Hino J05C-TI Workshop Manual
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Hino J05C-TI Workshop Manual

Hino J05C-TI Workshop Manual

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WORKSHOP
MANUAL
J05C-TI engine
All rights reserved. This manual may not be
reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd.
INDEX: ENGINE GROUP 1/2
GENERAL INTRODUCTION
ENGINE INTRODUCTION
ENGINE MECHANICAL
AIR INTAKE SYSTEM
EXHAUST SYSTEM
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
TURBOCHARGER
FUEL INJECTION PUMP
EMISSION CONTROL
ALTERNATOR
STARTER
AIR COMPRESSOR
ENGINE PTO
(POWER TAKE-OFF)
ENGINE RETARDER
ENGINE CONTROL

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Summary of Contents for Hino J05C-TI

  • Page 1 FUEL INJECTION PUMP EMISSION CONTROL ALTERNATOR STARTER AIR COMPRESSOR ENGINE PTO (POWER TAKE-OFF) ENGINE RETARDER ENGINE CONTROL All rights reserved. This manual may not be reproduced or copied in whole in part, with- out the written consent of Hino Motors, Ltd.
  • Page 2 INDEX: ENGINE GROUP 2/2 ENGINE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS Find manuals at https://best-manuals.com...
  • Page 3 1 MENU FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles. Applicable for J05C-TI engine When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Operation Manual.
  • Page 4 CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. MANUAL NO. S5-YJ05E07A CHAPTER MODEL J05C-TI GENERAL INTRODUCTION GN01-001 ENGINE INTRODUCTION EN01-001 ENGINE MECHANICAL EN02-001 AIR INTAKE SYSTEM EN03-001 EXHAUST SYSTEM...

  • Page 5: Table Of Contents

    GENERAL INTRODUCTION (ENGINE) GN01–1 GENERAL INTRODUCTION (ENGINE) G N 0 1 GN01-001 GENERAL INTRODUCTION (ENGINE) ...GN01-2 GENERAL PRECAUTIONS ......GN01-2 HOW TO USE THIS WORKSHOP MANUAL...GN01-4 IDENTIFICATION INFORMATION ....GN01-5 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS ...............GN01-6 DISMOUNTING AND MOUNTING ....GN01-7 Find manuals at https://best-manuals.com...

  • Page 6: General Introduction (Engine)

    Improper or incomplete work can cause a malfunction of the engine, which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your Hino dealer. CAUTION When working on your engine, observe the following general precautions to prevent personal injury and/or prop- erty damage, in addition to the particular NOTES or CAUTION in each chapter.
  • Page 7 GENERAL INTRODUCTION (ENGINE) GN01–3 TOWING • When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No.

  • Page 8: How To Use This Workshop Manual

    GN01–4 GENERAL INTRODUCTION (ENGINE) HOW TO USE THIS WORKSHOP MAN- M00010101BEC1002 This workshop manual is designed as a guide for servicing the vehi- cles. An INDEX is provided on the first page of each chapter. TROUBLESHOOTING is dealt with in each chapter. When beginning operations, refer to the TROUBLESHOOTING section for a guide to appropriate diagnosis.

  • Page 9: Identification Information

    GENERAL INTRODUCTION (ENGINE) GN01–5 Gasket Main idle gear Rear end plate Crankshaft gear Camshaft gear Injection pump drive gear Camshaft idle gear Power steering pump drive gear Idle gear thrust plate Sub–idle gear Idle gear shaft Oil pump gear Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft} T= 108 {1,100, 79} T= 172 {1,750, 125}...

  • Page 10: Specified Torque For Standard Bolts And Nuts

    GN01–6 GENERAL INTRODUCTION (ENGINE) SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS M00010101BEC1004 1. FLANGE BOLT Unit: N⋅m {kgf⋅cm, lbf⋅ft} Class Representation Diameter x Pitch M8 x 1.25 28.5 {290, 21.0} 36 {370, 26.8} M10 x 1.25 60 {610, 44.1} 74.5 {760, 55.0} M10 x 1.5 55 {560, 40.5} 68.5 {700, 50.6}...

  • Page 11: Dismounting And Mounting

    GENERAL INTRODUCTION (ENGINE) GN01–7 DISMOUNTING AND MOUNTING M00010101BEH1001 PROCEDURE FOR INSTALLING JOINTS AND GAS- KETS OF ENGINE PIPING 1. Gasket seal type (aluminum + rubber, asbestos or copper). Location of gasket seal Tightening torque chart Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft} 8 {0.315} 13 {130, 9}...
  • Page 12 GN01–8 GENERAL INTRODUCTION (ENGINE) Tightening torque chart Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft} 12 {0.472} 20 {200, 14} 14 {0.551} 31 {320, 23} 16 {0.630} 39 {400, 29} 18 {0.709} 59 {600, 43} 20 {0.787} 64 {650, 47} 3.
  • Page 13 ENGINE INTRODUCTION (J05C) EN01–1 ENGINE INTRODUCTION (J05C) E N 0 1 EN01-001 ENGINE ASSEMBLY ........ EN01-2 DATA AND SPECIFICATIONS ......EN01-2 TROUBLESHOOTING ........EN01-3 ENGINE TUNEUP ........... EN01-6 SPECIAL TOOL ..........EN01-11 OVERHAUL CRITERIA........EN01-12 DISMOUNTING AND MOUNTING ....EN01-13 LIQUID GASKET AND APPLICATION POINTS ............

  • Page 14: Engine Assembly

    EN01–2 ENGINE INTRODUCTION (J05C) ENGINE ASSEMBLY DATA AND SPECIFICATIONS M01010101BEI2001 Model J05C-TJ Diesel, 4 cycle, vertical, 4 cylinder, in-line overhead camshaft, Type water-cooled, direct injection Aspiration Turbocharged with intercooler Bore and stroke 114x130 mm {4.49x5.11 in.} Piston displacement 5.307 L {323.8 cu.in.} Compression ratio 18: 1 1-3-4-2 (The cylinder numbers are counted in order from the...

  • Page 15: Troubleshooting

    ENGINE INTRODUCTION (J05C) EN01–3 TROUBLESHOOTING M01010101BEF3001 Engine overheating Symptom Possible cause Remedy/Prevention Engine overheating (Coolant) Insufficient coolant Add coolant. Defective thermostat Replace thermostat. Coolant overflow due to leakage of Repair. exhaust into cooling system Coolant leakage from cylinder head Replace gasket. gasket Defective coolant pump Repair or replace.
  • Page 16 EN01–4 ENGINE INTRODUCTION (J05C) Piston seizure Symptom Possible cause Remedy/Prevention Piston seizure (Operation) Abrupt stoppage of engine after run- Operate engine properly. ning at high speed Hill climbing using unsuitable gear Select suitable gear. Piston seizure (Oil) Insufficient oil Add oil. Dirty oil Change oil.
  • Page 17 ENGINE INTRODUCTION (J05C) EN01–5 Symptom Possible cause Remedy/Prevention Difficulty starting engine (Nozzles) Seized nozzle Replace nozzle. Broken or fatigued nozzle spring Replace spring. Difficulty starting engine (Oil sys- Oil viscosity too high Use proper viscosity oil, or install an oil tem) immersion heater and warm up oil.

  • Page 18: Engine Tuneup

    EN01–6 ENGINE INTRODUCTION (J05C) ENGINE TUNEUP M01010101BEH3001 VALVE CLEARANCE CHECKING AND ADJUSTING PROCEDURES CAUTION: Valve clearance adjustment is performed only when the checking result is not within the specified value. PREPARATION OF CHECKING AND ADJUSTMENT Positioning the No.1 or No.4 piston at Top Dead Center of the compression stroke.
  • Page 19 ENGINE INTRODUCTION (J05C) EN01–7 VALVE CLEARANCE CHECKING NOTICE: Before beginning the checking, you must perform "PREPARATION OF CHECKING AND ADJUSTMENT" described on page EN01-6. You can understand which valve to adjust when No.1 or No.4 pis- ton is at the Top Dead Center of the compression stroke by the fol- lowing chart).
  • Page 20 EN01–8 ENGINE INTRODUCTION (J05C) VALVE CLEARANCE ADJUSTMENT CAUTION: Valve clearance adjustment is performed only when the checking result is outside the specified value. NOTICE: • Before beginning the adjustment you must perform "PREPA- RATION OF CHECKING AND ADJUSTMENT" described on page EN01-6.
  • Page 21 ENGINE INTRODUCTION (J05C) EN01–9 Tighten the adjusting screw C of the cross head until the feeler gauge does not move. ROCKER ARM TIGHTEN NOTICE: In this situation, clearance between adjusting screw C and valve stem head is zero. "ZERO" "ZERO" clearance clearance M01010100010...

  • Page 22: Start The Engine

    EN01–10 ENGINE INTRODUCTION (J05C) ADJUST THE INJECTION TIMING. Make sure that the timing mark on the outer periphery of the fly- wheel is aligned with the timing pointer. Loosen two adjusting bolts of the injection pump coupling. Do not remove the bolts. SST: Injection pump coupling wrench.

  • Page 23: Special Tool

    ENGINE INTRODUCTION (J05C) EN01–11 LUBRICATION CHECK THE ROCKER ARM. Remove the head cover. Set the engine revolution to the specified idling revolution. After the engine starts, check that oil is supplied to the following locations of all rocker arms within approximately 10 seconds. a.

  • Page 24: Overhaul Criteria

    EN01–12 ENGINE INTRODUCTION (J05C) OVERHAUL CRITERIA M01010101BEH3002 FACTORS TO DETERMINE THE ENGINE OVERHAUL LOW COMPRESSION PRESSURE Before measurement a. Charge the battery completely. b. Set the valve clearance to the correct value. c. Idle the engine (Coolant temperature at 80C {176°F}). d.

  • Page 25: Dismounting And Mounting

    ENGINE INTRODUCTION (J05C) EN01–13 d. Measure the oil pressure at a coolant temperature of 80°C {176°F} or more. Oil pressure Standard Limit 49-490 kPa Less than 49kPa {0.5-5.0 kg/cm {0.5 kg/cm 7.11-71.10 lbf/in. 7.11 lbf/in. OTHER FACTORS Increase of blowby gas M01010100023 Defective engine start Decrease of engine output...
  • Page 26 EN01–14 ENGINE INTRODUCTION (J05C) (10) Remove the cab mounting member from the frame. (11) Connect a cable from an engine hanger to the hanger bracket (1 point) on the front of the engine, and to the hanger bracket (1 point) on the flywheel housing at the rear of the engine. Using a hoist, raise the hanger until there is a bit of slack in the cables.

  • Page 27: Liquid Gasket And Application Points

    ENGINE INTRODUCTION (J05C) EN01–15 Connect and adjust the engine stop cable with adjusting nut so that clearance "A" between the clevis and cable stopper is 1-3 mm {0.04-0.11 in.}. Set the starter switch to the LOCK position. NOTICE: After adjustment, confirm correct execution of engine start and stop.
  • Page 28 EN01–16 ENGINE INTRODUCTION (J05C) For cartridge-type gasket, use an application gun. M01010100028 For tube-type liquid gasket, required width of application can be obtained by cutting the nozzle to suit. 1: Approxi- 2 mm wide when cut at the first step mately 2: Approxi- 5 mm wide when cut at the second step...
  • Page 29 ENGINE INTRODUCTION (J05C) EN01–17 Gasket Application Part name Application position and pattern to be Remarks width used Matching flange face with the cylinder head 1.5-2.5 Thermostat case {0.0591- Silver 0.0984} Matching face with the rear edge 1.5-2.5 Flange {0.0591- Silver 0.0984}...
  • Page 30 EN01–18 ENGINE INTRODUCTION (J05C) Gasket Application Part name Application position and pattern to be Remarks width used Matching parts of block upper face rear end, gasket, rear end plate, flywheel housing, cylin- — White der head gasket 1.5-2.5 Matching parts of oil seal retainer and block {0.0591- Black lower face front end...
  • Page 31 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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