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Summary of Contents for Hino J08E-UN
- Page 1 HINO DIESEL ENGINE WORKSHOP MANUAL J08E-UN (HS ENGINE for 32t) KSS-SMJ8-E102E 2007.6...
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- 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.
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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 ...... 1-11 Tightening of flare nuts and hoses......1-13 Taper thread sealant for piping ......1-14 Assembly of joints and gaskets 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 JP31002010102002 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 of (1) Question "Step 1" 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.
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Page 11: Precautions For Work
1–7 GENERAL Unit SI unit is used in this manual. SI unit is the international unit to unify the conventional different international units into one unit per quantity and to promote smooth technical communications. This manual shows both the SI unit and conventional units. The conventional units are shown in { }. Convent Conversion value Convent... - Page 12 1–8 GENERAL Precautions for service work Pay attention to the following points before service work Preparation before disassembly Prepare general tools, special tools and gauges before work. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected to ease assembly.
- Page 13 1–9 GENERAL Handling of wire harness Mark clamps and clips to prevent interference of a wire harness with body edge, sharp edge and bolts. Be sure to reassemble it to the original position. When parts are assembled, be careful not to pinch a wire harness.
- 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".
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Page 15: Tightening Of Engine Bolts And Nuts
1–11 GENERAL Tightening of engine bolts and nuts JP31002010102003 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 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) •...
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Page 17: Tightening Of Flare Nuts And Hoses
1–13 GENERAL Tightening of flare nuts and hoses JP31002010102004 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 18: Taper Thread Sealant For Piping
1–14 GENERAL Taper thread sealant for piping JP31002010102005 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 19: Assembly Of Joints And Gaskets For Piping
1–15 GENERAL Assembly of joints and gaskets for piping JP31002010102006 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 20 1–16 GENERAL Examples of joint methods in various pipes Metal sealing method Gasket sealing method Type A Type B (Flare pipe type) (Nipple connector type) Joint bolt Flare pipe Sealing surface: 3 places Connector Gasket Flare nut Connector nipple Joint bolt Sealing surface : 4 places Flare connector...
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Page 21: Handling Of Liquid Gasket
1–17 GENERAL Handling of liquid gasket JP31002010102007 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 22: Failure Diagnosis Table For Each Problem
1–18 GENERAL Failure diagnosis table for each problem JP31002010301001 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 23: Failure Diagnosis Procedures
1–19 GENERAL Failure diagnosis procedures JP31002010301002 Display of failure code If the system has an error, the failure code is displayed on the multiple display of gauge cluster . SAPH310020100027 Deletion method of past failure To delete past failures of the engine ECU, use HinoDX on the PC. - Page 24 1–20 GENERAL How to read troubleshooting for each diagnosis monitor code "Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be started from the code list.
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Page 25: 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 26 1–22 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 meaurement. Disconnect the connector from the ECU.
- Page 27 1–23 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 SAPH310020100037...
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Page 28: Connection Method Of Hinodx
SAPH310020100038 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"... - 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 ............
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Page 30: Engine Body
2–2 STANDARD VALUE Engine Body Standard value JP31002020205001 Unit : MPa {kgf/cm , lbf/in. Inspection item Standard value Repair limit Service limit Action 3.4-3.7MPa 2.7MPa Compression pressure {35-38kgf/cm {28kgf/ — (Engine revolution per cylinder: 150 r/min) 493-237lbf/ ,392lbf/ Tightening torque JP31002020205002 Unit:N⋅m{kgf⋅cm, lbf⋅ft} Tightening area... - Page 31 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...
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