Hino P11C-UP Workshop Manual
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Hino P11C-UP Workshop Manual

Hino P11C-UP Workshop Manual

Diesel engine
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HINO DIESEL ENGINE
WORKSHOP MANUAL
P11C-UP
(Shovel)
KSS-SHP1-E001E
2007.3

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  • Page 1 HINO DIESEL ENGINE WORKSHOP MANUAL P11C-UP (Shovel) KSS-SHP1-E001E 2007.3...
  • Page 2 Find manuals at https://best-manuals.com...
  • 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 "15.
  • Page 4 Find manuals at https://best-manuals.com...

  • Page 5: Table Of Contents

    1–1 GENERAL ENGINE 1 GENERAL Outline 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 chassis bolts and nuts..... 1-13 Tightening of flare nuts and hoses......1-15 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 JP30001010102002 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 Pre-inspection • Pre-inspection is performed in the following steps: Diagnosis inspection → Diagnosis deletion → Failure status check (Use the reproduction method if not reproduced.) → Diagnosis reconfirmation • Estimate the failure system before the reproduction test. Attach a tester and evaluate estimated failure together with failure status.
  • 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 JP30001010101001 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 terminal Loosen may be damaged.
  • Page 13 1–9 GENERAL Handling of connector When a connector is removed, hold the connector (as shown by the arrow in the left figure) 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 1–10 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".

  • Page 15: Tightening Of Engine Bolts And Nuts

    1–11 GENERAL Tightening of engine bolts and nuts JP30001010102003 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} M12 x 1.25 (Fine thread)
  • Page 16 1–12 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 Seal lock agent check (for loosening or tightening) •...

  • Page 17: Tightening Of Chassis Bolts And Nuts

    1–13 GENERAL Tightening of chassis bolts and nuts JP30001010102004 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 18 1–14 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} 68.5±13.5{700±140} (Chassis)

  • Page 19: Tightening Of Flare Nuts And Hoses

    1–15 GENERAL Tightening of flare nuts and hoses JP30001010102005 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 Hose outer diameter φ13,φ20,φ22, fitting at...

  • Page 20: Taper Thread Sealant For Piping

    1–16 GENERAL Taper thread sealant for piping JP30001010102006 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 21: Assembly Of Joints And Gaskets For Piping

    1–17 GENERAL Assembly of joints and gaskets for piping JP30001010102007 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} 20{200}...
  • Page 22 1–18 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 Gasket Connector Flare nut Connector nipple Joint bolt Sealing surface : 4 places Flare connector...

  • Page 23: Handling Of Liquid Gasket

    1–19 GENERAL Handling of liquid gasket JP30001010102008 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 24: Failure Diagnosis Table For Each Problem

    1–20 GENERAL Failure diagnosis table for each problem JP30001010301001 The cause and action for each item are described. 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...

  • Page 25: Failure Diagnosis Procedures

    1–21 GENERAL Failure diagnosis procedures JP30001010301002 Display of failure code If the system has an error, the failure code is displayed on the multiple display of gauge cluster. SAPH300010100032 Deletion method of past failure To delete past failures of the engine ECU, use HinoDX on the PC.
  • Page 26 1–22 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.

  • Page 27: 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 unit. Special tool : 09121-1040 Hino-Bowie...
  • Page 28 1–24 GENERAL 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 measurement. Disconnect the connector from the ECU.
  • Page 29 1–25 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 SAPH300010100041...

  • Page 30: Connection Method Of Hinodx

    SAPH300010100042 Connection of HinoDX Connect the engine failure diagnosis connector to the PC Engine ECU which installed HinoDX through the interface box. Special tool : 09121-1040 Hino-Bowie (Interface box) 09042-1220 Connecting cable Engine failure CD-ROM HinoDX diagnosis connector Set the starter key to "ON"...
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