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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