with the bracket.
  • Page 34 1B-10 Mechanical (4HK1) SST: 5-8840-0019-0 - sliding hammer 1. Injector 2. Injector sleeve Caution： ・ Store each ID code plate on the injector head with the cylinder number tag attached to avoid a mix-up. ・ Be extremely careful not to damage the injector nozzle.
  • Page 35 Mechanical (4HK1) 1B-11 Remove the camshaft bearing from the cylinder head assembly. Note： ・ Temporarily assemble the removed caps and bearings in the original position to avoid a mix- up after the bearings have been inspected. Remove the rocker arm shaft from the cylinder head assembly.

  • Page 36: Cylinder Block

    1B-12 Mechanical (4HK1) 22. Cylinder head assembly removal Remove the cylinder head assembly from the cylinder block. Note： ・ Loosening order of the head bolts Caution： ・ Since the idle gear C protrudes from the bottom surface of the cylinder head, be careful not to damage the gear.
  • Page 37 Mechanical (4HK1) 1B-13 disassembly Engine hanger bracket removal Remove the front engine hanger bracket from the cylinder head assembly. Remove the rear engine hanger bracket from the cylinder head assembly. 1. EGR cooler bracket 2. Bracket Inlet cover removal Remove EGR pipe C from the case.
  • Page 38 1B-14 Mechanical (4HK1) Caution： 1. Distance tube 2. Washer ・ Do not forget to remove the bolts indicated by 3. Exhaust manifold the arrow in the diagram. Remove the gasket from the cylinder head assembly. Thermostat removal Remove the fan guide bracket from the water outlet pipe.
  • Page 39 Mechanical (4HK1) 1B-15 1. Overheat switch Remove the idle gear C from the cylinder head 2. Engine coolant temperature sensor assembly. CMP sensor removal Remove the CMP sensor from the cylinder head assembly. 1. Idle gear C 2. Idle gear shaft 10.
  • Page 40 1B-16 Mechanical (4HK1) SST: 8-9439-6862-0 - pivot ASM 13. Valve stem oil seal removal Remove the valve stem oil seal from the valve guide using the pliers. Caution： ・ Do not reuse the valve stem oil seal. Remove the valve spring seat from the cylinder head assembly.
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