2006 New Holland Kobelco E385 Tier 3 Excavator Isuzu 4HK1/6HK1 Engine Workshop Manual (PN 604.13.649)

This New Holland Kobelco engine workshop manual, Form No. 604.13.649, is the January 2006 integration publication for the E385 (Tier 3) excavator. It contains service and repair information for the Isuzu 4HK1 and 6HK1 engines.

• Engine mechanical: Cylinder-head, piston, connecting-rod and crankshaft service, with bearing selection, cylinder-liner grading and component-specific angular-tightening requirements.

• Valve train and timing: Rocker-arm and camshaft service, valve-bridge adjustment, timing-gear alignment and the separate 6HK1 scissors-gear assembly procedure.

• Fuel system: Filter and sedimenter service, air bleeding, supply-vacuum testing, injector replacement and flow-rate programming, plus supply-pump and common-rail removal and installation.

• Lubrication and cooling: Oil-pressure testing, oil-pump inspection, oil-cooler service, thermostat testing and model-specific water-pump repair coverage.

• Engine electrical: Starter and generator overhaul, charging and starting fault charts, glow-plug checks, component wiring diagrams and bench-test connections.

• Exhaust and turbocharger: EGR valve and cooler replacement, exhaust troubleshooting, 6HK1 turbocharger overhaul and 4HK1 turbocharger inspection.

Written for skilled technicians, this manual assumes workshop measuring equipment and the diagnostic tools required for the documented programming work.

Cylinder Head, Bearings and Timing Gear Train

Cylinder-head coverage extends to valve guides, injector sleeves and valve-seat work. The 4HK1 head-gasket selection procedure uses piston protrusion; crankshaft and connecting-rod bearing tables match component grades before replacement parts are selected.

Inspection data include rocker-arm shaft wear limits, camshaft journal tolerances and valve-spring tension thresholds. Timing instructions distinguish the 6HK1 scissors-gear arrangement.

The valve-bridge adjustment cautions explain how a tilted bridge can seize and damage its guide. General Isuzu torque tables distinguish bolt strength and flange or hexagon heads, while individual component chapters supply their own tightening requirements.

Fuel Injection and Flow-Rate Programming

Replacement-injector programming includes QR-plate recording and the scan-tool/TIS 2000 Service Programming System procedure. Supply-pump installation covers gear-index checks and the associated ECM learning requirement.

The fuel-system vacuum test pairs gauge hookup information with filter and delivery-pipe checks, helping trace supply restrictions. The listed equipment includes pressure/vacuum gauge 380.002.629 and the 4HK1 adapter EN-47667.

The Fuel system diagram shows supply and leak-off routes. Common-rail illustrations identify the flow damper, pressure limiter and pressure sensor.

Lubrication and Cooling Checks

The Lubricating system diagram traces the cooler, filter and piston-cooling circuit. Oil-pump clearances and oil-cooler reassembly details accompany oil-pressure testing.

Cooling sections cover pressure-leak testing, overheating and overcooling fault tables, and thermostat inspection. The 6HK1 water-pump chapter includes bearing and seal-unit work; the 4HK1 procedure covers inspection and assembly replacement.

Sealant cautions explain how excess liquid gasket can block oil galleries or piston jets and cause seizure.

Starter and Generator Diagnosis

Starting-system diagnosis separates no-crank faults from slow cranking and cable-voltage-drop problems. Starter and generator sections cover disassembly, inspection, reassembly and testing, alongside glow-plug checks.

Reference drawings include generator performance-test wiring, the 6HK1 Charging Circuit and the starter Output Characteristic chart.

Turbocharger Repair and EGR Coverage

The 6HK1 Turbocharger Structured Diagram accompanies internal disassembly, shaft and bearing inspection, and reassembly. 4HK1 turbocharger coverage is inspection only: the manual identifies this unit as a design that cannot be overhauled.

EGR valve and cooler removal and installation are covered. Detailed electronic EGR diagnosis requires the separate Engine Control System chapter referenced by the manual.

Observe the manual’s electrical-isolation and hot-coolant precautions during engine service.

A Sample of Timing-Gear and Oil-Pressure Specifications

These timing-gear and lubrication values are a small selection of the service data included in the manual.

For both covered engines, the timing-gear table lists standard backlash of 0.10–0.17 mm and a service limit of 0.30 mm.

The lubrication check specifies oil pressure above 343 kPa (50 psi) at 2,000 rpm with the engine warm.

PDF Search, Bookmark Limitations and Included Pages

Text access and circuit detail: Main-chapter text is searchable; the outer cover and some diagram labels are outside the text search. Embedded bookmarks are only partly usable because numerous duplicate entries lead to the cover. Small wiring labels are readable when enlarged.

Supplied as one printable English PDF with 335 pages total, including the outer cover (1 page), title page (1 page), introduction (2 pages) and three otherwise blank separator pages. These seven pages are already included in the total.