Kawasaki KCM 4HK1 Isuzu Diesel Engine For 62Z7 67Z7 Wheel Loader Shop Manual PDF

IDE-2620H 0
0 Introduction (All) 2
Introduction3
safety information3
14A Service Information Guide (All) 4
Contents included in service information 5
Plastic gauge 7
Recommended liquid gasket 9
Thread locking adhesive agent 11
Term12
Abbreviations13
Standard bolts 17
1B Mechanical (4HK1)24
Cylinder head cover25
removal 25
installation26
Cylinder head assembly27
removal 27
disassembly 38
inspection 43
reassembly 50
installation58
Idle gear 75
removal 75
inspection 89
installation90
Inlet cover115
removal115
installation 120
Cylinder block129
removal129
inspection148
installation 149
Exhaust manifold 186
removal186
inspection190
installation 191
Crankshaft 197
removal197
disassembly 214
inspection215
reassembly219
installation 220
Piston 255
removal255
disassembly 267
inspection268
reassembly275
installation 277
Camshaft298
removal298
disassembly 300
inspection301
reassembly303
installation 304
Flywheel310
removal310
inspection312
installation 313
Crankshaft rear oil seal 315
removal315
installation 317
Rocker arm shaft 320
removal320
disassembly 322
inspection323
reassembly325
installation 326
Valve spring 330
removal330
inspection333
installation 334
Valve stem oil seal 341
removal341
installation 344
Crankshaft front oil seal 351
removal351
installation 353
CMP sensor 356
removal356
inspection357
installation 358
Front cover359
removal359
installation 361
Intake throttle valve 366
removal366
installation 367
CKP sensor 368
removal368
inspection369
installation 370
Supplementary Information 371
1C Fuel System (4HK1)398
Fuel supply pump 399
removal399
installation 401
Common rail assembly405
removal405
installation 408
Injector413
removal413
installation 417
Suction control valve 422
removal422
installation 423
Fuel filter425
removal425
installation 426
Relief valve 428
removal428
installation 429
Fuel filter element 431
removal431
installation 432
Fuel filter pressure sensor 434
removal434
installation 435
Supplementary Information 436
1D Cooling (4HK1) 442
Water pump assembly 443
removal443
inspection445
installation 446
Thermostat 449
removal449
inspection450
installation 451
Cooling fan belt 452
inspection452
Radiator453
inspection453
Engine coolant temperature sensor 454
removal454
inspection455
installation 456
Coolant 457
inspection457
Overheat switch 459
removal459
installation 460
Supplementary Information 461
1E Lubrication (4HK1)468
Oil pan 469
removal469
installation 470
Oil pump assembly471
removal471
disassembly 485
inspection486
reassembly488
installation 489
Oil level switch 514
removal514
installation 515
Oil cooler assembly 516
removal516
disassembly 521
reassembly522
installation 523
Oil pressure sensor 531
removal531
inspection532
installation 533
Engine oil 534
inspection534
Oil port cover535
removal535
installation 536
Supplementary Information 537
1F Induction (4HK1) 544
Boost temperature sensor 545
removal545
installation 546
Turbocharger assembly 547
removal547
inspection549
installation 550
Intercooler553
inspection553
Air cleaner element 554
inspection554
IMT sensor 555
removal555
installation 556
Boost sensor 557
removal557
inspection558
installation 559
Supplementary Information 560
1G Exhaust (4HK1) 562
DPD assembly 563
disassembly 563
inspection565
reassembly566
Exhaust differential pressure sensor 569
removal569
inspection570
installation 571
Exhaust gas temperature sensor 572
removal572
inspection573
installation 574
Supplementary Information 575
1H Aux Emission Control Devices (4HK1) 578
EGR valve 579
removal579
inspection582
installation 583
Supplementary Information 587
1J Electrical (4HK1) 592
Glow plug 593
removal593
inspection594
installation 595
Generator 596
removal596
disassembly 597
inspection598
reassembly602
installation 603
ECM 604
removal604
installation 605
Starter assembly 606
removal606
disassembly 607
inspection609
reassembly613
installation 615
Supplementary Information 616

1. 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.

2. When performing a procedure with two or more people, make sure to ensure each other’s safety.

3. When repairing the electrical system, make sure to disconnect the cable from the negative (-) battery terminal before working. Keep fire away when removing the battery cover.

4. Do not leave the engine running for an extended period of time or perform painting in a poorly ventilated working environment.

5. Make sure to use only the special tools if the procedure requires them for the work. Performing the procedure using other tools may cause damage to parts or personal injury.

6. Inspect the tools, instruments, and special tools regularly, and prepare them before working. Do not use tools such as a wrench that has lost its edges, a hammer with frayed edges, or a chipped chisel.

7. When performing work using a device such as a grinder, crane or welder, make sure to pay sufficient attention to the handling precautions. Wear work clothes and safety equipments in the other operations as well.

8. Be sure to check that there is no fuel leaks when performing maintenance on fuel systems