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Summary of Contents for Hino J05E-TB
- Page 1 HINO DIESEL ENGINE WORKSHOP MANUAL J05E-TB (25t) KSS-SMJ5-E103E 2010.7...
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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 ...... 1-10 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.
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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.
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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) •...
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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}...
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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...
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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
! CAUTION adjustment of the system in addition to failure diagnosis. Hino–DX With Hino–DX, failure of the common rail fuel injection system can be diagnosed. The interface box (Hino-Bowie) and the special cable are required for connection to the vehicle. - Page 25 1–21 GENERAL Deletion of past failures To delete past failures of the engine ECU, use Hino–DX on the PC. (Refer to "HinoDX operation manual".) SAPH311990100032 Connection of signal check harness To prevent damage to the ECU connector and to improve...
- 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 Vehicle side SAPH311990100038...
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Page 27: Connection Method Of Hinodx
Hino–DX through the interface box. Special tool : 09993-E9070 Hino-Bowie (Interface box) 09042-1220 Connecting cable Engine ECU CD-ROM Hino–DX Set the starter key to "ON" and start Hino–DX. Failure diagnosis connector SAPH311990100039 Failure diagnosis connector Hino-Bowie Connecting cable Connect to the failure diagnosis connector at the unit side. - 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 Emission Control............2-2 Tightening torque ............ 2-2 Electrical..............2-3 Standard value............2-3 Tightening torque ............
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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 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...
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