Page 1 HINO DIESEL ENGINE WORKSHOP MANUAL J05E-TH (HS ENGINE for 25t) KSS-SMJ5-E111E 2007.6...
Page 3 GENERAL STANDARD VALUE PARTS TO BE PREPARED ENGINE ASSEMBLY/DISASSEMBLY FUEL SYSTEM EMISSION CONTROL ELECTRICAL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION STARTING AND CHARGING TURBOCHARGER AIR COMPRESSOR FAILURE DIAGNOSIS FOR EACH ENGINE STATUS ENGINE DIAGNOSIS CODE For your information: This documentation does not contain any descriptions in regard to the hatched part "6.
Page 5: Table Of Contents
1–1 GENERAL 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 ...... 1-10 Tightening of chassis bolts and nuts..... 1-12 Tightening of flare nuts and hoses......1-14 Taper thread sealant for piping ......
Page 6: Warning
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality. • Items described in this manual are the procedures to be observed in service and repair. For service and repair according to this procedure, be sure to use the special tools designed for each purpose.
Page 7: How To Read This Manual
1–3 GENERAL How to read this manual JP31199010102002 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 8 1–4 GENERAL How to read troubleshooting Failure diagnosis in this manual describes Step 2 and Step 3 below : Hear from customers for conditions and environments (1) Question "Step 1" of failures and check the fact. Perform diagnosis inspection, status inspection, (2) Pre-inspection function inspection and basic inspection.
Page 9 1–5 GENERAL 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 10 1–6 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.
Page 11: Precautions For Work
1–7 GENERAL Safety information Precautions for work JP31199010101001 General precautions To ensure safety in work and to prevent accidents, observe the following items : Appearance Wear safety goggles. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work. Bind long hair at the back.
Page 12 1–8 GENERAL Precautions for electric system Removal of battery cable In an electric system, remove the cable from the battery minus (-) terminal to prevent burnout due to short-circuit. When the battery cable is removed, the battery Loosen terminal may be damaged. Loosen the nut completely and never pry it for removal.
Page 13 1–9 GENERAL Handling of connector When a connector is removed, hold the connector (as shown by the arrow in the left) and pull it out. Do not pull the wire harness. Unlock the locking connector before pulling. Insert the locking connector completely until it clicks. To insert a test lead into the connector, insert it from the back of the connector.
Page 14: Tightening Of Engine Bolts And Nuts
1–10 GENERAL Tightening of engine bolts and nuts JP31199010102003 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 15 1–11 GENERAL Precoated bolt Precoated bolt is the bolt with an application of a 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 Seal Lock Agent check (for loosening or tightening) •...
Page 16: Tightening Of Chassis Bolts And Nuts
1–12 GENERAL Tightening of chassis bolts and nuts JP31199010102004 Tightening torque of general standard bolts and nuts Selection method of tightening torque Find the applicable strength zone from the table below and select the bolt tightening torque from the table described later. Select the nut tightening torque from the mating bolt as described above.
Page 17 1–13 GENERAL Standard tightening torque table of general standard bolts and nuts (Representative standard seating is described) Unit : N⋅m{kgf⋅cm} Strength zone Bolt diameter (mm) 4.5±1.8{50±20} (Cab) 9.0±1.8{90±20} 11.5±2.0{117±23} 5.5±1.1{60±10} (Chassis) 14.0±3.5{140±40} (Cab) 22.0±4.0{220±40} 29.0±5.5{300±60} 17.0±3.0{170±30} (Chassis) 43.0±8.5{440±90} 57.0±11.0{580±110} (Cab) (Cab) 27.0±5.0{276±55} 51.5±10.0{530±100}...
Page 18: Tightening Of Flare Nuts And Hoses
1–14 GENERAL Tightening of flare nuts and hoses JP31199010102005 Tightening torque of pipe flare nut Unit : N⋅m{kgf⋅cm} Pipe outer diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15 Material Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80} Tightening torque of hoses Unit : N⋅m{kgf⋅cm} Hose outer diameter Hose outer diameter...
Page 19: Taper Thread Sealant For Piping
1–15 GENERAL Taper thread sealant for piping JP31199010102006 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
1–16 GENERAL Assembly of joints and gaskets for piping JP31199010102007 Tightening torque of joints Unit : N⋅m{kgf⋅cm} 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}...
Page 21 1–17 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 Sealing surface: 3 places Flare pipe Gasket Connector Flare nut Connector nipple Joint bolt Sealing surface : 4 places Flare connector...
Page 22: Handling Of Liquid Gasket
1–18 GENERAL Handling of liquid gasket JP31199010102008 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 overap parts at the beginning and at the end of application.
Page 23: Failure Diagnosis Table For Each Problem
1–19 GENERAL Failure diagnosis table for each problem JP31199010301001 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 Using Hinodx
HinoDX With HinoDX, 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. Special tool : 09121-1040 Hino-Bowie...
Page 25 1–21 GENERAL Deletion of past failures To delete past failures of the engine ECU, use HinoDX on the PC. (Refer to "HinoDX operation manual".) SAPH311990100032 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.
Page 26 1–22 GENERAL Terminal No. For the signal check harness connector, the ECU terminal number in the text is treated as follows : ECU unit Signal check harness ECU side Unit side SAPH311990100038...
Page 27: Connection Method Of Hinodx
Remove the left side cover at the rear of the driver's seat and connect the failure diagnosis connector with a PC which installed HinoDX through the interface box. Special tool : 09121-1040 Hino-Bowie (Interface box) 09042-1220 Connecting cable CD-ROM HinoDX Engine ECU Set the starter key to "ON"...
Page 29 2–1 STANDARD VALUE ENGINE 2 STANDARD VALUE Specification (performance) System drawing Engine Body..............2-2 Standard value............2-2 Tightening torque ............ 2-2 Fuel System ..............2-2 Tightening torque ............ 2-2 Electrical..............2-3 Standard value............2-3 Tightening torque ............ 2-3 Intake ................2-3 Tightening torque ............
Page 30: Engine Body
2–2 STANDARD VALUE Engine Body Standard value JP31199020205001 MPa {kgf/cm , lbf/in. Repair Service Inspection item Standard value Action limit limit Compression pressure 3.4-3.7 — (Engine revolution per cylinder: 150 r/min) {35-38, 493-237} {28, 392} Tightening torque JP31199020205002 Unit:N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark...
Page 31: Electrical
2–3 STANDARD VALUE Electrical Standard value JP31199020205018 Inspection item item item Standard value Remark 8 - 10mm {0.3152 - 0.394in.} Compression Deflection (Reference push force 98N gauge (09444- {10kgf, 22lbf}) 1210) is used. When installing Belt tension a new belt gauge (95506- 490 - 570 N Tension...
Page 32: Engine Mechanical
2–4 STANDARD VALUE Engine Mechanical Standard value JP31199020205006 Unit : mm {in.} Inspection item Standard value Repair limit Service limit Action — — 0.30 {0.0118} Valve clearance (cold) — — 0.45 {0.0177} 0.01 - 0.08 — — Cylinder liner protrusion {0.003 - 0.003} —...
Page 33 2–5 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Approx. 11.5 — — {0.4527} Free joint clearance Approx. 14 — — Second {0.5512} 0.3 - 0.40 — 1.5 {0.0591} {0.0118 - 0.0157} Gap between ends 0.75 - 0.9 Replace —...
Page 34 2–6 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Replace piston pin 0.015 - 0.036 0.08 — Connecting rod bushing oil clearance {0.0006 - 0.0014} {0.0031} connecting rod bushing Replace the 63.8 — Crank pin outer diameter 65 {2.5590} crankshaft.
Page 35 2–7 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Replace 0.20 - 0.52 connecting — Connecting rod end play 1.0 {0.0394} {0.0079 - 0.0205} rod or crankshaft –0.15 Camshaft journal outer Replace — 40 {1.5748} diameter {–0.0059} camshaft Bearing Camshaft bearing inner...
Page 36 2–8 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action Allowable angle 30° - 30° 30°35' Valve seat angle Allowable angle 45° - 45° 30°30' Correction Allowable angle 29°30 - 30° 45° Valve face angle Allowable angle 44°30 - 45°...
Page 37 2–9 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action 0.030 - 0.167 0.30 — Crank - Main idle {0.0012 - 0.0066} {0.0012} Main idle - Pump 0.032 - 0.096 0.10 — drive idle {0.0013 - 0.0038} {0.00393} Pump drive idle - 0.020 - 0.083 0.10...
Page 38 2–10 STANDARD VALUE Inspection item Standard value Repair limit Service limit Action — — Shaft outer diameter 34 {1.3386} Bushing inner — — 34 {1.3386} diameter Replace Clearance between 0.025 - 0.075 0.20 — shaft or shaft and bushing {0.0002 - 0.0030} {0.0079} bushing idle...
Page 39 2–11 STANDARD VALUE Valve timing Exhaust valve open (before BDC) 54° Exhaust valve close (after TDC) 13° Intake valve open (before TDC) 14° Intake valve close (after BDC) 30° Tightening torque JP31199020205007 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Crankshaft pulley mounting bolt 118 {1,203, 87}...
Page 40: Tightening Torque
2–12 STANDARD VALUE Exhaust Tightening torque JP31199020205008 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Exhaust manifold mounting stud bolt 30 {300, 22} Exhaust manifold mounting nut 53 {540, 40} Cooling Standard value JP31199020205009 Standard Repair Service Inspection item Action value limit...
Page 41 2–13 STANDARD VALUE Repair Service Inspection item Standard value Action limit limit — — Outer diameter of drive gear 54 {2.1260} Cylinder block side — — 54 {2.1260} Oil pump chamber inner diameter Clearance between drive gear and 0.100 - 0.202 0.30 Replace drive —...
Page 42: Tightening Torque
2–14 STANDARD VALUE Tightening torque JP31199020205011 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Oil pan mounting bolt 30 {300, 22} Oil strainer 31 {320, 23} Oil pan drain cock 41 {420, 30} Oil pump mounting bolt 28.5 {290, 21} 24.5±4.9 {250±50, 18±4} 24.5±4.9 {250±50, 18±4} Oil circuit spring plug...
Page 43: Tightening Torque (Alternator 50A)
2–15 STANDARD VALUE Tightening torque (Alternator 50A) JP31199020205013 Unit : N⋅m{kgf⋅cm, lbf⋅ft} Tightening area Tightening torque Remark Bearing cover mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} Pulley mounting nut 127 - 157 {1, 300 - 1, 600, 94 - 116} Feed coil - Rear bracket 2.9 - 3.9 {30 - 39, 2 - 3} Heat sink mounting bolt...
Page 44: Tightening Torque (Starter)
2–16 STANDARD VALUE Standard Inspection item Service limit Action value Metal bushing inner diameter of shaft Replace shaft 9 {0.3543} 9.2 {0.3622} assembly assembly Replace Bearing housing inner diameter of rear 28 {1.1024} 28.1 {1.1063} or more commutator end bracket frame Between C terminal and M Start...
Page 45 3–1 PARTS TO BE PREPARED ENGINE 3 PARTS TO BE PREPARED Special tool (SST) Special tool Engine Body..............3-2 Special tool ............. 3-2 Fuel System ..............3-2 Lubricant, etc............3-2 Electrical..............3-2 Special tool ............. 3-2 Engine Mechanical ............. 3-3 Special tool .............
Page 46: Engine Body
3–2 PARTS TO BE PREPARED Engine Body Special tool JP31199030901001 Shape Part No. Description Remark 09491–1010 Wire rope For engine lifting 09552–1030 Compression gauge adapter 09552–1060 Compression gauge adapter 09552–1110 Compression gauge adapter Fuel System Lubricant, etc. JP31199030901002 Name Remark Guide pin (SZ105-08067) For supply pump positioning Electrical...
Page 47: Engine Mechanical
3–3 PARTS TO BE PREPARED Engine Mechanical Special tool JP31199030901004 Shape Part No. Name Remark For crankshaft front oil seal 09420–1731 Oil seal puller removal For crankshaft front oil seal 09407–1030 Oil seal press press-fit For assembly/disassembly 09433–1070 Eye bolt of cylinder head For assembly/disassembly 09470–1170...
Page 48 3–4 PARTS TO BE PREPARED Shape Part No. Name Remark For valve stem seal 09472–2100 mounting For removal and inspection 09420–2100 Cylinder liner puller of cylinder liner For assembly/disassembly 09442–1011 Piston ring expander of piston ring For mounting of connecting rod small end bushing 9191–08252 Bolt...
Page 49 3–5 PARTS TO BE PREPARED Shape Part No. Name Remark 09441–1370 Piston ring holder For piston mounting For assembly/disassembly 09481–1340 Guide of flywheel For crankshaft rear oil seal 09420–1742 Oil seal puller removal 09420–1100 For main/sub idle gear Sliding hammer assembly and cam idle gear 09420–1442 shaft removal...
Page 50: Instruments
3–6 PARTS TO BE PREPARED Shape Part No. Name Remark For cooling jet inspection 09470–1280 Tool assembly and adjustment Instruments JP31199030901005 Name Remark Micrometer For measurement of part outer diameter Cylinder gauge For measurement of part inner diameter Thickness gauge For measurement of each clearance Dial gauge For measurement of parts...
Page 51: Starting And Charging
3–7 PARTS TO BE PREPARED Starting and Charging Jig (reference dimensional drawing for manufacture) JP31199030901009 This is used for assembly of bearing. Reference dimensions are shown in the figures below: Jig B (Support jig) Unit : mm{in.} Jig A (Roller bearing insertion jig) φ23{20.827} φ25{0.984} 1C{0.039}...
Page 52: Instruments
3–8 PARTS TO BE PREPARED Instruments JP31199030901010 Alternator Name Remark Circuit tester For measurement of parts Micrometer For measurement of parts Regulator checker (G&M Machinery ICD-101D or For inspection of regulator equivalent) Starter Name Remark Circuit tester For measurement of parts Micrometer For measurement of part outer diameter Growler tester...
Page 53: Engine Failure Diagnosis
• Display: 800 x 600, 256 colors or more Failure diagnosis software HinoDX (CD-ROM) Used together with the cable between the vehicle 09121–1040 Hino-Bowie (Interface box) and Hino-Bowie (09042- 1220) This is installed as interruption between vehicle 09049–1080 Signal check harness harness and the ECU.
Page 55 4–1 ENGINE ASSEMBLY/DISASSEMBLY ENGINE 4 ENGINE ASSEMBLY/DISASSEMBLY Service procedure Overhaul item Inspection Before Service ......... 4-2 Measurement of compression pressure ....4-2 Engine Body..............4-4 Removal ..............4-4 Installation............... 4-6 Work after installation ..........4-6...
Page 56: Inspection Before Service
4–2 ENGINE ASSEMBLY/DISASSEMBLY Inspection Before Service Measurement of compression pressure JP31199040702001 • Measure the compression pressure before NOTICE disassembly of the engine and record the result. Regular measurement of the compression pressure can tell the engine status. Preparation before measurement Charge the battery completely.
Page 57 4–3 ENGINE ASSEMBLY/DISASSEMBLY Measure the compression pressure of each cylinder continuously. Engine revolution 150r/min {rpm} Compression pressure: Unit MPa {kgf/cm ,lbf/in. Standard value 3.4 - 3.7 {35 - 38 ,493 - 537} Service limit 2.7 {28, 392} Difference between 0.3{3, 44} or less cylinders If the compression pressure is the service limit or less or if the difference between cylinders is over the standard...
Page 58: Engine Body
4–4 ENGINE ASSEMBLY/DISASSEMBLY Engine Body Removal JP31199040702002 Preliminary work before removal of engine Place the vehicle on a level ground. Block tires with scotch. Remove the battery cable from the battery minus terminal. Drain of coolant and engine oil Right side of engine Drain coolant from the radiator drain cock and the oil cooler drain plug.
Page 59 4–5 ENGINE ASSEMBLY/DISASSEMBLY Disconnection of fuel hose Remove the fuel hoses (feed side and return side). Wrap the removed hose with a plastic sheet with its end facing upward to prevent spill of fuel. • Wipe spilled fuel with a rag. ! CAUTION SAPH311990400004 Disconnection of water, engine oil pipes, etc.
Page 60: Installation
Engine oil amount (L{us gal}) Oil pan Oil filter and etc Approx. 18{4.76} Approx. 2.5{0.66} Filler cap SAPH311990400008 • Please use Hino genuine engine oil ! CAUTION Multi grade SAE #10W-30 Single grade SAE #30 Air bleeding of fuel system...
Page 61 5–1 FUEL SYSTEM ENGINE 5 FUEL SYSTEM Setup layout Layout Fuel System ..............5-2 Fuel system diagram..........5-2 Part layout .............. 5-3 Fuel filter drain (on machine main unit)....5-5 Replacement of fuel filter element (on machine main unit) ........... 5-6 Replacement of supply pump ........
Page 62: Fuel System
5–2 FUEL SYSTEM Fuel System Fuel system diagram JP31199050402001 Feed pipe Injection pipe Flow damper Injector Common rail Leakage pipe Pressure limiter Through feed pipe Overflow pipe Supply pump Fuel tank Fuel filter SAPH311190500001...
Page 63: Part Layout
5–3 FUEL SYSTEM Part layout JP31199050402003 SAPH311190500002 11195 Nozzle clamp holder 23670 Injector 11334 Bearing holder case 23810 Common rail assembly 11491A Common rail bracket 9645A O–ring* 22100 Supply pump 9851A O–ring* *Parts not to be reused. Tightening torque 22825 63.7N⋅m {650 kgf⋅cm, 47lbf⋅ft} 9068-08320 28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}...
Page 64 5–4 FUEL SYSTEM SAPH311190500003 23081 Leakage pipe 23816A Through feed pipe 23711 Injection pipe 23816B Through feed pipe 23712 Injection pipe 9659B Gasket* 23713 Injection pipe 9659C Gasket* 23714 Injection pipe 9659D Gasket* 23783A Fuel pipe 9659E Gasket* 23816 Through feed pipe *Parts not to be reused.
Page 65: Fuel Filter Drain (On Machine Main Unit)
5–5 FUEL SYSTEM Fuel filter drain (on machine main unit) JP31199050704001 Prepare a water container under the drain pipe. Air bleeding bolt Priming pump Loosen the fuel filter air bleeding bolt and the drain valve. Discharge water at the bottom of the fuel filter case. •...
Page 66: Replacement Of Fuel Filter Element (On Machine Main Unit)
5–6 FUEL SYSTEM Replacement of fuel filter element (on machine main unit) JP31002050704002 • The frequency for water draining and replacement of the fuel filter element differs ! CAUTION according to the fuel situation in the use region. Replace the fuel filter element every 500 hours or when the engine output decreases, whichever occurs first.
Page 67 5–7 FUEL SYSTEM Installation of fuel filter element • Fuel filter element is not reused. ! CAUTION The soiling and the foreign material of the clamp face are removed. Install the fuel filter element with according to tightening angle in the table below of a turn after the O-ring of the fuel filter element comes into contact with the fuel filter head.
Page 68 5–8 FUEL SYSTEM Installation of water cup • Fuel filter element is not reused. ! CAUTION • Install the O-ring after applying fuel to the surface of the O-ring. • Do not use a tool, but tighten by hand. Fuel filter element Tightening angle (Image with the fuel filter seen from below) O-ring...
Page 69: Replacement Of Supply Pump
5–9 FUEL SYSTEM Replacement of supply pump JP31199050704003 Compression upper dead center setting of No.1 cylinder Turn the crankshaft counterclockwise when viewed from the flywheel. Set the timing mark in the flywheel housing inspection window to "1". Flywheel Remove the inspection window plug in the bearing holder case of the supply pump.
Page 70 5–10 FUEL SYSTEM Secure the supply pump, install the injection pump drive gear on the shaft, and use a vice or similar to prevent turning while tightening the nut. Tightening torque : 63.7 N⋅m {650 kgf⋅cm, 47 lbf⋅ft} • Do not use the guide bolt for stopper key of ! CAUTION the shaft.
Page 71: Inspection Of Supply Pump
5–11 FUEL SYSTEM Inspection of supply pump JP31199050704004 Inspection of suction control valve and fuel temperature sensor Measure the resistance of the suction control valve terminals and the fuel temperature sensor terminals using a circuit tester. If it is beyond the standard, remove the Fuel temperature sensor supply pump assembly and request for replacement at the...
Page 72: Replacement Of Injector
5–12 FUEL SYSTEM Replacement of injector JP31199050704005 Removal of injector Remove the fixing bolt and remove the plate and the injection pipe oil seal. Remove the nozzle clamp holder and remove the injector. Installation of injector Attach a new O-ring to the groove of the cylinder head and insert the injector.
Page 73: Inspection Of Injector
Read the injector QR code with the scanner of the QR code reader and prepare the correction data file. Enter the injector correction value directly from the PC tools to the engine ECU. QR Code reader Hino-Bowie Engine-use code QR code Connector New injector...
Page 74: Replacement Of Common Rail
5–14 FUEL SYSTEM Replacement of common rail JP31199050704007 Removal of common rail Remove the common rail together with the flow damper, pressure sensor and pressure limiter from the intake manifold. • Remove dirt around parts before removing ! CAUTION Pressure limiter the common rail Flow damper Pressure sensor...
Page 75 7–1 ELECTRICAL ENGINE 7 ELECTRICAL Setup layout Layout Electrical System............7-2 Part layout ............... 7-2 Layout of components..........7-5 Inspection of components ........7-8 Installation of component ........7-10 Installation of starter ..........7-10 Installation of alternator ........7-11...
Page 76: Electrical System
7–2 ELECTRICAL Electrical System Part layout JP31199070402001 SAPH311990700001 82051 Injector harness 89390 Boost pressure sensor 83420 Water temperature sender gauge 89410 Engine sub revolution sensor 83530 Oil pressure warning switch 89411 Engine main revolution sensor Tightening torque 9190-06121 4N⋅m{40kgf⋅cm, 3lbf⋅ft}...
Page 77 7–3 ELECTRICAL SAPH311990700002 12509 Alternator brace 9011-64410 Through bolt 12511 Alternator bracket 9241-10107 Fixing bolt at brace 27040 Alternator assembly 9189A Adjusting bolt 28100 Starter assembly Tightening torque 9069A 154N⋅m{1,570kgf⋅cm, 114lbf⋅ft} 9241-10107 51N⋅m{520kgf⋅cm, 38lbf⋅ft} 9011-64401 83N⋅m{850kgf⋅cm, 61lbf⋅ft} 9241-14147 154N⋅m{1,570kgf⋅cm, 114lbf⋅ft} 9189A 5.9N⋅m{60kgf⋅cm, 4lbf⋅ft}...
Page 78 7–4 ELECTRICAL SAPH311990700003 19110 Glow plug...
Page 79: Layout Of Components
7–5 ELECTRICAL Layout of components JP31199070402003 Boost pressure sensor Engine sub revolution sensor Engine main revolution sensor Engine revolution sensor Common rail pressure sensor Fuel temperature sensor Suction control valve (SCV) Left side view SAPH311990700004...
Page 80 7–6 ELECTRICAL Oil pressure warning switch Coolamt temperature sender gauge Engine sub revolution sensor Engine main revolution sensor Boost pressure sensor Suction control valve (SCV) Fuel temperature sensor Upper view SAPH311990700005...
Page 81 7–7 ELECTRICAL Boost pressure sensor Coolamt temperature sender gauge Engine revolution sensor Front view SAPH311990700006 Service procedure Overhaul item...
Page 82: Inspection Of Components
7–8 ELECTRICAL Inspection of components JP31199070702001 Inspection of oil pressure warning switch (Laid out on the oil filter) Apply pressure with air or oil and check continuity between terminals using a circuit tester. If it is faulty, replace it. At no load or less than 39kPa With continuity {0.4kgf/cm ,5.6565lbf/in.
Page 83 7–9 ELECTRICAL Inspection of glow plug Measure continuity between the body and the terminal using a circuit tester. If it is faulty, replace the glow plug. Standard value Resistance value : Ω(Normal temperature 2.59 - 3.29 20°C{68°F}) SAPH311990700010 Inspection of suction control valve SCV and fuel temperature sensor For inspection and replacement of the suction control valve (SCV) and the fuel temperature sensor, refer to the...
Page 84: Installation Of Component
7–10 ELECTRICAL Installation of component JP31199070702002 Installation of engine revolution sensor Confirm that there are O-rings on the sensors and then mount one sensor on top of the flywheel housing and one on the cam housing. • Since this sensor is a flange type, gap does O-ring NOTICE not have to be adjusted.
Page 85: Installation Of Alternator
7–11 ELECTRICAL Installation of alternator JP31199070702004 Installation of alternator Tighten the alternator temporarily using through bolts and nuts. Tighten the adjusting bolts and fixing bolts temporarily. V–belt tension adjustment Coolant Pump Pulley When installing a Item At the time of inspection new belt 8 - 10mm 10 - 12mm...
Page 87 8–1 INTAKE ENGINE 8 INTAKE Setup layout Layout Intake Manifold ............8-2 Part layout ............... 8-2 Replacement............8-4...
Page 88 8–2 INTAKE Intake Manifold Part layout JP31199080402001 SAPH311990800001 17103 Intake pipe 17113 Intake pipe 17111 Intake manifold 17171 Gasket* *Parts not to be reused. Tightening torque 9068-08320 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft} 9240-08087 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft} 9068-08550 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft}...
Page 89 8–3 INTAKE SAPH311990800002 17104A Gasket* 17148 Plate *Parts not to be reused. Service procedure Replacement procedure item...
Page 90 8–4 INTAKE Replacement JP31199080704001 Removal of intake manifold Remove bolts and nuts and remove the intake manifold. Installation of intake manifold Clean inside of the intake manifold and the cylinder head. Assemble a new gasket. • Install the gasket so that the protrusion may ! CAUTION come at the rear end stud bolt of the cylinder head.
Page 91 9–1 ENGINE MECHANICAL ENGINE 9 ENGINE MECHANICAL Setup layout Layout Cylinder Head ............. 9-2 Part layout ............... 9-2 Replacement of cylinder head ........ 9-4 Liquid gasket application procedure for semicircular plug (only when semicircular plug is removed) ..9-7 Replacement of head cover ........9-7 Overhaul of cylinder head ........
Page 92: Cylinder Head
9–2 ENGINE MECHANICAL Cylinder Head Part layout JP31199090402001 SAPH311990900001 11101 Cylinder head assembly 11135 Exhaust valve seat 11122 Valve guide 11176 Nozzle seat 11131 Intake valve seat 900115 O-ring* *Parts not to be reused.
Page 93 9–3 ENGINE MECHANICAL SAPH311990900002 11115 Cylinder head gasket 12108 Oil filler cap 11188 Semicircular plug 12505 Silent block 11201 Cylinder head cover 23074 Injection pipe oil seal* 11213 Head cover gasket *Parts not to be reused. Tightening torque 11185 59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90°+90° 9069B 59N⋅m{600kgf⋅cm, 44lbf⋅ft} 11185A...
Page 94: Replacement Of Cylinder Head
9–4 ENGINE MECHANICAL Replacement of cylinder head JP31199090704001 Removal of cylinder head and head gasket First remove the head bolts 1 to 3. Then gradually loosen the head bolts 4 to 21 from the outside to the inside (approx. 1/4 turn each time) and remove them.
Page 95 9–5 ENGINE MECHANICAL Installation of cylinder head gasket and liquid gasket application procedure Cut the rear end plate gasket to be flush with the surface Water hole seal ring of the cylinder block upper surface using a scraper. Install the cylinder head gasket on the cylinder block and the flywheel housing.
Page 96 9–6 ENGINE MECHANICAL Align the dowel pins of the cylinder block using a special tool and hoist and mount the cylinder head. Figure is an example of work. Special tool : 09433–1070 Eye bolt • Before mounting the cylinder head, make ! CAUTION sure that there is no foreign matter in the cylinder.
Page 97: Liquid Gasket Application Procedure For Semicircular Plug (Only When Semicircular Plug Is Removed)
9–7 ENGINE MECHANICAL (10) Tighten the remaining bolts (M10) 1 to 3 in the order shown in the figure. This just 3 tighten Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft} SAPH311990900012 Liquid gasket application procedure for semicircular plug (only when semicircular plug is removed) JP31199090704002 Remove liquid gasket from the cylinder plug and the...
Page 98: Overhaul Of Cylinder Head
9–8 ENGINE MECHANICAL Coat the semicircular plugs with liquid gasket (Three Bond TB 1207B-Black or equivalent) just before you install the cylinder head cover. • Install the oil cooler within 20 minutes after ! CAUTION application of the liquid gasket. SAPH311990900015 Put the cylinder head cover on the cylinder head and Cylinder...
Page 99 9–9 ENGINE MECHANICAL Replacement of valve seat • The valve seat replacement procedure below Backing Valve seat ! CAUTION metal may damage the cylinder head depending on the case. It is recommended that a request for replacement be made to a machining vendor. Electric welding Valve If the valve seat is replaced, use an out-of-use valve.
Page 100 9–10 ENGINE MECHANICAL After attaching a new O-ring into the nozzle seat hole of Cylinder head the cylinder head, apply the liquid gasket [Threebond TB1211 (white) or equivalent] at the lower part of a new O-ring nozzle seat and assemble it on the cylinder head. •...
Page 101: Cylinder Block
9–11 ENGINE MECHANICAL Cylinder Block Part layout JP31199090402002 SAPH311990900026 11401 Cylinder block assembly 11467 Cylinder liner 11408 Cooling jet Tightening torque 22N ⋅m{220kgf⋅cm, 16lbf⋅ft} 11521 69N⋅m{700kgf⋅cm, 51lbf⋅ft}+90°+45° 15605 Service procedure Overhaul item...
Page 102: Overhaul
9–12 ENGINE MECHANICAL Overhaul JP31199090702002 Replacement of cylinder liner Put match marks on the flange surfaces of the cylinder block and the cylinder liner using a oil based marker. • Store removed cylinder liners for each ! CAUTION Match mark cylinder number.
Page 103 9–13 ENGINE MECHANICAL • When a new cylinder liner is installed, install ! CAUTION Liner identification mark Engine type the cylinder liner with the same identification mark (A, B, C) stamped on the cylinder block. Block front Front of engine SAPH311990900030 Cylinder liner A, B and C marking...
Page 104 9–14 ENGINE MECHANICAL Connect the injection test oil hose from the lower part of the cylinder block to the special tool check bolt. • Use new engine oil for injection of oil. ! CAUTION Check bolt Oil hose SAPH311990900034 Set a special tool on the cylinder block. Special tool : 09470–1280 Tool assembly Special tool Tool assembly...
Page 105 9–15 ENGINE MECHANICAL If injection does not hit the target circle, correct it with a special tool. Special tool : 09472–1620 Tool If it cannot be corrected, install a new cooling jet for reinspection. Remove the check bolt and install the cooling jet on the cylinder block using the genuine oil check valve.
Page 106: Timing Gear Cover And Flywheel Housing
9–16 ENGINE MECHANICAL Timing Gear Cover and Flywheel Housing Part layout JP31199090402003 SAPH311990900040 11309 Front oil seal retainer 11390 End plate 11351 Flywheel housing 9828A Front oil seal* 11357 Gasket* 9828B Rear oil seal* 11357A Gasket* *Parts not to be reused. Tightening torque 9068-08000 36N⋅m{370kgf⋅cm, 27lbf⋅ft}...
Page 107: Replacement Of Flywheel Housing
9–17 ENGINE MECHANICAL Replacement of flywheel housing JP31199090702003 Removal of flywheel housing Remove bolts and remove the flywheel housing. • Remove bolts fixing the flywheel housing ! CAUTION from the cylinder block. SAPH311990900041 Installation of flywheel housing Liquid gasket Remove contamination from the joint surfaces of the flywheel housing and the end plate using a scraper.
Page 108: Replacement Of Crankshaft Front Oil Seal
9–18 ENGINE MECHANICAL Installation of end plate Install the end plate and a new gasket with bolts. • Make sure that there is no dirt or foreign ! CAUTION matter on the installation surface of the cylinder block and the screw holes. Apply sealant (Super 5M or equivalent) to the thread of the Torx bolt.
Page 109 9–19 ENGINE MECHANICAL Remove two bolts which installed the plate of the special tool oil seal puller on the crankshaft. Attach the accompanying center bolt to the special tool oil seal puller and tighten it. Pull out the front oil seal. SAPH311990900048 Installation of front oil seal Guide...
Page 110: Replacement Of Crankshaft Rear Oil Seal
9–20 ENGINE MECHANICAL Replacement of crankshaft rear oil seal JP31199090704005 Removal of rear oil seal Install the plate of the special tool oil seal puller on the crankshaft using two flywheel assembly mounting bolts. Special tool : 09420–1742 Oil seal puller •...
Page 111 9–21 ENGINE MECHANICAL Remove contamination from the joint surface of the rear oil seal and the flywheel housing Apply small amount of engine oil to the seal area of the rear oil seal. Install the oil seal press guide inserting a new rear oil seal with accompanying guide bolts on the crankshaft.
Page 112: Main Moving Parts
9–22 ENGINE MECHANICAL Main Moving Parts Part layout JP31199090402004 SAPH311990900059 11011 Thrust bearing 13260 Connecting rod assembly 11701 Main bearing 13271 Connecting rod bush 11703 Main bearing US 0.25 13411 Crankshaft 11704 Main bearing US 0.50 13450 Flywheel assembly 13005 Piston, Piston ring set 13453 Ring gear...
Page 113: Replacement Of Piston And Connecting Rod
9–23 ENGINE MECHANICAL Replacement of piston and connecting rod JP31199090702005 Removal of piston Figure is an Remove bolts and remove the connecting rod cap. example of work. • Insert a large flat tip screwdriver into the ! CAUTION flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft.
Page 114 9–24 ENGINE MECHANICAL Disassembly of piston and connecting rod Remove the retainer ring using snap ring pliers. Remove the piston pin using the brass bar and disconnect the piston from the connecting rod. SAPH311990900064 Remove the piston ring using a special tool. Special tool : 09442–1011 Piston ring expander •...
Page 115 9–25 ENGINE MECHANICAL Face the side with the piston ring identification print upward and install in the order of the oil ring, second ring and top ring using a special tool. • The identification print is present only on the NOTICE secondary ring and the top and bottom of the top ring and the oil ring are not identified.
Page 116 9–26 ENGINE MECHANICAL Insert the piston carefully so that the connecting rod may not come in contact with the cooling jet. • Face the "0" mark on the piston toward the ! CAUTION exhaust side for insertion. • Set the crankshaft of the cylinder as the top dead center for assembly.
Page 117: Inspection Of Piston And Connecting Rod
9–27 ENGINE MECHANICAL Tighten the connecting rod bolt and mark the bolt head in the same direction with paint. Paint mark Tightening torque : 69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft} Connecting rod cap (10) Retighten the connecting rod bolt 90 °. (11) Retighten the connecting rod bolt further 45 °.
Page 118 9–28 ENGINE MECHANICAL Measure the piston ring groove using a thickness gauge. If it is out of the service limit, replace the piston. Standard value Service limit (mm{in.}) (mm{in.}) Top ring groove 2.5{0.0984} 2.70{0.1063} Second ring groove 2{0.0787} 2.20{0.0866} Oil ring groove 4{0.1575} 4.10{0.1614} SAPH311990900078...
Page 119: Replacement Of Connecting Rod Bushing
9–29 ENGINE MECHANICAL Replacement of connecting rod bushing JP31199090704006 Removal of connecting rod bushing Press Put the special tool press sub-assembly together with the Sub-assembly Wing nut special tool guide nut and fix them using the special tool wing nut. Guide Special tool : 09481–1130 Guide 09402–1530 Press sub-assembly...
Page 120 9–30 ENGINE MECHANICAL Chamfer one side of the connecting rod small end uniformly according to the figure. Chamfer • Remove burr completely. ! CAUTION • After chamfering, remove dirt from the inner surface at the small end and from the oil hole. SAPH311990900086 Installation of connecting rod bushing Install a new bushing on the special tool spindle and...
Page 121: Replacement Of Crankshaft
9–31 ENGINE MECHANICAL Replacement of crankshaft JP31199090704007 Removal of crankshaft Remove the main bearing cap and the main shaft bearing. Remove the crankshaft using a hoist. • Since the part is heavy, be careful for ! CAUTION handling. • Store removed main bearing caps and main bearings for each cylinder number.
Page 122 9–32 ENGINE MECHANICAL Measure the underhead length of the bearing cap bolt using a vernier calipers. If it is out of the service limit, replace it with a new one. Service limit (mm{in.}) 108{4.252} Underhead length SAPH311990900073 Apply engine oil to the bolt seat and the bolt thread of the bearing cap bolt.
Page 123: Inspection Of Crankshaft
9–33 ENGINE MECHANICAL Inspection of crankshaft JP31199090703002 Inspection of end play Measure the end play of the crankshaft using a dial gauge. If it is beyond the repair limit, replace the thrust bearing. If it is beyond the service limit, replace the crankshaft.
Page 124 9–34 ENGINE MECHANICAL Measure the crankshaft center journal width using a vernier calipers. If it is out of the service limit, replace the Figure is an example of work. crankshaft. Standard value (mm{in.}) Service limit (mm{in.}) 36{1.4173} 37.0{1.4567} SAPH311990900098 Inspection of crankshaft oil clearance Measure the outer diameter of the crankshaft journal using a micrometer.
Page 125 9–35 ENGINE MECHANICAL Dimension of fillet "R" Crank pin Radius is 2.5 to 3.0mm {0.0984 to 0.1181 in.} Radius is incomplete. Step Step small. Journal 2.5 to 3.0mm {0.0984 to 0.1181 in.} Good Poor SAPH311990900101 Inspection of crack and damage on crankshaft and of oil Figure is an hole example of work.
Page 126: Replacement Of Crankshaft Pulley
9–36 ENGINE MECHANICAL Replacement procedure item Replacement of crankshaft pulley JP31199090704008 Removal of crankshaft pulley Remove bolts and remove the crankshaft pulley. • Insert a large flat tip screwdriver into the NOTICE flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft.
Page 127 9–37 ENGINE MECHANICAL Removal of ring gear Heat the entire ring gear circumference with a burner until it is about 200 °C(392°F). • Do not touch the ring gear and the flywheel ! CAUTION with bare hand while they are hot. SAPH311990900109 Hit the circumference of the ring gear gently using a backing rod to remove the ring gear from the flywheel.
Page 128 9–38 ENGINE MECHANICAL Installation of flywheel Make sure that there is no burr or dirt on the joint surface of the crankshaft and the flywheel and the screw hole. Install the special tool into the bolt hole of the crankshaft. Special tool : 09481–1340 Guide •...
Page 129: Camshaft And Idle Gear
9–39 ENGINE MECHANICAL Camshaft and Idle Gear Part layout JP31199090402005 SAPH311990900117 13501 Camshaft assembly 13572B Idle gear thrust plate 13505 Cam idle gear 13581 Idle gear shaft 13505A Sub-idle gear 13581A Idle gear shaft 13505B Main idle gear 13581B Idle gear shaft 13520 Camshaft gear 9867A...
Page 130: Removal Of Camshaft
9–40 ENGINE MECHANICAL Removal of camshaft JP31199090702006 Removal of rocker arm and camshaft assembly Loosen the lock nut and turn the adjusting screw completely. Rock nut • Removal without turning the adjusting screw ! CAUTION may bend the rocker shaft. SAPH311990900118 Loosen the rocker arm support bolts gradually from the center and remove the rocker arm and the rocker arm...
Page 131: Inspection Of Camshaft And Camshaft Bearing
9–41 ENGINE MECHANICAL Inspection of camshaft and camshaft bearing JP31199090702008 Inspection of cam height on camshaft Measure the cam height using a micrometer. If it is beyond the service limit, replace the camshaft. Standard value Service limit (mm{in.}) (mm{in.}) 50.067{1.9711} 49.987{1.9680} height 52.104{2.0513}...
Page 132: Assembly Of Camshaft
9–42 ENGINE MECHANICAL Assembly of camshaft JP31199090702009 Measure the camshaft mounting bolt using a vernier calipers. If it is out of the service limit, replace it with a new one. Service limit (mm{in.}) 31{1.2205} Underhead length SAPH311990900124 Fix the camshaft gear using a vice. Apply engine oil to the seat and the bolt thread of the camshaft gear mounting bolt.
Page 133: Installation Of Camshaft
9–43 ENGINE MECHANICAL Installation of camshaft JP31199090702010 Align the No. 1 cylinder to the compression top dead center. Installation of camshaft and rocker arm. Place the camshaft so that two holes at 180 degrees from Timing decision the three drilled holes of the camshaft gear may be drill hole horizontal to the upper surface of the camshaft housing.
Page 134 9–44 ENGINE MECHANICAL Apply engine oil to the cam threads and set the rocker arm in position, making sure it is correctly laid on the crosshead. Then, tighten the bolts in the sequence shown in the figure, making several passes and gradually tightening them each time.
Page 135: Gear Train Layout
9–45 ENGINE MECHANICAL Gear train layout JP31199090402006 SAPH311990900130 Service procedure Overhaul item Removal of timing gear JP31199090702011 Removal of main idle gear Remove the idle gear shaft mounting bolt and pull out the main idle gear assembly using a special tool. Special tool : 09420–1100 Sliding hammer 09420–1442 Sliding hammer Remove the idle gear thrust plate.
Page 136: Inspection Of Timing Gear Components
9–46 ENGINE MECHANICAL Removal of sub-idle gear Remove the idle gear shaft mounting bolt and the idle gear thrust plate and pull out the sub-idle gear assembly using a special tool. Special tool : 09420–1100 Sliding hammer 09420–1442 Sliding hammer Remove the idle gear thrust plate.
Page 137: Installation Of Timing Gear
9–47 ENGINE MECHANICAL Installation of timing gear JP31199090702013 Installation of sub-idle gear Install the idle gear shaft on the sub-idle gear. Thrust plate Install the idle gear thrust plate. Provide the lubricating hole of the idle gear shaft in the vertical direction.
Page 138 9–48 ENGINE MECHANICAL Face the lubricating hole of the idle gear shaft toward the oil pan (downward). Install A in the figure by adjusting the timing of the crankshaft gear and the main idle gear as in Sub-idle gear the detailed drawing. Oil pump gear Main idle gear...
Page 139: Overhaul Of Sub-Idle Gear (Bearing Case Side)
9–49 ENGINE MECHANICAL Overhaul of sub-idle gear (bearing case side) JP31199090702014 Removal of bearing case assembly Remove the supply pump. "Reference : Replacement, Supply pump". Disconnect the bearing case assembly. • One bolt is tightened from the timing gear ! CAUTION case.
Page 140 9–50 ENGINE MECHANICAL Inspection of clearance between sub-idle gear shaft and sub-idle gear bushing Measure the outer diameter of the idle gear shaft. SAPH311990900142 Measure the inner diameter of the sub-idle gear. Calculate the clearance. If it is beyond the standard value, replace the shaft and the bushing.
Page 141: Inspection Of Installation Status For Each Gear
9–51 ENGINE MECHANICAL Inspection of installation status for each gear JP31199090703003 Inspection of backlash between camshaft gear and cam idle gear Insert a large flat tip screwdriver into the cam idle gear from the side of the camshaft gear of the camshaft housing to prevent turning of the cam idle gear.
Page 142 9–52 ENGINE MECHANICAL Measure backlash between the main idle gear and the air compressor idle gear using a dial gauge and a magnet stand. If it is beyond the service limit, replace each gear. • If the magnet stand is not stable, provide a NOTICE steel plate for measurement using bolt holes of the cylinder block.
Page 143 9–53 ENGINE MECHANICAL Inspection of backlash between sub-idle gear at cam idle gear and oil pump gear Insert a large flat tip screwdriver into the sub-idle gear to prevent turning of the sub-idle gear. SAPH311990900154 Measure backlash between the sub-idle gear and the oil pump gear using a dial gauge and a magnet stand.
Page 144 9–54 ENGINE MECHANICAL Measure backlash between the cam idle gear and the sub-idle gear using a dial gauge. If it is beyond the service limit, replace each gear. Standard value (mm{in.}) Service limit (mm{in.}) 0.050 - 0.218 0.30{0.0118} {0.0020 - 0.0086} Setup layout Layout SAPH311990900158...
Page 145: Valve System
9–55 ENGINE MECHANICAL Valve System Part layout JP31199090402007 SAPH311990900159 13706 Crosshead assembly 13735 Valve spring upper seat 13709 Adjusting screw (rocker arm) 13787 Adjusting screw (cross head) 13711 Intake valve 13830 Rocker arm intake 13715 Exhaust valve 13840 Rocker arm (exhaust) 13719 Valve stem seal* 13901...
Page 146: Overhaul Of Valve System
9–56 ENGINE MECHANICAL Overhaul of valve system JP31199090702015 Inspection of rocker arm oil clearance Measure the outer diameter of the rocker shaft using a micrometer. Standard value (mm{in.}) Service limit (mm{in.}) 22{0.8661} 21.92{0.8630} Measure the rocker arm bushing inner diameter using a cylinder gauge.
Page 147 9–57 ENGINE MECHANICAL Replacement of valve stem seal Valve stem seal Special tool After removing the valve stem seal, assemble the valve spring lower seat. Apply engine oil to the lip and the inner Valve spring lower seat surface of the valve stem seal. Strike the valve guide using a special tool until the special tool comes in contact with the valve spring lower sea Special tool : 09472–2100 Bar...
Page 148 9–58 ENGINE MECHANICAL Inspection of valve spring Clearance A Measure squareness of the valve spring using a square or a thickness gauge. If it is beyond the service limit (clearance A), replace the valve spring. Clearance A (mm{in.}) 2.0{0.0787} SAPH311990900166 Measure the free length of the valve spring using a vernier calipers.
Page 149: Adjustment Of Valve Clearance
9–59 ENGINE MECHANICAL Attachment procedure item Adjustment of valve clearance JP31199090706001 Precautions before adjustment • Before adjustment, make sure that bolts of ! CAUTION the cylinder head, rocker arm support, nozzle clamp, camshaft housing and camshaft bearing cap are tightened to the specified torque.
Page 150 9–60 ENGINE MECHANICAL Tighten the adjusting screw of the crosshead until the thickness gauge does not move. Close contact Close contact SAPH311990900173 While loosening the adjusting screw of the crosshead gradually, tighten the lock nut of the crosshead at the Start position where feel on the thickness gauge is appropriate.
Page 151 10–1 EXHAUST ENGINE 10 EXHAUST Setup layout Layout Exhaust Manifold............10-2 Part layout ............. 10-2 Replacement............10-4...
Page 152 10–2 EXHAUST Exhaust Manifold Part layout JP31199100402001 SAPH311991000001 17104 Gasket* 17141 Exhaust manifold *Parts not to be reused. Tightening torque 9209A 53 N⋅m {540 kgf⋅cm, 40lbf⋅ft}...
Page 153 10–3 EXHAUST SAPH311991000002 17104A Gasket* 17148 Plate *Parts not to be reused. Service procedure Replacement procedure item...
Page 154 10–4 EXHAUST Replacement JP31199100704001 Removal of exhaust manifold Remove nuts and remove the exhaust manifold. Replacement of stud bolt Remove dirt (e.g. sealant) at the female thread of the cylinder head and clean the thread again with tap (M10 x 1.5).
Page 155 11–1 COOLING ENGINE 11 COOLING System drawing System drawing Cooling System ............11-2 Cooling system drawing........11-2 Part layout ............. 11-3 Replacement of thermostat case ......11-4 Inspection of thermostat ........11-5 Replacement of coolant pump ......11-6...
Page 156: Cooling System
11–2 COOLING Cooling System Cooling system drawing JP31199110803001 Reservoir Water temperature Thermostat case Cylinder head Thermostat Cylinder block Turbo charger heater Oil cooler Coolant pump Drain cock Drain cock SAPH311991100001 Setup layout Layout...
Page 157: Part Layout
11–3 COOLING Part layout JP31199110402002 SAPH311991100002 16100 Coolant pump assembly 16325 Gasket* 16173 Coolant pump pulley 16331 Thermostat case cover 16303 Thermostat case 16377 Fan spacer 16306 Cooling fan 9851A O–ring* 16323 Thermostat case cover *Parts not to be reused. Service procedure Replacement procedure item...
Page 158: Replacement Of Thermostat Case
11–4 COOLING Replacement of thermostat case JP31199110704001 Removal of thermostat case Remove bolts and remove the thermostat case. Remove the O-ring from the groove on the coolant pump. SAPH311991100003 Installation of thermostat case Remove contamination on the joint between the Liquid gasket thermostat case and the cylinder head using a scraper.
Page 159: Inspection Of Thermostat
11–5 COOLING Inspection of thermostat JP31199110703001 Individual inspection of thermostat Wire Thermometer Put the thermostat in water as shown in the figure and heat it. • Support the thermostat in the center to ! CAUTION prevent approach to the heat source. •...
Page 160: Replacement Of Coolant Pump
11–6 COOLING Replacement of coolant pump JP31199110704002 Removal of coolant pump Remove bolts and remove the coolant pump. SAPH311991100009 Installation of coolant pump Liquid gasket Remove contamination on the joint surface between the coolant pump and the cylinder block using a scraper and degrease the surface.
Page 161 12–1 LUBRICATION ENGINE 12 LUBRICATION System drawing System drawing Oil Cooler, Oil Filter and Oil Pump......12-2 System drawing ............ 12-2 Part layout ............. 12-3 Replacement of oil cooler ........12-5 Overhaul of oil cooler ..........12-6 Replacement of oil pump ........12-9 Overhaul of oil pump...........
Page 162: Oil Cooler, Oil Filter And Oil Pump
12–2 LUBRICATION Oil Cooler, Oil Filter and Oil Pump System drawing JP31199120805001 Roller pin Roller Rocker Adjusting Valve Crosshead Rocker arm screw shaft Camshaft Cam idle gear shaft Sub-idle gear shaft Turbocharger Main Oil pump Oil filter Oil cooler oil hole Connecting Piston pin Crankshaft...
Page 163: Part Layout
12–3 LUBRICATION Part layout JP31199120402001 SAPH311991200002 15012 Oil pump cover assembly 15710 Oil cooler 15104 Oil strainer 9500-40400 Cotter pin* 15107 Driven gear 9851A O–ring* 15110 Oil pump assembly 9851B D–ring* 15119 Gasket* 15139 Seat2 15132 Relief valve spring 15139A Seat1 15135 Safety valve...
Page 164 12–4 LUBRICATION SAPH311991200003 15662 Drain plug 9644A O–ring* 15675 Safety valve 9739A Elbow 15701 Oil cooler case 9851A O–ring* 15710 Oil cooler assembly 9851B O–ring* 15712 Oil cooler element 9851C O–ring* 15717 Gasket* 9851D O–ring* 15720 Oil cooler case assembly 9851E O–ring* *Parts not to be reused.
Page 165: Replacement Of Oil Cooler
12–5 LUBRICATION Replacement of oil cooler JP31199120704001 Removal of oil cooler Remove bolts and hose joint, and remove the oil cooler. SAPH311991200004 If it is difficult to remove the oil cooler due to liquid gasket Figure is an sticking to the cylinder block, put a flat tip screwdriver at example of work.
Page 166: Overhaul Of Oil Cooler
12–6 LUBRICATION Insert the positioning stud into the screw hole of the cylinder block and install the oil cooler. After temporary tightening with bolts, remove the positioning stud and tighten bolts. Tightening torque : 24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} •...
Page 167 12–7 LUBRICATION Remove the oil pressure warning switch. SAPH311991200012 Inspection of safety valve wear and damage If wear or damage is found, replace it. SAPH311991200013 Inspection of oil pressure warning switch For inspection of oil pressure warning switch, refer to "Inspection of components"- "Electrical".
Page 168 12–8 LUBRICATION Installation of oil cooler element Assemble new gasket and new O-ring and assemble the oil cooler element with nuts. Tightening torque : 24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} • In handling the oil cooler element, be careful ! CAUTION not to give damage to it.
Page 169: Replacement Of Oil Pump
12–9 LUBRICATION Replacement of oil pump JP31199120704002 Removal of oil pump Dismount the engine from the machine. Remove the flywheel. Remove the flywheel housing. Remove the timing gear. Remove the oil pump. Installation of oil pump Apply engine oil to the pump case and the bearing (shaded area) of the cylinder block.
Page 170: Overhaul Of Oil Pump
12–10 LUBRICATION Overhaul of oil pump JP31199120702002 Remove the driven gear. SAPH311991200016 Remove the cotter pin and remove seat 2, seat 1, relief valve spring and safety valve. • When the cotter pin is removed, seat 2 and ! CAUTION the relief valve spring may eject out.
Page 171 12–11 LUBRICATION End play inspection between drive gear and cylinder block Measure the drive gear width and the pump chamber depth at the cylinder block using a depth gauge. Standard value Measuring area (mm{in.}) Width of drive gear 28.5{1.1220} Depth of pump chamber at 28.5{1.1220} cylinder block SAPH311991200020...
Page 172 12–12 LUBRICATION Inspection of clearance betweeen outer diameter of driven gear shaft and inner diameter of driven gear bushing Measure the outer diameter of the driven gear shaft using a micrometer and measure the inner diameter of the driven gear bushing using a cylinder gauge. Standard value Measuring area (mm{in.})
Page 173: Replacement Of Oil Strainer
12–13 LUBRICATION Inspection of drive gear backlash Fix the oil pump assembly with a vice. Measure backlash between the drive gear and the driven gear using a dial gauge. If it is beyond the service limit, replace the oil pump assembly. Standard value (mm{in.}) Service limit (mm{in.}) 0.072 - 0.277...
Page 174: Oil Pan
12–14 LUBRICATION Oil Pan Part layout JP31199120402003 SAPH311991200029 12111 Oil pan assembly 12149 Drain plug 12151 Oil pan gasket* 9659A Gasket* *Parts not to be reused. Tightening torque 12149 30 N⋅m {300 kgf⋅cm, 22lbf⋅ft} 9068-08800 30 N⋅m {300 kgf⋅cm, 22lbf⋅ft} Service procedure Replacement procedure item...
Page 175: Replacement
12–15 LUBRICATION Replacement JP31199120704004 Installation of oil pan Cut the gasket of the rear end plate to be flush to the cylinder block lower surface using a scraper. Make sure that there is no deformation, dirt or oil on the joint surface between the cylinder block and the oil pan.
Page 176: Inspection Of Lubrication Status
12–16 LUBRICATION Inspection of lubrication status JP31199120703001 Inspection of valve system • Perform inspection with the water ! CAUTION temperature at 60 °C{140°F}. Remove the head cover. • To prevent spread of engine oil, attach a jig ! CAUTION which cuts a head cover in half. Cut it to the degree that the camshaft is covered.
Page 177 13–1 STARTING AND CHARGING ENGINE 13 STARTING AND CHARGING Setup layout Layout Starter ................ 13-2 Part layout (typical example)......... 13-2 Disassembly............13-3 Inspection of components ........13-9 Assembly ............13-14 Alternator (50A) ............13-21 Part layout (typical example of 50A) ....13-21 Circuit drawing (50A) ..........
Page 178: Starter
13–2 STARTING AND CHARGING Starter Part layout (typical example) JP31199130402001 SAPH311991300001 28011 Clutch assembly 28138 Packing* 28100 Starter 28140 Brush holder assembly 28111 Bushing 28142 Brush 28111A Bushing 28142A Brush 28113 Lever assembly 28143 Spring 28115 Start drive housing 28150 Center bracket 28117 Packing*...
Page 179: Disassembly
13–3 STARTING AND CHARGING Disassembly JP31199130702001 • Fix the starter on the working table to ease NOTICE M lead wire accessibility. M terminal MRemoval of lead wire Remove the cap of the M terminal. Remove nuts and remove the M lead wire. SAPH311991300002 Removal of commutator end frame Loosen and remove two through bolts.
Page 180 13–4 STARTING AND CHARGING Removal of brush holder assembly Brush holder Lift the spring using a flat tip screwdriver or pliers. Assembly Remove four brushes from the brush holder assembly. • Do not cut the brush lead fixing clamp. ! CAUTION Remove the brush holder assembly from the armature assembly.
Page 181 13–5 STARTING AND CHARGING Removal of armature assembly Remove the armature assembly by lifting. Armature • When the armature assembly is removed, the assembly ! CAUTION washer at the end of the gear may be dropped and lost. Be careful for handling. Center bracket assembly SAPH311991300008...
Page 182 13–6 STARTING AND CHARGING 10. Removal of internal gear Remove the internal gear from the center bracket. • Make sure that the gear is not damaged or ! CAUTION chipped. Internal gear Center bracket SAPH311991300012 11. Removal of shim washer Remove the shim washer from the center bracket.
Page 183 13–7 STARTING AND CHARGING 13. Removal of center bracket Center bracket Remove two set bolts at the switch using a box screwdriver or offset wrench. Lift and remove the center bracket. Clutch assembly SAPH311991300016 14. Removal of lever Hold the lever holder and press the entire lever to the clutch.
Page 184 13–8 STARTING AND CHARGING 15. Removal of brake plate Hold the clutch case outer diameter and slide the clutch assembly upward. Pinch the clip end fixing the brake plate and remove it by bending. SAPH311991300019 Remove the brake plate. Brake plate SAPH311991300020 16.
Page 185: Inspection Of Components
13–9 STARTING AND CHARGING 18. Removal of packing Turn the center bracket upside down again and remove the packing. • Packing must not be reused. ! CAUTION Packing SAPH311991300023 Inspection procedure item Inspection of components JP31199130703001 Inspection of yoke assembly Make sure that the coil lead wire has electric continuity using a circuit tester.
Page 186 13–10 STARTING AND CHARGING Inspection of armature assembly Turn the armature assembly using a commercially Piece of steel available growler tester and put a piece of steel on the armature assembly. Make sure that the steel piece is not vibrating on the core circumference. Growler tester SAPH311991300027 Make sure that adjacent segments of the commutator...
Page 187 13–11 STARTING AND CHARGING Measure the undercut depth between segments. If the undercut depth is beyond the service limit, repair it. Standard value (mm{in.}) Service limit (mm{in.}) Undercut length: 0.5 - 0.8{0.0197 - 0.0315} 0.2{0.0079} or less 0.5 to 0.8 mm Segment {0.0197 - 0.0315} •...
Page 188 13–12 STARTING AND CHARGING Inspection of shaft assembly Measure the outer diameter of the shaft using a micrometer If it is beyond the service limit, replace the shaft. Standard value Service limit Measuring area (mm{in.}) (mm{in.}) 25.90{1.0197} or Area 26{1.0236} less SAPH311991300035 12.04{0.4740} or...
Page 189 13–13 STARTING AND CHARGING Measure the bearing metal inner diameter (3 in the figure) of the shaft assembly using a cylinder gauge. If it is beyond the service limit, replace the shaft assembly. Standard value (mm{in.}) Service limit (mm{in.}) 9{0.3543} 9.2{3.6220} Measure the bearing housing inner diameter (4 in the figure) of the commutator end frame using a cylinder...
Page 190: Assembly
13–14 STARTING AND CHARGING Push the end of the start magnet switch assembly (close the internal contact) and make sure that there is electric continuity between the B terminal and the M terminal using a circuit tester. SAPH311991300043 Overhaul item Assembly JP31199130702002 Installation of packing...
Page 191 13–15 STARTING AND CHARGING Installation of brake plate Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the brake plate. Brake plate SAPH311991300045 Installation of lever Lubricate parts (refer to the lubrication point drawing and the lubrication list).
Page 192 13–16 STARTING AND CHARGING Install the retainer clip using a tool such as snap ring pliers. Retainer clip Pinion stopper Pinion SAPH311991300014 Installation of shim washer Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the shim washer on the center bracket.
Page 193 13–17 STARTING AND CHARGING 11. Installation of cover Install a new packing. Packing Cover Install the cover on the center bracket assembly. SAPH311991300010 12. Installation of rear bearing Install the bearing on the armature assembly using a press. • When the bearing is removed, replace it with ! CAUTION a new one.
Page 194 13–18 STARTING AND CHARGING 16. Installation of brush holder assembly Brush holder Lift the spring using a flat tip screwdriver, long-nose pliers Assembly or pliers. Install four brushes on the brush holder assembly. Spring Brush Brush lead Clamp SAPH311991300005 17. Installation of commutator end frame Tighten the through bolt of the commutator end frame.
Page 195 13–19 STARTING AND CHARGING 18. Installation of lead wire M lead wire Install the M lead wire. M terminal SAPH311991300002 19. Lubrication Refer to the following figure and table for lubricant to be applied. • There shall be no lubricant on the commutator surface, brush and contact. ! CAUTION SAPH311991300046...
Page 196 13–20 STARTING AND CHARGING Table of lubricant Amount Lubricant Code Lubricating point Lubricant used Remark (g{oz}) manufacturer Pinion case metal 0.8 - 1.5 Multemp AC-N Kyodo Yushi and grease reservoir {0.03 - 0.05} Bracket center metal 0.5 - 1.5 Multemp AC-N Kyodo Yushi and grease reservoir {0.03 - 0.05}...
Page 197: Alternator (50A)
13–21 STARTING AND CHARGING Alternator (50A) Part layout (typical example of 50A) JP31199130402002 SAPH311991300047 27017 Feed coil 27383A Insulator 27040 Alternator 27389 Insulator 27310 Drive end frame assembly 27392 Cover 27311 Drive end frame 27410 Stator coil 27312 Bearing cover 27412 Collar 27330...
Page 198: Circuit Drawing (50A)
13–22 STARTING AND CHARGING Circuit drawing (50A) JP31199130803001 Capacitor Diode Fuse Load Lamp 1.4 to 3W Starter switch Feed coil Regulator Battery 24V Stator coil Alternator SAPH311991300048 Service procedure Overhaul item...
Page 199: Disassembly
13–23 STARTING AND CHARGING Disassembly JP31199130702003 • Place a rubber mat and perform work on the ! CAUTION mat. Disconnection of front from rear Remove fixing bolts and remove the cover. • Press the tabs of the cover for removal. Be ! CAUTION careful not to break the tab with excessive force.
Page 200 13–24 STARTING AND CHARGING Remove the rotor assembly using a press. • Do not damage the end of the thread. ! CAUTION • Support the rotor assembly to prevent fall of the rotor assembly. SAPH311991300053 Remove three bolts with a screwdriver and remove the bearing cover.
Page 201 13–25 STARTING AND CHARGING Remove the stator coil from the rear bracket. • Do not damage the stator coil. ! CAUTION SAPH311991300057 Remove solder of the lead wire connecting the regulator and the field coil using a soldering bit. • Remove the lead wire of the field coil by ! CAUTION raising the terminal of the regulator.
Page 202: Inspection Of Components
13–26 STARTING AND CHARGING Remove five bolts using a screwdriver and remove the heat sink assembly (plus), heat sink assembly (minus) and regulator all together. • Screw lock is used. Since torque is high until ! CAUTION bolt is removed, be careful not to damage the groove of the bolt head.
Page 203 13–27 STARTING AND CHARGING Measure the resistance between the stator coil core and each terminal using a megger tester. Standard value (MΩ) 1 or more SAPH311991300065 Measure the resistance of the field coil using a circuit tester. Standard value (Ω) 6.4 - 7.0 •...
Page 204 13–28 STARTING AND CHARGING Measure the outer diameter of the shaft at the roller bearing insertion area of the rotor assembly using a micrometer. Standard value (mm{in.}) 17{0.6693} Service limit (mm{in.}) 16.98{0.6685} SAPH311991300069 Inspection of diode, capacitor and regulator Measure the resistance of the holder between the minus diode and the heat sink holder using a circuit tester.
Page 205: Assembly
13–29 STARTING AND CHARGING Assembly JP31199130702004 • Place a rubber mat and perform work on the ! CAUTION mat. Jig C Assembly of front Press fit a new ball bearing into the front bracket using a press and jig C. •...
Page 206 13–30 STARTING AND CHARGING Assembly of rear Press fit a new roller bearing into the rear bracket using a Jig A press, jig A and jig B. • Press fit until jig A comes in contact with the ! CAUTION Roller bearing rear bracket.
Page 207 13–31 STARTING AND CHARGING Solder the lead wire connecting the regulator and the field coil, and connecting the stator coil and the diode using a soldering bit. • Perform soldering after tightening of bolts. ! CAUTION • Bend and fix the regulator terminal before soldering the lead wire of the field coil.
Page 208 13–32 STARTING AND CHARGING Install the coupler holder and tighten bolts. Tightening torque : 1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1 - 2 lbf⋅ft} SAPH311991300085 Align the tab and install the cover. Fix it with bolts. Tightening torque : 3.3 - 4.4 N⋅m {34 - 44 kgf⋅cm, 2 - 3 lbf⋅ft} •...
Page 209: Inspection After Assembly
13–33 STARTING AND CHARGING Inspection after assembly JP31199130703003 • Place a rubber mat and perform work on the ! CAUTION mat. Inspection of rotation Turn the pulley with hand to check if there is no interference with internal parts and if rotation is smooth. SAPH311991300087 Measure the resistance between B and E terminals and between P and E terminals using a circuit tester.
Page 211 14–1 TURBOCHARGER ENGINE 14 TURBOCHARGER Setup layout Layout Turbocharger Assembly........... 14-2 Part layout ............14-2 Inspection ............. 14-3 Replacement............14-6...
Page 212: Turbocharger Assembly
14–2 TURBOCHARGER Turbocharger Assembly Part layout JP31199140402001 SAPH311991400001 15407 Oil inlet pipe 24109 Gasket* 16691 Coolant pipe 24109A Gasket* 16691A Coolant pipe 24135 Gasket* 17291 Exhaust manifold connector 24135A Gasket* 24100 Turbocharger assembly 9654-12100 Gasket* 24107 Oil outlet pipe 9659A Gasket* *Parts not to be reused.
Page 213: Inspection
14–3 TURBOCHARGER Inspection JP31199140501001 Inspection of turbine shaft axial play Inspect play of the turbine shaft at the exhaust side using a special tool. Special tool : 09444-1800 Tool assembly If the measurement value is beyond the standard value, ask the manufacturer to overhaul the unit. Axial direction 0.1 {0.0039} Standard value...
Page 214 14–4 TURBOCHARGER When the guide (key No. 9) is fixed, move the bar (key No. 4) vertically and fix the guide (key No. 9) with the stopper (key No. 10) so that the needle of the dial gauge may come at the center. SAPH311991400006 Hold the puller (key No.
Page 215 14–5 TURBOCHARGER Special Tool Details Key No. Part name Key No. Part name Assembly Tool assembly Stopper Gauge (dial gauge) Bolt Guide Sleeve Stopper Bolt Bolt Puller Bolt Sleeve Hook Plate Snap ring (cotter pin) Plate Bar (spring) Guide Bolt SAPH311991400009 Service procedure Replacement procedure item...
Page 216: Replacement
14–6 TURBOCHARGER Replacement JP31199140704001 Removal Remove the boost pipe and U-turn pipe. Disconnect all pipes connected to the turbocharger. • Loosen union bolt of the coolant pipe, drain ! CAUTION coolant and remove the pipe. Disconnect the lower pipe similarly and remove the oil pipe. •...
Page 217 14–7 TURBOCHARGER Air intake system Make sure that there is no dirt or foreign matter in the air intake system. Do not use sealant at the inlet/outlet of air to prevent failures such as damage due to clogging or loosening of tightened areas.
Page 219 16–1 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS ENGINE 16 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Failure diagnosis Failure diagnosis list FAILURE DIAGNOSIS FOR EACH ENGINE STATUS ..................16-2 Engine mechanical ..........16-2 Alternator .............. 16-5 Starter ..............16-6 Turbocharger............16-7...
Page 220: Failure Diagnosis For Each Engine Status
16–2 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Engine mechanical JP31199160601001 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 Replace head gasket Engine overheat...
Page 221 16–3 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status Cause Action Piston seizure Abnormal combustion Refer to overheat section. Piston seizure Cooling unit Refer to overheat section. Insufficient engine power (air Clogging of air cleaner element Clean or replace air cleaner cleaner) element Insufficient engine power...
Page 222 16–4 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status Cause Action Faulty idling (nozzle) Faulty injection pressure Injection pressure inspection Faulty spray status Adjust or replace nozzle Carbon deposit at nozzle end Remove carbon Seizure of needle valve Replace nozzle Faulty idling (engine) Faulty valve clearance Adjustment of valve clearance Faulty contact of valve seat...
Page 223: Alternator
16–5 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Alternator JP31199160601002 Status Cause Action Lamp is ON.→Charge current Faulty regulator (open PTr) Replace regulator. does not run (alternator). Faulty stator coil (disconnection, Replace stator coil. rare shorting) Fault feed coil (disconnection, rare Replace feed coil.
Page 224: Starter
16–6 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Starter JP31199160601003 Status Cause Action Starter does not turn. Turning is Faulty connection of starter key Repair connecting area. low. Flat battery Charge or replace. Disconnection, loosening or After cleaning, tighten. corrosion of battery terminal Grounding wire is disconnected.
Page 225: Turbocharger
16–7 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Turbocharger JP31199160601004 Status Cause Action Exhaust smoke is black Clogging of air cleaner element Clean or replace air cleaner (insufficient intake air). element. Air intake inlet is closed. Recover normal status. Leak from connection of air intake Check and repair.
Page 226 16–8 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status Cause Action Exhaust smoke is white. Engine oil runs out to the blower or Repair or replace pipe. the turbine due to clogging or deformation of the oil return pipe. Negative pressure at the back of Check and replace the pipe.
Page 227 16–9 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status Cause Action Vibration Loosening between turbocharger Check the turbocharger mounting and intake/exhaust pipe and status and repair faulty areas. between oil pipe and mounting area Failure of metal, contact between Replace turbocharger. Remove revolving part and peripheral parts, foreign matter completely, if any.
Page 229 17–1 ENGINE DIAGNOSIS CODE ENGINE 17 ENGINE DIAGNOSIS CODE General General information Engine ECU ............... 17-2 Injector common 1 ground short Precautions ............17-2 (DTC code P1211), System block diagram........... 17-3 Injector common 2 ground short Inspection ............. 17-4 (DTC code P1214) ..........17-34 Table of failure code ..........
Page 230: Engine Diagnosis Code
17–2 ENGINE DIAGNOSIS CODE Engine ECU Precautions JP31199170102001 • Make sure that each connector is connected ! CAUTION before inspection. • Do not place a tester rod on the connecting surface of the connector. Otherwise, terminals are damaged or short-circuited. •...
Page 231: System Block Diagram
17–3 ENGINE DIAGNOSIS CODE System block diagram JP31199170803001 ACT Relay Fuse Each Sensor Power Main relay Fuse Key switch signal Starter signal Battery Accelerator signal 1,2 Diagnosis tool Diagnosis switch Accelerator sensor for operation Engine speed main sensor Engine speed sub sensor PC Diagnosis tool Glow relay Injector drive signal...
Page 232: Inspection
PC which installed HinoDX through the interface box. Engine ECU Failure diagnosis connector SAPH311991700003 Special tool : 09121-1040 Hino-Bowie (Interface Failure diagnosis connector box) 09042-1220 Connecting cable CD-ROM HinoDX Hino-Bowie Connecting cable Connect to the failure diagnosis connector at the unit side.
Page 233: Table Of Failure Code
17–5 ENGINE DIAGNOSIS CODE Table of failure code JP31199170601001 • For the system status by indication of DTC code in the table, refer to "1. Pre-inspection, NOTICE Inspection, Engine ECU". "Reference : Inspection, Engine ECU, Engine diagnosis code" [a] Failure diagnosis and DTC code Estimated failure cause Page...
Page 234 17–6 ENGINE DIAGNOSIS CODE [a] Failure diagnosis and DTC code Estimated failure cause Page [b] Alarm display (alarm status) P0203 Injector circuit malfunction -cylinder 3 17-38 a. Low output P0204 Injector circuit malfunction -cylinder 4 17-38 b. DTC code indication. P0237 Boost pressure sensor circuit low input 17-19...
Page 235 17–7 ENGINE DIAGNOSIS CODE [a] Failure diagnosis and DTC code Estimated failure cause Page [b] Alarm display (alarm status) P0219 Engine overrun 17-17 a. Other problems P0263 Cylinder 1 contribution/balance fault 17-41 b. No indication P0266 Cylinder 2 contribution/balance fault 17-41 P0269 Cylinder 3 contribution/balance fault...
Page 236: Signal Check Harness
17–8 ENGINE DIAGNOSIS CODE Signal check harness JP31199170301001 Signal check harness • When measuring terminal of the engine ECU, ! CAUTION connect the signal check harness to prevent damage to the connector. Place the tester rod on the contact box of the signal check harness for measurement.
Page 237 17–9 ENGINE DIAGNOSIS CODE Connection of signal check harness Set the starter key to "OFF" and disconnect the connector from the engine ECU. Connect the signal check harness to the engine ECU and the unit harness. Special tool : Signal check harness (09049-1080) Specification (performance) Wiring diagram Unit harness...
Page 238: Computer Pin Arrangement
17–10 ENGINE DIAGNOSIS CODE Computer pin arrangement JP31199170201001 SAPH311991700008 Failure diagnosis Failure diagnosis list...
Page 239: Check The Ecu Power Supply Voltage
17–11 ENGINE DIAGNOSIS CODE Check the ECU power supply voltage JP31199170601002 Measurement of voltage between terminals Set the starter key to "OFF" and connect the signal check harness. Turn the starter key "ON" and measure voltage between terminals A5, A6, A7 and terminals D1, E4, E5. Standard value : 20 V or more •...
Page 240: Engine Speed Main Sensor Circuit Malfunction (Dtc Code P0335)
17–12 ENGINE DIAGNOSIS CODE Engine speed main sensor circuit malfunction (DTC code P0335) JP31199170601004 Measurement of resistance between terminals Set the starter key to "OFF" and connect the signal check harness. Disconnect the ECU side connector of the signal check harness and measure the resistance between terminal B6 and terminal B7.
Page 241 17–13 ENGINE DIAGNOSIS CODE Measurement of resistance between terminals Disconnect the connector of the main engine speed sensor and measure the resistance between No. 1 and No. 2 terminals at the sensor. Standard value : Approx. 125.5 ± 17 Ω (20 °C{68 °F}) Failure of main engine speed sensor SAPH311991700013 Harness disconnection or connector failure...
Page 242: Engine Speed Sub Sensor Circuit Malfunction (Dtc Code P0340)
17–14 ENGINE DIAGNOSIS CODE Engine speed sub sensor circuit malfunction (DTC code P0340) JP31199170601005 Measurement of voltage between sensor terminals Set the starter key to "OFF" and connect the signal check harness. Disconnect the connector of the sub-speed sensor. Set the starter key to "ON" and measure voltage between the +5V terminal and the GND terminal of the sub-speed sensor connector (at unit harness side).
Page 243: Engine Speed Main And Sub Sensor Circuit Malfunction (Dtc Code P0335)
17–15 ENGINE DIAGNOSIS CODE Measurement of voltage between terminals Set the starter key to "OFF" and connect the connector of the sub-speed sensor. Start the engine and keep idling status. Measure voltage between terminal D19 and terminal D30 of the signal check harness. After measurement, stop the engine.
Page 244: Coolant Temperature Sensor Malfunction (Dtc Code P0117, P0118)
17–16 ENGINE DIAGNOSIS CODE Coolant temperature sensor malfunction (DTC code P0117, P0118) JP31199170601007 P0117 Coolant temperature sensor circuit low input P0118 Coolant temperature sensor circuit high input Measurement of resistance between terminals Set the starter key to "OFF" and connect the signal check harness.
Page 245: Engine Overheat (Dtc Code P0217)
17–17 ENGINE DIAGNOSIS CODE Engine overheat (DTC code P0217) JP31199170601008 Measurement of resistance between terminals Set the starter key to "OFF", disconnect the connector of the coolant temperature sensor and measure the resistance between No. 1 and No. 2 terminals at the sensor. Standard value (Measure either one point of the following.) : 2.45kΩ...
Page 246: Fuel Temperature Sensor Malfunction (Dtc Code P0182, P0183)
17–18 ENGINE DIAGNOSIS CODE Fuel temperature sensor malfunction (DTC code P0182, P0183) JP31199170601010 P0182 Fuel temperature sensor circuit low input P0183 Fuel temperature sensor circuit high input Measurement of resistance between terminals Set the starter key to "OFF" and connect the signal check harness.
Page 247: Boost Pressure Sensor Malfunction (Dtc Code P0108, P0237)
17–19 ENGINE DIAGNOSIS CODE Boost pressure sensor malfunction (DTC code P0108, P0237) JP31199170601011 P0108 Boost pressure sensor circuit high input P0237 Boost pressure sensor circuit low input Measurement of voltage between sensor terminals Set the starter key to "OFF" and connect the signal check harness.
Page 248 17–20 ENGINE DIAGNOSIS CODE Measurement of voltage between terminals Set the starter key to "OFF" and connect the connector of the boost pressure sensor. Set the starter key to "ON" and measure the voltage between terminal D27 and terminal D33 of the signal check harness. Standard value : 0.2 to 4.8 V [4] Go to measurement of voltage between terminals.
Page 249: Turbocharger Over Boost (Dtc Code P0234)
17–21 ENGINE DIAGNOSIS CODE Turbocharger over boost (DTC code P0234) JP31199170601012 Inspection with failure diagnosis tool After failure, perform failure diagnosis with a failure diagnosis tool (HinoDX) using PC. Connect the failure diagnosis tool (HinoDX) using PC and set the starter key to "ON". SAPH311991700026 Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
Page 250: Excessive Common Rail Pressure, Supply Pump Excess Forced Feed (Dtc Code P0088)
17–22 ENGINE DIAGNOSIS CODE Excessive common rail pressure, supply pump excess forced feed (DTC code P0088) JP31199170601014 Measurement of voltage between terminals Set the starter key to "OFF" and connect the signal check harness. Start and warm-up the engine until the coolant temperature gauge moves.
Page 251: Common Rail Pressure Sensor Malfunction (Dtc Code P0191)
17–23 ENGINE DIAGNOSIS CODE Common rail pressure sensor malfunction (DTC code P0191) JP31199170601015 Measurement of voltage between terminals Set the starter key to "OFF" and connect the signal check harness. Set the starter key to "ON" and measure the voltage between terminals D20/D31 and terminal D33.
Page 252: Common Rail Pressure Sensor Malfunction (Dtc Code P0192, P0193)
17–24 ENGINE DIAGNOSIS CODE Common rail pressure sensor malfunction (DTC code P0192, P0193) JP31199170601016 P0192 Common rail pressure sensor circuit low input P0193 Common rail pressure sensor circuit high input Measurement of voltage between terminals Set the starter key to "OFF" and connect the signal check harness.
Page 253 17–25 ENGINE DIAGNOSIS CODE Measurement of resistance between terminals Set the starter key to "OFF" and disconnect the ECU side connector of the signal check harness. Measure the resistance between terminals D20/D31 of the signal check harness and the SIG terminal of the common rail pressure sensor connector (at unit harness side).
Page 254: Accelerator Sensor 1 Malfunction (Dtc Code P2122, P2123)
17–26 ENGINE DIAGNOSIS CODE Accelerator sensor 1 malfunction (DTC code P2122, P2123) JP31199170601017 P2122 Accelerator sensor circuit 1 low voltage P2123 Accelerator sensor circuit 1 high voltage Measurement of voltage between terminals Set the starter key to "OFF" and connect the signal check harness.
Page 255 17–27 ENGINE DIAGNOSIS CODE Voltage measuring at the output port of the mechatronic controller With the starter key set to "ON", do not open the slot and measure the voltage between pin 25 of the pin connector 28 of the mechatronics controller and B21 of the signal check harness.
Page 256: Accelerator Sensor 2 Malfunction (Dtc Code P2127, P2128)
17–28 ENGINE DIAGNOSIS CODE Accelerator sensor 1 malfunction (DTC code P2127, P2128) JP31199170601018 P2127 Accelerator sensor circuit 2 low voltage P2128 Accelerator sensor circuit 2 high voltage Measurement of voltage between terminals Set the starter key to "OFF" and connect the signal check harness.
Page 257 17–29 ENGINE DIAGNOSIS CODE Voltage measuring at the output port of the mechatronic controller With the starter key set to "ON", do not open the slot and measure the voltage between pin 25 of the pin connector 28 of the mechatronics controller and B21 of the signal check harness.
Page 258: Accelerator Sensor 1 And 2 Malfunction (Dtc Code P2120)
17–30 ENGINE DIAGNOSIS CODE Accelerator sensor 1 and 2 malfunction (DTC code P2120) JP31199170601019 Inspection item Take action of DTC code P2120. "Reference : Accelerator sensor 1 malfunction (DTC code P2122, P2123), Engine ECU, Engine diagnosis code" "Reference : Accelerator sensor 2 malfunction (DTC code P2126), Engine ECU, Engine diagnosis code"...
Page 259: Emergency Accelerator Sensor Malfunction (Dtc Code P1133)
17–31 ENGINE DIAGNOSIS CODE Emergency accelerator sensor malfunction (DTC code P1133) JP03Z01030703026 Power supply voltage measuring With the ECU connector connected, disconnect the sensor connector and measure the voltage between the power terminal (+5 V) and the GND terminal. • The connector in the figure is seen from the ! CAUTION fitting surface.
Page 260 17–32 ENGINE DIAGNOSIS CODE Measurement of voltage between terminals Connect the sensor connector and measure the voltage between terminals A23 and B20 of the signal check harness. Standard value : Approx. 0.0 to 3.2 V (idle to full throttle) [4] Go to measurement of voltage between terminals. SAPH311991700040 Engine ECU failure, engine ECU connector failure Measurement of voltage between sensor terminals...
Page 261: Atmospheric Pressure Sensor Malfunction (Dtc Code P2228, P2229)
17–33 ENGINE DIAGNOSIS CODE Atmospheric pressure sensor malfunction (DTC code P2228, P2229) JP31199170601020 P2228 Atmospheric pressure sensor circuit low input P2229 Atmospheric pressure sensor circuit high input Check of diagnosis code After deleting the past failures with the failure diagnosis tool (HinoDX) using PC, check again if the same code (DTC code P2228, P2229) is output.
Page 262: Injector Common 1 Ground Short
17–34 ENGINE DIAGNOSIS CODE Injector common 1 ground short (DTC code P1211), Injector common 2 ground short (DTC code P1214) JP31199170601021 Measurement of resistance between terminals Set the starter key to "OFF" and connect the signal check harness. Disconnect the ECU side connector of the signal check harness.
Page 263: (Dtc Code P1214)
17–35 ENGINE DIAGNOSIS CODE Measurement of resistance between injector terminals Set the starter key to "OFF". The injector clustered connector at the front side of the engine shall be disconnected. Measure the resistance between terminals of the injector clustered connector (at unit harness side). Terminal to measure resistance DTC code –...
Page 264: Injector Common 1 Power Source Line Short (Dtc Code P1212), Injector Common 2 Power Source Line Short (Dtc Code P1215)
17–36 ENGINE DIAGNOSIS CODE Injector common 1 power source line short (DTC code P1212), Injector common 2 power source line short (DTC code P1215) JP31199170601022 Measurement of voltage between terminals Set the starter key to "OFF" and connect the signal check harness.
Page 265 17–37 ENGINE DIAGNOSIS CODE Measurement of voltage between injector terminals Set the starter key to "OFF". The injector clustered connector at the front side of the engine shall be disconnected and set the starter key to "ON". Measure the voltage between terminals of the injector clustered connector (at unit harness side).
Page 266: Injector Circuit Malfunction (Dtc Code P0201 To P0204)
17–38 ENGINE DIAGNOSIS CODE Injector circuit malfunction (DTC code P0201 to P0204) JP31199170601023 P0201 Injector circuit malfunction -cylinder 1 P0202 Injector circuit malfunction -cylinder 2 P0203 Injector circuit malfunction -cylinder 3 P0204 Injector circuit malfunction -cylinder 4 Measurement of resistance between terminals Set the starter key to "OFF"...
Page 267 17–39 ENGINE DIAGNOSIS CODE Measurement of resistance between injector terminals The injector clustered connector at the front side of the engine shall be disconnected. Measure the resistance between terminals of the injector 1 2 3 4 clustered connector (male) at the cam housing. 5 6 7 8 9 10 11 12 Terminal to measure...
Page 268 17–40 ENGINE DIAGNOSIS CODE Measurement of resistance between injector terminals Remove the terminal cap of the injector of the cylinder indicated by the failure code and measure the insulation resistance between the terminal and the upper body. Standard value : 1, 000 MΩ or more Injector TWV coil disconnection (Replace the injector assembly.) SAPH311991700048...
Page 269: Cylinder Contribution/Balance Fault (Dtc Codes P0263, P0266, P0269, P0272)
17–41 ENGINE DIAGNOSIS CODE Cylinder contribution/balance fault (DTC codes P0263, P0266, P0269, P0272) JP31199170601024 P0263 Cylinder 1 contribution/balance fault P0266 Cylinder 2 contribution/balance fault P0269 Cylinder 3 contribution/balance fault P0272 Cylinder 4 contribution/balance fault Inspection of flow damper 1 Set the starter key to "OFF" and stop the engine. Wait for approx.
Page 270 17–42 ENGINE DIAGNOSIS CODE Check of failure code Make sure that other failure code is not output. If other failure code is output, repair the failure first and delete the past failure with the failure diagnosis tool (HinoDX) using Then, if this failure code is output again, the following failures may be estimated.
Page 271: Supply Pump Scv Malfunction (Dtc Code P0628, P0629)
17–43 ENGINE DIAGNOSIS CODE Supply pump SCV malfunction (DTC code P0628, P0629) JP31199170601025 P0628 Supply pump SCV malfunction (Full discharge mode) P0629 Supply pump SCV malfunction (Power source line short) Measurement of resistance between solenoid terminals Set the starter key to "OFF", disconnect the connector of the supply pump solenoid valve and measure the resistance between No.
Page 272 17–44 ENGINE DIAGNOSIS CODE Measurement of voltage between terminals Turn "ON" the starter key. Measure voltage between terminal E4 and terminals E8/E9 of the signal check harness. Standard value : Pulse waveform at 24V ↔ 0V Failure of ECU connector SAPH311991700053 Engine ECU failure •...
Page 273: Supply Pump Scv Sticking
17–45 ENGINE DIAGNOSIS CODE Supply pump SCV sticking (DTC code P2635), Supply pump malfunction (DTC code P2635), Supply pump abnormal pressure record (DTC code P2635) JP31199170601026 Inspection of supply pump Set the starter key to "OFF" and stop the engine. Wait for approx.
Page 274: Preheat Circuit Malfunction (Dtc Code P0540)
17–46 ENGINE DIAGNOSIS CODE Preheat circuit malfunction (DTC code P0540) JP31199170601030 Measurement of resistance between terminals Set the starter key to "OFF" and connect the signal check harness. Disconnect the ECU side connector of the signal check harness and measure the resistance between terminals C1, C2 and terminals D1, E4, E5.
Page 275: Injector Correction Data Conformity Error (Dtc Code P1601)
17–47 ENGINE DIAGNOSIS CODE Injector correction data conformity error (DTC code P1601) JP31199170601031 Inspection of QR code Read the QR code data with the failure diagnosis tool (HinoDX) using PC. Reference value: This shall coincide with the QR code managed by the unit manufacturer. Write the QR code again.
Page 276: Ecu Charge Circuit Malfunction (Dtc Code P0200, P0611)
17–48 ENGINE DIAGNOSIS CODE ECU charge circuit malfunction (DTC code P0200, P0611) JP31199170601033 P0200 ECU charge circuit high input P0611 ECU charge circuit malfunction Check of ECU Set the starter key to "OFF" and set it to "ON" again. After deleting the past failure, check if the same code (DTC code P0611, P0200) is output again.
Page 277: Main Relay Malfunction (Dtc Code P0686)
17–49 ENGINE DIAGNOSIS CODE Main relay malfunction (DTC code P0686) JP31199170601034 Measurement of voltage between terminals Set the starter key to "OFF" and connect the signal check harness. Disconnect the ECU side connector of the signal check harness and set the starter key to "ON". Measure the voltage Frame between terminals A5, A6, A7 and the chassis GND.

Hino J05E-TH Workshop Manual

1 1 General

2 Standard Value

3 Parts to be Prepared

4 Engine Assembly/Disassembly

5 Fuel System

7 Electrical

9 Engine Mechanical

11 Cooling

12 Lubrication

13 Starting and Charging

14 Turbocharger

16 Failure Diagnosis for each Engine Status

17 Engine Diagnosis Code

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Summary of Contents for Hino J05E-TH