Hitachi 6WG1 Industrial Engines Workshop Repair Service Manual

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This Manual describes the structure and the troubleshooting of electronic control fuel injection system (common rail type) in 6WG1 industrial engines. Use this manual sufficiently to perform service work properly and quickly.

TABLE OF CONTENTS :

Control System
Engine Control
(Electronic control fuel injection system (Common rail type))

Disassemble and Assemble Engine
General Information
Engine Mechanical (6WG1(Common rail))
Cooling System (6WG1(Common rail))
Fuel System (6WG1(Common rail))
Electrical System (6WG1(Common rail))
Lubricating System (6WG1(Common rail))
Intake System (6WG1(Common rail))
Preheating System (6WG1(Common rail))

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 846

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Engine Manual(1/2)
Introduction
General Contents
Control System
Engine Control (Electronic control fuel injection system (Common rail type))
How to use this manual
Table of abbreviation
List of parts according to engine control specifications
About colors of wirings
About wiring diagrams
How to read trouble diagnosis section
Precautions on Service Work
Procedure of trouble diagnosis
Information:
Interview
Pre-inspection
Information:
Trouble Diagnosis
Description of terms
How to read DTC
Confirmation after repair
List of final check items
How to clear DTC
Trouble diagnosis with scan tool
About scan tool display
How to use trouble diagnosis-related tool
How to use Tech2
Components of Tech2
Each part of Tech2
Precautions on handling Tech2
Power supply
Check items before use
How to connect Tech2
Operation procedure
List of functions of Tech2
Diagnostic procedure
DTC application menu display screen
Data Display
Snapshot
Actuator test
Injector balance test
View captured data.
Tool options
Rewrite setting of Q adjust correction data by Tech2
Injector ID code (No. 1 cylinder – No. 6 cylinder) registration setting using Tech2
ID code upload (Tech2)
ID code download (Tech2)
How to use TIS 2000
TIS 2000 installation procedure
How to display snapshot
Software download
How to Inspect Injector
How to use injector checker
Components of injector checker
Method to identify using non-contact infrared thermometer
How to use flash tool
Refer to related document.
How to use breaker box
Breaker box inspection procedure
How to connect breaker box
Example of use for breaker box
Engine Control System
Description of function and operation
About engine control (common rail) system
System control schematic diagram
Table of Input/Output
Electronic control fuel injection system (Common rail type)
System schematic diagram
Fuel system
EGR (Exhaust gas recirculation)
Idling control
Speed limit control
Engine speed output to tachometer
Preheating control
Engine Control Module (ECM)
Engine component location diagram
Supply pump
PCV (pressure control valve)
Fuel temperature (FT) sensor
G sensor
Common rail
Flow damper
Pressure limiter
Common rail pressure sensor
Injector
Engine coolant temperature (ECT) sensor
Crankshaft position (CKP) sensor
Engine oil pressure sensor
Accelerator position (AP) sensor
Intake air temperature (IAT) sensor
EGR position sensor
Boost pressure sensor
Boost temperature sensor
Diagnosis lamp
DLC (data link connector)
Diagnostic switch
Memory clear switch
Mode selector switch (1, 2, 3)
Wiring diagram of engine control module (ECM)
Pin arrangement of engine control module (ECM)
Circuit diagram
Main relay circuit
Starter for ECM control, glow circuit
Starter for safety relay, glow circuit
CAN, GND, DLC circuits
Indicator lamp, tachometer circuit
Injector circuit
PCV circuit
CKP sensor, vehicle speed sensor, fuel temperature sensor, engine coolant temperature sensor, engine oil pressure sensor circuit
Boost temperature sensor, boost pressure sensor circuit
G sensor, common rail pressure sensor, EGR circuit
Accelerator position sensor, barometric pressure sensor, intake air temperature sensor circuit
Idling selector switch, idle up switch, idle down switch, mode map switch circuit
Memory clear switch, engine stop switch circuit
Engine harness location
H94/H95 connector
Connector list
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
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 code
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: P0091/P1291 (Flash code 247/248) PCV circuit fault (PCV1 open circuit or GND short circuit / PCV2 open circuit or GND short circuit)
DTC: P0092/P1292 (Flash code 217/218) PCV circuit fault (PCV1+B short circuit / PCV2+B short circuit / PCV2+B short circuit)
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, 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, open circuit)
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: P0205 (Flash code 275) Open circuit in injection nozzle #5 drive system
DTC: P0206 (Flash code 276) Open circuit in injection nozzle #6 drive system
DTC: P0219 (Flash code 543) Overrun
DTC: P0237 (Flash code 32) Boost sensor pressure 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) G sensor fault (no signal)
DTC: P0341 (Flash code 14) G 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 295) 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 51/52) CPU fault
DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)
DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)
DTC: P0615 (Flash code 19) Starter cut relay circuit fault
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault
DTC: P1093 (Flash code 227) No pump pressure feed (2nd stage)
DTC: P1094 (Flash code 226) No pump pressure feed (1st stage)
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: 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
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
Difference by each machine manufacturer
Hitachi Construction Machinery Co., Ltd.
List of DTC
About wiring diagrams

Engine Manual(2/2)
Introduction
General Contents
Disassemble and Assemble Engine
General Information
General Information
Service Precautions
Reading the model
General information
Engine mechanical (6WG1 (Common rail))
6WG1-TC Engine
Service Precautions
Reading the model
Explanation of functions and operations
Functional check:
Main data and specifications
Engine accessories
Component parts
Removal
Installation
Engine exterior equipment
Component parts
Removal
Inspection
Installation
Torque specifications
Cylinder head
Component parts
Removal
Disassembly
Inspection
Assembly
Installation
Torque specifications
Special tools
Rocker arm
Component parts
Disassembly
Inspection
Assembly
Camshaft
Component parts
Disassembly
Inspection
Assembly
Torque specifications
Timing gear
Component parts
Removal
Inspection
Disassembly
Assembly
Installation
Torque specifications
Special tools
Flywheel, flywheel housing
Component parts
Removal
Disassembly
Inspection
Assembly
Installation
Torque specifications
Special tools
Piston, connecting rod
Component parts
Removal
Disassembly
Inspection
Assembly
Installation
Torque specifications
Special tools
Crankshaft
Component parts
Removal
Disassembly
Inspection
Assembly
Installation
Special tools
Cylinder block
Component parts
Disassembly
Inspection
Assembly
Torque specifications
Cooling system (6WG1 (Common rail))
Cooling system
Service Precautions
Explanation of functions and operations
Trouble shooting
Engine overheats
Engine overcools
Main data and specifications
Thermostat
Component parts
Removal
Inspection
Installation
Torque specifications
Special tools
Water pump
Component parts
Disassembly
Inspection
Assembly
Torque specifications
Special tools
Fuel system (6WG1 (Common rail))
Fuel system
Service Precautions
Explanation of functions and operations
Functional check:
Main data and specifications
Fuel filter
Component parts
Disassembly
Inspection
Assembly
Electrical system (6WG1 (Common rail))
Starting system
Service Precautions
Explanation of functions and operations
Trouble shooting
Even if the starter switch is switched on, the starter does not function
The pinion advances but does not engage the ring gear
The pinion engagement motor turns but the engine does not turn
The pinion engages but the engine does not turn
After starting the engine, the starter doesn’t stop when the starter switch is turned off
Main data and specifications
Starter
Component parts
Disassembly
Inspection
Assembly
Torque specifications
Charging system
Service Precautions
Trouble shooting
Does not charge at all
Lack of electrical charge
Overcharged
Charging current is unstable
Abnormal noises come from the generator
Main data and specifications
Generator
Component parts
Disassembly
Inspection
Assembly
Functional check:
Torque specifications
Lubricating system (6WG1 (Common rail))
Lubricating system
Service Precautions
Explanation of functions and operations
Main data and specifications
Oil filter
Component parts
Disassembly
Assembly
Special tools
Oil pan, oil jet
Component parts
Removal
Installation
Torque specifications
Oil pump
Component parts
Disassembly
Inspection
Assembly
Torque specifications
Oil cooler
Component parts
Disassembly
Inspection
Assembly
Torque specifications
Intake system (6WG1 (Common rail))
Turbocharging system
Service Precautions
Explanation of functions and operations
Trouble shooting
If faults or vibrations occur
When the turbocharger is thought to be mainly fine but output power is low
Oil is leaking in the exhaust pipe or intake pipe, exhaust gas is white
Main data and specifications
Turbocharger
Component parts
Disassembly
Inspection
Assembly
Preheating system (6WG1 (Common rail))
Preheating system
Service Precautions
Explanation of functions and operations
Functional check
Trouble shooting
Glow indicator lamp doesn’t light
Preheating doesn’t function
Preheating time is either too long or too short
Main data and specifications

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