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Summary of Contents for New Holland Hino E385C
- Page 1 SERVICE MANUAL E385C Hino Diesel Engine Supplement to Service Manual 84527569A Print No. 84532047A...
- Page 2 SERVICE MANUAL E385C Hino Diesel Engine Supplement to Service Manual 84527569A Print no. 84532047A Edition English 09/11 CONSTRUCTION Find manuals at https://best-manuals.com...
- Page 3 Many accidents can be avoided if the causes are known and opportune cautions taken beforehand. There is no device or protection, no matter how advanced, that may prove so effective at avoiding accidents as a careful and attentive behaviour. NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. COPYRIGHT BY Product Support Strada di Settimo, 323 - S.
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Page 4: Table Of Contents
E385C ENGINE (HINO DIESEL ENGINE J08E-UV) CONTENTS Group 1 General ..................W5-1 Group 2 Standard Value ................W5-2 Group 3 Parts to be prepared ..............W5-3 Group 4 Engine assembly/disassembly ............. W5-4 Group 5 Fuel System ................. W5-5 Group 6 Emission Control ................ - Page 5 Find manuals at https://best-manuals.com...
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Page 6: General
GENERAL E385C ENGINE 1 GENERAL General General information Warning ..............1-2 How to read this manual ........1-3 Precautions for work ..........1-7 Tightening of engine bolts and nuts ...... 1-11 Tightening of flare nuts and hoses......1-13 Taper thread sealant for piping ......1-14 Assembly of joints and gaskets for piping..... -
Page 7: Warning
E385C GENERAL Warning JP30002010102001 This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who perform service with the way not specified in this manual may not only damage the machine, but also put service engineers and surrounding people in danger. -
Page 8: How To Read This Manual
GENERAL E385C How to read this manual JP30002010102002 Scope of repair work Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement, assembly⋅disassembly and inspection⋅adjustment" and "Final inspection". This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement, assembly⋅disassembly and inspection⋅adjustment"... - Page 9 E385C GENERAL How to read troubleshooting Failure diagnosis in this manual describes Step 2 and Step 3 below : Hear from customers for conditions and environments of (1) Question "Step 1" failures and check the fact. Perform diagnosis inspection, status inspection, (2) Pre-inspection function inspection and basic inspection.
- Page 10 GENERAL E385C How to read explanation details Part layout Example 9–17 ENGINE MECHANICAL [J08E] Timing Gear Cover and Flywheel Housing Part layout JP04117090402003 Part name code Part catalog Fig. No. SAPH041170900182 11308 Flywheel housing 11390 End plate Description of 11309 Oil seal retainer 9828A Front oil seal*...
- Page 11 E385C GENERAL Definition of terms Terms in this manual are defined as follows : Direction Individual unit Front/back direction The power input side is front and the output side is back. Rotating direction When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is left rotation.
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Page 12: Precautions For Work
GENERAL E385C Unit SI unit is used in this manual. SI unit is the international unit to unify the conventional different international units into one unit per quantity and to promote smooth technical communications. This manual shows both the SI unit and conventional units. The conventional units are shown in { }. Convent Conversion value Convent... - Page 13 E385C GENERAL To tow a failure machine, refer to “Towing” in the "Operation manual" of the machine. Precautions for service work Pay attention to the following points before service work Preparation before disassembly Prepare general tools, special tools and gauges before work. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected to ease assembly.
- Page 14 GENERAL E385C Handling of electronic parts Do not give impact on electronic parts such as computer and relay. Do not place electronic parts at a high temperature and humidity area. Do not expose electronic parts to water in washing of a vehicle.
- Page 15 E385C GENERAL Precautions for electric welding Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding circuit, resulting in damage to electric and electronic parts. Observe the following items for electric welding. Turn "OFF" the starter switch. Make sure that switches are "OFF".
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Page 16: Tightening Of Engine Bolts And Nuts
GENERAL E385C Tightening of engine bolts and nuts JP30002010102003 Tightening torque of general standard bolts For bolts with seatings Unit : N⋅m{kgf⋅cm} Screw diameter x Pitch M8 x 1.25 (Coarse thread) 28.5{290} 36{370} M10 x 1.25 (Fine thread) 60{610} 74.5{760} M10 x 1.5 (Coarse thread) 55{560} 68.5{700}... - Page 17 E385C GENERAL Precoated bolt Precoated bolt is the bolt with application of seal lock agent at the thread. When re-application of lock agent is required When precoated bolts are removed When precoated bolts are moved due to tightening check (for loosening or tightening) Seal Lock Agent •...
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Page 18: Tightening Of Flare Nuts And Hoses
GENERAL E385C Tightening of flare nuts and hoses JP30002010102005 Tightening torque of pipe flare nut Unit : N⇒m{kgf×cm, lbf×ft} Pipe outer diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15 Material 15±5 21±1 32±3 44±5 64±5 66±2.5 Steel pipe {153±50, {214±10, {326±31, {449±51, {653±51, {673±25,... -
Page 19: Taper Thread Sealant For Piping
E385C GENERAL Taper thread sealant for piping JP30002010102006 The taper thread of the air pipe joint has application of sealant [Loctite # 575 (by Japan Loctite)]. Follow the procedures below for connection or disconnection of pipes. For disconnection Removal of joint (Example: Use of magnetic valve) The sealant ( # Loctite 575) has strong sealing feature. -
Page 20: Assembly Of Joints And Gaskets For Piping
GENERAL E385C Assembly of joints and gaskets for piping JP30002010102007 Tightening torque of joints Unit : N⋅m{kgf⋅cm, lbf-ft} Metal sealing method Sealing method (Flare pipe type, nipple connector type) Gasket sealing method (Aluminum + Rubber or Copper) Tightening screw Type A Type B size 13 {130, 9}... - Page 21 E385C GENERAL Examples of joint methods in various pipes Metal sealing method Gasket sealing method Type A Type B (Flare pipe type) (Nipple connector type) Joint bolt Flare pipe Sealing surface: 3 places Connector Gasket Flare nut Connector nipple Joint bolt Sealing surface : 4 places Flare connector...
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Page 22: Handling Of Liquid Gasket
GENERAL E385C Handling of liquid gasket JP30002010102008 Application of liquid gasket and part assembly procedure Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent deposit of oil, moisture, dirt, etc. Be sure to overlap parts at the beginning and at the end of application. -
Page 23: Failure Diagnosis Table For Each Problem
E385C GENERAL Failure diagnosis table for each problem JP30002010301001 Causes and actions are described for each item. Engine mechanical JP03Z01020601001 Status Cause Action Engine overheat (coolant) Insufficient coolant Replenish coolant Faulty thermostat Replace thermostat Water leak from cooling system Correction Faulty coolant pump Repair or replace Faulty head gasket... -
Page 24: Failure Diagnosis Procedures
GENERAL E385C Failure diagnosis procedures JP30002010301002 Display of failure code If the system has an error, the failure code is displayed on the multiple display of gauge cluster . SAPH30ZCE0100025 Deletion method of past failure To delete past failures of the engine ECU, use HINO–DX on the PC. - Page 25 E385C GENERAL How to read troubleshooting for each diagnosis monitor code "Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be started from the code list.
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Page 26: Failure Diagnosis Using Hino-Dx
GENERAL E385C Failure diagnosis using Hino-DX JP30002010301003 Hino-DX is used for inspection and adjustment ! CAUTION of the system in addition to failure diagnosis. Hino-DX With Hino-DX, failure of the common rail fuel injection system can be diagnosed. The interface box (Hino- Bowie) and the special cable are required for connection to the vehicle. - Page 27 E385C GENERAL List of failure diagnosis tools Part name Part No. External shape General description and function • Operating system(OS): (DOS/V standard) Windows95, Windows98(IE5.0 or later), Windows2000(SP3, IE5.0 or later), WindowsXP(SP1a, IE6.0 or later). — • CPU and memory: Conditions that assure operation of the above operating system •...
- Page 28 GENERAL E385C Connection of signal check harness To prevent damage to the ECU connector and to improve accessibility, connect the signal check harness and put a testing rod on the signal check connector of the signal check harness for meaurement. Disconnect the connector from the ECU.
- Page 29 E385C GENERAL Terminal No. For the signal check harness connector, the ECU terminal number in the text is treated as follows : Signal check harness(for engine control system) Engine ECU Engine side Machine side harness harness Engine Machine harness harness SAPH30ZCE0100038 W5-1-24...
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Page 30: Connection Method Of Hinodx
GENERAL E385C Connection method of HinoDX JP30ZCE010301004 Removal of the maintenance cover Remove the maintenance cover on the rear cover behind the operator seat by pushing down the tab at the top (at one location). • The engine fault diagnosis connector (16 P) is NOTICE on the inside. -
Page 31: Chassis Number And Engine Number
E385C GENERAL Chassis number and engine number JP30002010401001 Engine type and engine number Engine type and engine number are stamped at the left (Example) cylinder block when viewed from the cooling fan. For order of parts, information of this number will facilitate procedures smoothly. -
Page 32: Standard Value
E385C STANDARD VALUE ENGINE 2 STANDARD VALUE Specification (performance) System drawing Engine Mounting/Dismounting ......... 2-2 Standard value............2-2 Fuel System ..............2-2 Tightening torque............ 2-2 Emission Control............2-3 Tightening torque............ 2-3 Electrical..............2-3 Standard value............2-3 Tightening torque............ 2-3 Intake ................2-4 Tightening torque............ -
Page 33: Fuel System
E385C STANDARD VALUE Engine Mounting/Dismounting Standard value JP30ZCE020205001 Unit : MPa {kgf/cm , lbf/in. Standard Inspection item Repair limit Service limit Action value 3.4 - 3.7 3.1 - 3.2 Compression pressure — {35 - 37, {31 - 32, (Engine revolution per cylinder: 280 r/min) 494 - 536} 450 - 464} Fuel System... -
Page 34: Emission Control
E385C STANDARD VALUE Emission Control Tightening torque JP30ZCE020205003 Unit : N⋅m{kgf⋅cm, lbf⋅ft}Electrical Tightening area Tightening torque Remark EGR cooler mounting bolt 36 {367, 26} EGR cooler - Exhaust manifold 68.5 {700, 51} EGR pipe A mounting bolt 55 {560, 41} Electrical Standard value JP30ZCE020205004... -
Page 35: Intake
E385C STANDARD VALUE Intake Tightening torque JP30ZCE020205006 Unit : N⇒m{kgf⇒cm, lbf⇒ft} Tightening area Tightening torque Remark Intake manifold mounting bolt 28.5 {290, 21} Intake throttle valve mounting bolt 28.5 {290, 21} Intake pipe - Intake manifold 55 {560, 41} Engine Mechanical Standard value JP30002020205006 Unit : mm {in.}... - Page 36 E385C STANDARD VALUE Inspection item Standard value Repair limit Service limit Action 0.3 - 0.40 — 1.5 {0.0591} {0.0118 - 0.0157} Cylinder liner 0.75 - 0.90 Replace — Joint for assembly Second 1.2 {0.0472} {0.0295 - 0.0354} piston ring Clearance 0.15 - 0.3 —...
- Page 37 E385C STANDARD VALUE Inspection item Standard value Repair limit Service limit Action 64.3 Replace the — Crank pin outer diameter 65 {2.5590} {2.5315} crankshaft. Replace bearing for 0.031 - 0.082 — Connecting rod oil clearance 0.2 {0.0079} clearance {0.0012 - 0.0032} of 0.3 or more 0.20 - 0.52...
- Page 38 E385C STANDARD VALUE Inspection item Standard value Repair limit Service limit Action 21.92 Replace — Rocker shaft outer diameter 22 {0.8661} {0.8630} rocker shaft 22.08 Replace rocker — Rocker arm bushing inner diameter 22 {0.8661} {0.8693} arm bushing Replace rocker shaft 0.030 - 0.101 0.15 —...
- Page 39 E385C STANDARD VALUE Inspection item Standard value Repair limit Service limit Action — — Set length 44.8 {1.764} 129N — — Set load {13.1kgf} Outer 64.6 61.6 Replace — Free length {2.5433} {2.4252} spring Replace — — Squareness {0.0787} spring Valve 46.8 springs...
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Page 40: Standard Value
E385C STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Main idle - Pump drive 0.032 - 0.096 0.30 — idle {0.0013 - 0.0038} {0.0118} Pump drive idle - 0.020 - 0.083 0.10 — Pump drive {0.0008 - 0.0033} {0.0039} 0.030 - 0.113 0.30... - Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...
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