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Hitachi 6HK1 Workshop Manual
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Hitachi 6HK1 Workshop Manual

Hitachi 6HK1 Workshop Manual

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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (K) 2016, 02
PART NO.
EWDDN50-EN-01
Engine Manual
Workshop Manual
6HK1
Tier 4 Compatible
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 6HK1

  • Page 1 PART NO. EWDDN50-EN-01 Engine Manual Workshop Manual 6HK1 Tier 4 Compatible 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) 2016, 02 Engine Manual...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 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 Introduction Service Information Guide Maintenance Information Functional Inspection Symptom DTC Information Engine Control Mechanical Fuel System Cooling  Lubrication Induction Exhaust Aux. Emission Control Devices Electrical Maintenance Information (Urea SCR System) Functional Inspection (Urea SCR System) 38D Symptom (Urea SCR System) DTC Information (Urea SCR System) 10M Emission Control (Urea SCR System) – Wiring Diagram Find manuals at https://best-manuals.com...
  • Page 4 Find manuals at https://best-manuals.com...
  • Page 5 Introduction (All models) 0-1 Introduction Introduction (All models) Table of Contents Introduction................0-2 safety information............0-2 Find manuals at https://best-manuals.com...
  • Page 6 0-2 Introduction (All models) Introduction safety information Be sure to check that there is no fuel leaks when performing maintenance on fuel systems. Repair work safety information 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.

  • Page 7: Table Of Contents

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

  • Page 8: Contents Included In Service Information

    14A-2 Service Information Guide (All models) Contents included in service information Contents included in service information Includes the maintenance precautions specific to each item. Removal Includes the removal procedure for repairing parts and Disconnection devices, etc. Includes the disconnection procedures of wiring, piping, etc.
  • Page 9 Service Information Guide (All models) 14A-3 1. Vehicle front 9. Gas or warm air 2. Upper 10. Mixing of outside air and gas, or cold air and 3. Operating section or operating direction warm air 4. Detail on a section 11.

  • Page 10: Plastic Gauge

    14A-4 Service Information Guide (All models) 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 } ：...
  • Page 11 Service Information Guide (All models) 14A-5...

  • Page 12: Recommended Liquid Gasket

    14A-6 Service Information Guide (All models) Recommended liquid gasket Using the thread liquid gasket Manufacturer Type Product name Area used (reference) name ThreeBond 1207B ThreeBond Engine oil seal retainer Silicon type ThreeBond 1207C ThreeBond Engine oil pan (room temperature ThreeBond 1201 ThreeBond Timing gear case vulcanization...
  • Page 13 Service Information Guide (All models) 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 models) Thread locking adhesive agent Using the thread locking adhesive agent Type Color Loctite 242 Blue Loctite 262 Loctite 271 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.

  • Page 15: Term

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

  • Page 16: Abbreviations

    14A-10 Service Information Guide (All models) Abbreviations Abbreviations...
  • Page 17 Service Information Guide (All models) 14A-11 Abbreviation Description Analog/Digital ABDC After bottom dead center Alternating current Accessory Alternating current generator Actuator American Petroleum Industry Assembly ATDC After top dead center Automatic transmission fluid Battery + terminal Battery BBDC Before bottom dead center Bracket Bearing BTDC...
  • Page 18 14A-12 Service Information Guide (All models) Generator Ground Hydrocarbon HO2S Superheat O2 sensor Idle air control Intake air temperature Integrated circuit ID Plate ID plate (Name plate) IDSS ISUZU　Diagnostic　Service　System Intake manifold temperature Intake Injection International Organization for Standardization Intake shutter position Intake throttle position Joint connector Japan Industrial Standard...
  • Page 19 Service Information Guide (All models) 14A-13 Right side Relay RAM (Random access memory) Reference ROM (Read only memory) Rail pressure Rear Rear Rear Society of Automotive Engineers Slow blow fuse Suction control valve Signal Shield Starter/start Standards Switch Top dead center TEMP Temperature Throttle position...

  • Page 20: Standard Bolts

    14A-14 Service Information Guide (All models) Standard bolts 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.
  • Page 21 Service Information Guide (All models) 14A-15 Strength category Bolt head Hex bolt Flange bolt Hex bolt Flange bolt shape ： 3.9 to 7.8 N・m { 0.4 to ： 4.6 to 8.5 N・m { 0.5 to ： 4.9 to 9.8 N・m { 0.5 to ：...
  • Page 22 14A-16 Service Information Guide (All models) ： 358.9 to 539.4 N・m ： 430.5 to 711.0 N・m M24 x 2 { 36.6 to 55.0 kgf・m / { 43.9 to 72.5 kgf・m / 265 to 398 lb・ft } 318 to 524 lb・ft } ：...
  • Page 23 Service Information Guide (All models) 14A-17 Strength category Bolt head Hex bolt Flange bolt Hex bolt Flange bolt shape ： 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 lb・in } lb・in }...
  • Page 24 14A-18 Service Information Guide (All models) ： 490.8 to 810.5 N・m ： 554.1 to 830.6 N・m M24 x 2 { 50.0 to 82.6 kgf・m / { 56.5 to 84.7 kgf・m / 362 to 598 lb・ft } 409 to 613 lb・ft } ：...
  • Page 25 Service Information Guide (All models) 14A-19 Flare nut width across flat Tightening torque for large/medium size Pipe diameter vehicles Previous ： 12.8 to 18.6 N・m { 1.3 to 1.9 kgf・ ： 14 mm ： 14 mm ： 4.6 mm { 0.181 in } m / 9 to 14 lb・ft } { 0.55 in } { 0.55 in }...
  • Page 27 Mechanical (6HK1) 1B-1 Engine Mechanical (6HK1) Table of Contents Cylinder head cover............1B-2 installation...............1B-306 removal...............1B-2 Crankshaft front oil seal..........1B-308 installation..............1B-3 removal..............1B-308 Cylinder head assembly...........1B-4 installation...............1B-310 removal...............1B-4 Crankshaft rear oil seal..........1B-314 disassembly...............1B-16 removal..............1B-314 inspection..............1B-22 installation...............1B-316 reassembly..............1B-29 Rocker arm shaft............1B-319 installation..............1B-39 removal..............1B-319 Idle gear.................1B-57 disassembly.............1B-321...

  • Page 28: Cylinder Head Cover

    1B-2 Mechanical (6HK1) Cylinder head cover removal 3. Lower cover Cylinder head cover removal Disconnect the water pipe bracket from the cylinder head cover. Disconnect the ventilation hose from the air breather. 1. Ventilation hose 2. Water pipe bracket 3. Clip Remove the cylinder head cover from the lower cover.

  • Page 29: Installation

    Mechanical (6HK1) 1B-3 installation tightening torque： 20 N・m { 2.0 kgf・m / 14 lb・ft } Cylinder head cover installation Align the head cover gasket to the cylinder head cover. Install the cylinder head cover to the lower cover. tightening torque： 13 N・m { 1.3 kgf・m / 115 lb・in } Note：...

  • Page 30: Cylinder Head Assembly

    1B-4 Mechanical (6HK1) Cylinder head assembly removal Battery ground cable disconnect Disconnect the battery ground cable from the battery. Caution： ・ Do not disconnect the battery cable for 3 minutes after turning OFF the ignition switch. Coolant drain Remove the radiator cap from the radiator.

  • Page 31: Removal

    Mechanical (6HK1) 1B-5 Remove the water return pipe from the cylinder head assembly. 10. Disconnect the water feed pipe from the turbocharger assembly. Note： ・ Remove the clip. 11. Remove the water feed pipe from the cylinder block. Note： ・ Remove the clip.
  • Page 32 1B-6 Mechanical (6HK1) 1. Water rubber hose 1. EGR cooler C 2. EGR bracket C Remove the EGR pipe B from the EGR valve and 3. EGR cooler B the EGR cooler C. 4. EGR cooler bracket A Remove the EGR heat protector from the EGR pipe 1.
  • Page 33 Mechanical (6HK1) 1B-7 1. EGR valve Oil separator bracket removal Remove the clip from the cylinder block. Remove the ventilation hose from the air breather. Remove the oil separator bracket from the cylinder head assembly. 1. EGR cooler A 2. EGR pipe A 3.
  • Page 34 1B-8 Mechanical (6HK1) 1. EGR cooler water pipe Remove the fan guide stay from the fan guide and the fan guide bracket.
  • Page 35 Mechanical (6HK1) 1B-9 1. Fan guide 12. Intake throttle valve removal 2. Fan guide stay Remove the air duct from the intake throttle valve. 3. Fan guide bracket Disconnect the harness connector from the intake Disconnect the radiator upper hose from the water throttle valve.
  • Page 36 1B-10 Mechanical (6HK1) Disconnect the harness connector from the boost pressure sensor/boost temperature sensor. Disconnect the harness connector from the IMT sensor. Remove the harness clip from the inlet pipe. Remove the glow plug from the cylinder head assembly. 1. Boost pressure sensor/boost temperature sensor 2.
  • Page 37 Mechanical (6HK1) 1B-11 1. No.1 injection pipe 1. Fuel leak-off pipe 2. No.2 injection pipe 18. Common rail assembly removal 3. No.3 injection pipe 4. No.4 injection pipe Disconnect the harness connector from the fuel 5. No.5 injection pipe pressure sensor.
  • Page 38 1B-12 Mechanical (6HK1) 1. Cylinder head cover 1. Injector 2. Head cover gasket 2. Injector harness 3. Lower cover 3. Terminal nut 20. Injector harness removal Remove the injector harness from the cylinder head assembly. Remove the connector from the lower cover.
  • Page 39 Mechanical (6HK1) 1B-13 Remove the injector leak-off pipe from the injector. Caution： ・ When removing the injector using the special Remove the injector from the cylinder head tool, check that the injector sleeve has not assembly. been removed as well.
  • Page 40 1B-14 Mechanical (6HK1) 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 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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