Hitachi 4HK1-24V Electronic Control Fuel Injection System (Common Rail Type) Engine Repair Service Manual
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This Troubleshooting Manual describes the structure and the troubleshooting of electronic control fuel injection system (common rail type) in 4HK1 industrial engines. Use this manual sufficiently to perform service work properly and quickly.
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Manual No. : KM-4HK1-E-02 (1/2)
Total Pages : 548
This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.
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TABLE OF CONTENTS :
Introduction
General Contents
Control System
4HK1-24V Electronic Control Fuel Injection System (Common Rail Type)
How to Use This Manual
How to use this manual
Table of abbreviation
Conversion formula
About colors of wirings
About wiring diagrams
How to read trouble diagnosis section
Precautions on Service Work
Electrical system
Fuel injection system
Procedure of Trouble Diagnosis
About trouble diagnosis
Trouble diagnostic procedure
Interview
Pre-inspection
Trouble diagnosis
How to read DTC
Confirmation after repair
List of final check items
How to clear DTC
Trouble diagnosis with scan tool
Data reference value
How to Inspect Injector
How to use injector checker
Method to identify using non-contact infrared thermometer
Injector balance test (Tech2, EMPSIII)
How to Use Breaker Box
Breaker box inspection procedure
Engine Control System
Description of function and operation for engine control (common rail) system
Engine control module (ECM)
Engine component location diagram
Wiring diagram of engine control module (ECM)
Pin arrangement of engine control module (ECM)
Circuit diagram
Engine harness location
Connector list
List of Function Checks
List of function checks
OBD system check
Diagnosis lamp illumination circuit system check
Diagnosis lamp blinking circuit system check
Scan tool power supply circuit system check (Tech2)
Scan tool power supply circuit system check (EMPSIII)
Scan tool communication circuit system check
Starting circuit system check
Starting system check
Fuel system check
Intake system check
Exhaust system check
EGR control system check
QOS system check
List of Diagnostic Trouble Codes
List of diagnostic trouble codes
DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply pump)
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump)
DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short
DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short)
DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short)
DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short circuit)
DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit)
DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply)
DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short)
DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit)
DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault)
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system
DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system
DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system
DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system
DTC: P0219 (Flash code 543) Overrun
DTC: P0237 (Flash code 32) Boost pressure sensor fault (low voltage fault, open circuit)
DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit)
DTC: P0335 (Flash code 15) Crank sensor fault (no signal)
DTC: P0336 (Flash code 15) Crank sensor fault (signal fault)
DTC: P0340 (Flash code 14) Cam sensor fault (no signal)
DTC: P0341 (Flash code 14) Cam sensor fault (signal fault)
DTC: P0380 (Flash code 66) Glow relay circuit fault
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault
DTC: P0487 (Flash code 44) EGR position sensor fault
DTC: P0488 (Flash code 45) EGR valve control fault
DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short)
DTC: P0523 (Flash code 294) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short)
DTC: P0601 (Flash code 53) ROM fault
DTC: P0603 (Flash code 54) EEPROM fault
DTC: P0606 (Flash code 51) CPU fault
DTC: P0606 (Flash code 52) CPU monitoring IC fault
DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)
DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault
DTC: P1093 (Flash code 227) No pump pressure feed
DTC: P1095 (Flash code 225) Pressure limiter open
DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short)
DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit)
DTC: P1173 (Flash code 542) Overheat
DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault
DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault
DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault
DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault)
DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault)
DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault)
DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault)
DTC: P1293 (Flash code 221) Fuel intake pressure sensor fault (low voltage fault, open circuit, ground short)
DTC: P1294 (Flash code 221) Fuel intake pressure sensor fault (high voltage fault, short to power supply, ground short)
DTC: P1345 (Flash code 16) Cam sensor out of phase
DTC: P1625 (Flash code 416) Main relay fault
DTC: P1630 (Flash code 36) A/D conversion fault
DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1
DTC: P1632 (Flash code 55) Voltage fault in 5 V power supply 2
DTC: P1633 (Flash code 55) Voltage fault in 5-V power supply 3
DTC: P1634 (Flash code 55) Voltage fault in 5-V power supply 4
DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5
DTC: U2104 (Flash code 84) CAN Bus fault
DTC: U2106 (Flash code 85) CAN timeout fault
List of Trouble Symptom
List of trouble symptom
Engine start failure
Engine stall
Engine hunting, rough idling
Engine output shortage
Exhaust gas contains a lot of white smoke.
Exhaust gas contains a lot of black smoke.
Noise
Fuel consumption deteriorates.
Oil consumption deteriorates.
Special Tool
List of special tool
Hitachi 4HK1-24V Electronic Control Fuel Injection System Engine Repair Service Manual.pdf