Manitowoc Engine J08E Engine Hand Book Parts Catalog Manual

ENGINE HAND BOOK PARTS CATALOG

ENGINE J08E Book code No. : S2GG45011ZE01

2015.08

Items that can result in death or severe personal injury if handled improperly.

Items that can result in personal injury and/or property damage, such as engine damage, if handled improperly.

Items that should be followed to ensure proper engine performance and to prevent engine from trouble and damage.

WARNING

CAUTION

ADVICE

manufacturer.

CT4-001E July 2015

· For information on the handling of equipment other than HINO engine, please refer to the “Operation Manual” supplied by your machine

standard specifications may be different for your engine. Please refer to the “Operation Manual” of your machine.

· , , represents, from the left to the right, order of importance. · The contents of this handbook are based on the standard specifications of HINO industrial engines. Depending upon the machines,

Items that are referring to the engine handling, operating, inspection and maintenance.

Items that will result in death or severe personal injury if handled improperly.

DANGER

''CAUTION'', ''ADVICE'' and '' ''. They are particularly important.

This handbook has been prepared to give you a thorough understanding of the operation of the HINO engine together with guidance on a simple and periodic inspection and maintenance. Please make sure to read this handbook carefully before you start your engine so that you can operate it safely, comfortably and friendlily to social environment. · Read very carefully those sections which have signs ''Important fundamentals you must know'', ''DANGER'', ''WARNING'',

We thank you very much for having purchased a HINO engine this time.

FOREWORD

TABLE OF CONTENTS

7. TABLE OF DIAGNOSIS CODE FOR TROUBLES

6. TROUBLESHOOTING

5. LUBRICATION

4. INSPECTION AND MAINTENANCE

3. PROPER OPERATION

2. BASIC ENGINE CARE

1. IMPORTANT FUNDAMENTALS YOU MUST KNOW

HA00 - 002A

1. IMPORTANT FUNDAMENTALS YOU MUST KNOW

PRECAUTIONS DURING OPERATION ...................................... P1- 2

1-1

PRECAUTIONS DURING OPERATION

Never fill the tank with gasoline. If you pour the gasoline into the tank by mistake, extract the gasoline completely before starting the engine. Starting the engine with gasoline in the tank is dangerous as it can result in a fire or engine damage.

WARNING

·

conforms to EN590 (2009).

Mixed biodiesel fuel are compatible with the EN14214.

The use of biodiesel fuel that does not conform to EN14214 or fuel that does not conform to EN590 (2009) may cause damage to the injectors and supply pump.

Use ultra-low sulfur diesel fuel [S10: Sulfur content 10 ppm or less] as fuel.

(In cold areas, use fuel suitable for the area's temperature range.) When fuel other than the specified fuel, such as gasoline, kerosene, or alcohol-type fuel is filled in or mixed with other fuel, this not only can cause a fire, but can

· Please use only diesel fuel that

WARNING

NOTICE: · Use diesel fuel with cetane number 45 or higher. · Fuel additives should not be used. · Do not use fuel of bad quality or substitute fuel. It may deteriorate engine performance and may cause troubles which will not be covered by warranty.

USE THE SPECIFIED FUEL

·

·

USING SUBSTITUTE FUEL WILL DETERIORATE ENGINE PERFORMANCE

EA01 - 001A

also damage the sliding parts of the fuel-lubricated components in the supply pump and the injectors, which may lead to malfunctions of the engine or the fuel system. It will also cause a gradual deterioration of the exhaust gas while generating soot and white smoke, eventually leaving the catalyst ineffective.

Make sure that the specified diesel fuel is being supplied. If an incorrect fuel has been filled in by mistake, it must be removed completely.

When refueling, take care not to inhale fuel vapors. Some fuel components are harmful to your health.

IMPORTANT FUNDAMENTALS YOU MUST KNOW

FUEL Please use only the specified fuel to ensure the right engine performances.

Engine damage caused by use of improper fuels is not covered under warranty.

1-2

When replenishing fuel, always observe the following items. · Always stop the engine. · Keep burning cigarettes etc. away. · Remove and install the fuel cap carefully. Pulling or turning the handle with excessive force can damage the cap or the filler and can lead to fuel leakage. · When opening the fuel cap or performing other operations related to filling up, first touch a metal part to discharge any static electricity from your body. When your body is charged with static electricity, a discharge spark may ignite the fuel and cause injuries through burns.

WARNING

REPLENISH THE FUEL · When filling fuel, make sure that no dust or water gets into the tank. · Make sure to fasten the fuel tank cap securely. Remove the drain plug below the tank occasionally and drain sediment and water content at the bottom of the tank together with the fuel.

·

·

·

·

·

pressure has built up in the fuel tank because of high temperatures etc., there is danger that fuel will spurt out of the filler port. If you hear a hissing sound when opening the fuel cap, do not open it further. Open slowly after that sound has stopped.

Insert the fuel nozzle carefully, so that it does not damage the filler.

Insert the fuel nozzle correctly deep into the filler, and make sure that it will not come off while filling up.

While filling up, do not touch people or objects which could be statically charged. (You may become charged again.)

Keep persons who have not discharged their static charge away from the filler port.

After completion of filling up, make sure that the fuel cap has been closed correctly.

While filling up, avoid inhalation of gasoline fumes. The fumes include harmful components.

· Open the fuel cap slowly. When the

1-3

·

additives and fuel efficiency enhancing additive, used engine oil may cause sliding failure of the fuel lubrication part of the injector and in the supply pump, and smoke.

Please do not attach any fuel efficiency improving device inside the fuel tank.

Debris abrasion or powder (commercially available) may cause damage to the injector and supply pump device that you just installed.

· If you use fuel draining agents, fuel

WARNING

DO NOT ADD ADDITIVES TO FUEL OR DO NOT INSTALL ANY UNIT IN THE FUEL TANK

IMPORTANT FUNDAMENTALS YOU MUST KNOW

·

·

·

·

·

enough, and be careful of accumulation of water and the development of microorganisms.

Check that the oil level is as written in the manual.

Since water accumulates easily, frequently drain it from the fuel filter.

In this case, carry out the drainage of water from the fuel filter as written in the manual.

Use biodiesel fuel within 6 months from the date of manufacture.

Also, be sure to use it all up within three months after refueling.

When using biodiesel fuel that does not meet the EN590 (2009), cleans the piping and tanks, and replace with a new fuel filter element.

Biodiesel fuel is harmful to the skin and eyes. Please wear protective glasses and gloves when handling.

· Check that the storage tank is cleans

WARNING

TA07 - 002A

Never remove the radiator cap while it is hot. Opening the cap carelessly can lead burn injury due to spurting out of hot coolant and steam. Make sure to fasten the radiator cap securely.

WARNING

BE CAREFUL WITH THE RADIATOR CAP

HA01 - 010A

NOTICE: · When only water is added, the concentration of the long-life coolant is lowered, which causes the rust prevention effect and the anti-freeze performance to decrease.

FOR COOLANT USE LONG LIFE COOLANT (LLC) MIXED WITH WATER ................................................... Page 4-21

DH-2 CJ-4 E-6, E-9

In order to maintain a trouble-free functioning of the DPR (exhaust gas after treatment system) for a long time, it is recommended to use the specified (recommended) brand of engine oil.

ADVICE

HINO recommends these oil to the Tier4 regulation countries, and use ultralow sulfur fuel only.

API ACEA

JASO

· Oil quality

ENGINE OIL SELECTION

USE THE PROPER ENGINE OIL The engine oil must be able to withstand heat and oxidation. It must be stable in viscosity in spite of temperature change.

Hino genuine engine oil has been made in order to satisfy such performance and you are kindly asked to use proper oil depending upon the using condition of your engine.

It is necessary to use oil of different viscosities in accordance with the outside temperature. Be sure to select the proper oil.

IMPORTANT FUNDAMENTALS YOU MUST KNOW

PLEASE CONTACT YOUR DEALER IF YOU ARE USING BIODIESEL FUEL

1-4

-22

-30

-40

-40

-20

-4

0

32

10

50

20

66

SAE 15W-40

SAE 10W-30

SAE 5W-30

-10

14 30

88

· Viscosity recommendations (SAE) 40 °C

104 °F

Even when the needle of the coolant temperature gauge is in the red zone, immediately stopping the engine can cause seizure. Therefore, do not stop the engine, but continue to be run it in idle until the needle has returned to the normal range.

CAUTION

EA01 - 003A

WARNING

When the warning lamps light up or the instruments indicate any abnormality, be sure to idle the engine immediately and carry out inspections and repairs in accordance with operation handbook.

If you continue to operate ignoring the warnings of the warning lamps or the instruments, it might result in an unexpected accident. When you cannot find the cause or you cannot service it by yourself, have the engine inspected and repaired at the nearest your dealer.

WARNING

PAY ATTENTION TO THE METERS, GAUGES AND LAMPS WHILE RUNNING THE ENGINE

1-5

INSTRUMENTS WILL NOT OPERATE, IF THE SWITCH IS KEPT “OFF” DURING OPERATION. EA01 - 005A

Never turn off the starter switch while operating the engine. If you turn these switches off, warning lamps and instruments which are necessary for operation will not work and therefore it is extremely dangerous. It may also lead to the generation of high voltages in the electrical circuits, causing damages to the diodes.

WARNING

NEVER TURN OFF THE STARTER SWITCH WHILE OPERATING THE ENGINE ............. ..................................................... Page 3-2

IMPORTANT FUNDAMENTALS YOU MUST KNOW

·

load and high speed, continue warming up until the coolant temperature gauge starts moving.

When the engine has been operated at high load and high speed, keep the engine idling until the turbocharger has cooled down, before stopping the engine.

· When the engine is operated at high

CAUTION

MAINTENANCE OF ENGINES EQUIPPED WITH TURBOCHARGER

·

such as the belt and the fan while the engine is running, your hands or clothes can get caught and you might cause an unexpected injury.

After finishing the work, be careful not to leave any rag, paper and tool in the engine compartment. Pay special attention to any flammable materials since they can cause fire.

· If you touch or get close turning parts

WARNING

EA01 - 005A

CLEAN AIR CLEANER

ing it, and perform idling before stopping the engine.

· Be sure to warm up the engine before operat-

PERIODICAL REPLACEMENT OF THE OIL FILTER AND OF THE ENGINE OIL OF GOOD QUALITY

turbocharger properly, it is necessary to practice the periodical replacement of the engine oil of the specified (recommended) and of the oil filter, as well as cleaning the air cleaner periodically.

· In order to keep the function of the

·

·

oxide (CO) which is colorless and odorless but harmful. Inhaling exhaust gas is dangerous as it can result in carbon monoxide poisoning.

Do not keep the engine running in a poorly ventilated area. Surrounded areas such as indoor areas are especially dangerous because such areas can be filled with exhaust gas, which can result in carbon monoxide poisoning.

Check your exhaust pipe occasionally. If you find a hole or crack, coupler damage, or anything unusual with the exhaust pipe, have the engine inspected and repaired at the nearest your dealer. Keep using the engine under such conditions can cause the exhaust gas to enter the indoor areas and result in carbon monoxide poisoning.

· Exhaust gas contains carbon mon-

WARNING

BE CAREFUL WITH EXHAUST GAS

IMPORTANT FUNDAMENTALS YOU MUST KNOW

INSPECTION AND MAINTENANCE

1-6

Never pour water into the air intake port when washing to avoid malfunction of the air intake system.

CAUTION

AT05 - 003A

ENGINE WASHING When you wash the engine, use running water to flush away dirt and other foreign materials.

During the washing, pay particular attention to areas where mud and dirt may gather.

Do not put water inside of the exhaust system directly from the opening of the tail pipe. Doing so may damage the catalyst and sensors.

CAUTION

AT05 - 002A

IMPORTANT FUNDAMENTALS YOU MUST KNOW 1-7

MEMO

2. BASIC ENGINE CARE

BREAKING-IN THE NEW ENGINE ................................... P2- 4

ENGINE INSPECTION ..................... P2- 3

WARRANTY ...................................... P2- 2

2-1

WARRANTY

As Hino industrial engines are manufactured based on a high level of technology and thorough quality control, we are convinced that you will be very satisfied with their performance and functions. However, if a defect is caused by materials or the manufacturing process, we will perform service free of charge within the scope listed in the <Warranty> chapter. For details, please refer to <Warranty>.

2-2

[P11 SERIES]

[J08 SERIES]

TB04 - 033A

HB01 - 003A

ENGRAVED POSITION

ENGRAVED POSITION

graved on the crank case on the side of the engine.

EXAMPLE: P11C TA10001

· The engine model and serial numbers are en-

ENGINE MODEL AND NUMBER

BASIC ENGINE CARE

·

EB01 - 002A

EB01 - 001A

GENUINE PARTS When purchasing parts, always specify “HINO genuine parts”. Since we guarantee the quality of “HINO genuine parts”, you can depend upon their reliability. “HINO genuine parts” or as shown below on carry the label the products themselves or are packed in the box or wrapping paper with the same labels.

PERIODIC INSPECTION Periodic inspection and maintenance is absolutely necessary in order to ensure maximum engine performance and long service life. Conduct periodic inspection and maintenance and oil and/or grease replacement according to the methods described in the periodic inspection and maintenance chart and the lubricants table contained in this handbook. Please bear in mind that problems caused by neglecting inspection or oil and/or grease replacement shall not be covered by the warranty.

EB01 - 003A

PERIODIC INSPECTION

ENGINE INSPECTION

PERIODIC INSPECTION

EB01 - 004A

The degradation of the engine progresses and the performance of the component parts and of its equipment reduces depending upon the length of operation period as well as the quality of care. Please make sure to perform regular inspections and maintenance, in order to avoid damage and to reduce exhaust gas and noises which adversely affect the social environment.

ADVICE

BASIC ENGINE CARE

Please note that the periodic replacement of parts is to be carried out on your own responsibility and paid for by yourself. It is different from repair work covered by the warranty.

Depending upon operation conditions and other circumstances it may be necessary to replace such parts earlier than the specified schedule. At such time please consult your dealer.

ADVICE

PERIODIC REPLACEMENT PARTS With the passage of time, there will be a deterioration in quality of material of rubber parts of the engine, which are important from the safety point of view. It is difficult to determine how much longer these parts can be used safely during periodic inspection.

Since such parts play an important role in ensuring their performance, function and safety, make sure to replace these parts periodically according to the schedule specified by HINO.

2-3

EB01 - 005A

3.FUEL LEVEL FUEL GAUGE

1.ENGINE OIL LEVEL

the engine, inspect the following items before starting the engine.

1. Engine oil level 2. Coolant level 3. Fuel level

· To ensure always safe and trouble-free use of

2.COOLANT LEVEL

tained in “PRECAUTIONS OF SAFETY” on page 4-2.

· To ensure safety, follow the instruction con-

HB02 - 005A

INSPECTION AND MAINTENANCE To ensure optimum engine performance, check the following inspection items which are included in the periodic inspection and maintenance chart and conduct inspection and maintenance regularly. These items and procedures can be performed by a person with basic knowledge of engine structure and components.

DAILY(BEFORE STARTING THE ENGINE) INSPECTION

·

BASIC ENGINE CARE

2-4

Pay attention to the following points when breaking-in the engine. · Be sure to warm up sufficiently. · Avoid racing the engine. It is not only puts a strain on the engine, but also wastes fuel. · Make every effort not to operate the engine in overload. · After the 30 hours of breaking-in period, change the engine oil.

· The first 30 hours is the breaking-in period.

HB03 - 005A

BREAKING-IN THE NEW ENGINE

3. PROPER OPERATION

HD00 - 003A

LONG-TERM STORAGE OF THE ENGINE ................................ P3- 8

HANDLING IN HOT WEATHER .......... P3- 7

HANDLING IN COLD WEATHER ........ P3- 6

STOPPING THE ENGINE .................. P3- 5

DRIVING NOTES ............................... P3- 5

ENGINE WARM-UP ............................ P3- 4

STARTING THE ENGINE .................. P3- 3

STARTER SWITCH ........................... P3- 2

Items contained in this section are based on the standard specifications of HINO industrial engines. Depending upon the machine model, they may not be the same as your engine. Please refer to the “OPERATION MANUAL” of your machine.

ADVICE

3-1

·

STARTER SWITCH

IF THE SWITCH IS LEFT IN THE ''ON'' POSITION FOR A LONG PERIOD OF TIME WHEN THE ENGINE IS NOT RUNNING

WHILE THE ENGINE IS NOT RUNNING

EC01 - 001A

DISCHARGE

Be sure to always set the switch to the “OFF” position when the engine is not running. Leaving the switch in the “ON ” position for a long period of time when the engine is not running may result in loss of battery power and cause the engine not to start.

ADVICE

“OFF” position In this position, the key can be inserted or removed.

Be sure to set the switch to this position after the engine is stopped.

KEY POSITIONS

3-2

WARNING

INSTRUMENTS WILL NOT OPERATE, IF THE SWITCH IS KEPT “OFF” DURING OPERATION.

EA01 - 005A

Always keep the key in the “ON” position while running. When it is in the “OFF” position, the warning lamps and instruments necessary for operation will not operate and it is very dangerous. It also damages the electric circuit.

ning.

· This is the position in which the engine is run-

“ON” position

PROPER OPERATION

· This is the position to start the engine.

“START” position

2. Turn the starter key to the “START” position and start the engine.

HD02 - 006A

1. Insert the starter key and turn it to the “ON” position. Check that all instruments are operating properly.

NORMAL STARTING AND WHEN THE ENGINE IS WARMED UP

Depending on the machine, they may be different in the way the engine is started and stopped. Please refer to the “OPERATION MANUAL” of your machine. · Do not perform warm-up operation in an insufficiently ventilated building. Exhaust gas can cause carbon monoxide poisoning, which is dangerous. · Before warm-up operation, confirm that there is no combustible matter near the exhaust port. Easily combustible items can cause a fire, due to the heat of the exhaust.

STARTING THE ENGINE

HD02 - 006A

1. Turn the starter key to the “ON” position.

WHEN YOU FIND IT DIFFICULT TO START THE ENGINE IN COLD WEATHER

If there is anything abnormal with the operation or the lighting up of any of the instruments or warning lamps, turn off the starter switch, and inspect the abnormal area.

ADVICE

PROPER OPERATION

ter extinction of the preheat indicator lamp will facilitate raising engine revolution.

· Starting the engine within 3.5 seconds af-

TE002 - 024A

3. Simultaneously with the extinction (approx. five seconds) of the preheat indicator lamp, turn the starter key to the “START” position and start the engine.

EC02 - 002A

EXTINCTION

2. If the coolant temperature is low, the preheat indicator lamp lights up and it turns off when preheating is completed.

3-3

ADVICE

EC02 - 001A

DO NOT ENGAGE THE STARTER FOR MORE THAN 15 SECONDS AT A TIME.

the accelerator lever to the high-speed position, then start the engine. After the engine has started, return the lever to set a suitable engine speed. · Heater plug (J series engine) and intake air heater (P series engine) use a lot of electricity. Please avoid repeated operation of them, since it gives excessive strain to batteries. · If the engine does not start on the first attempt, wait approximately 30 seconds for the batteries to recover before trying again. · Do not engage the starter for more than 15 seconds at a time. This can cause starter trouble or the battery to become exhausted.

· When starting the engine is difficult, set

3-4

2. Continue warm-up the engine until the needle of the coolant temperature gauge starts moving.

1. When the engine starts, use the accelerator lever to run the engine at a little higher than the normal idling speed. · Warm-up for approximately five minutes.

· Do not perform warm-up operation in an insufficiently ventilated building.

Exhaust gas can cause carbon monoxide poisoning, which is dangerous. · Before warm-up operation, confirm that there is no combustible matter near the exhaust port. Easily combustible items can cause a fire, due to the heat of the exhaust.

WARNING

ENGINE WARM-UP

PROPER OPERATION

When operating the engine, make sure that there are no combustible materials near the exhaust pipe. The heat from the exhaust can cause a fire.

WARNING

How to distinguish the exhaust gas color (when the engine is warm) Colorless...... Complete combustion Black...... Incomplete combustion White...... Oil combustion due to oil loss via piston rings or valve guides

1. Pay attention to the engine noise and check the color of the exhaust gas. If you notice any abnormality of the engine noise, stop the engine immediately and perform inspection and repairs. Also, monitor the color of the exhaust gas to identify combustion condition.

warm-up and make sure to inspect the following items.

· Observe the condition of the engine during

3. When the needle has started moving, return the engine to the normal idling speed.

The normal idling speed rate is different depending on the machines. Please refer to the “OPERATION MANUAL” of your machine.

If in cold weather the needle does not enter the normal operating temperature zone even after an extended period of time, use a radiator curtain or such to reduce the radiator core area and over-cooling.

When the coolant temperature is abnormally low, it results in a higher fuel consumption and a premature wear of engine parts.

RED ZONE

2. Check that the coolant temperature is normal.

Through the action of the thermostat, the temperature of the coolant is kept within the normal operating temperature zone. The engine is started, and then the needle of the coolant temperature gauge starts moving to the right and enters the normal operating temperature zone.

1. Is the engine oil pressure normal?

2. What about the coolant temperature?

EC04 - 001A

5. Are there any abnormal noises from the engine or other sources?

4. Are there any leakages of fuel or coolant?

3. What is the state of alternator power generation?

Pay attention to the following while operating.

(1) The oil pressure is normal.

(2) The coolant temperature is normal. (Generally below 95°C {203°F} at the maximum ambient temperature.)

(3) The batteries are properly charged.

(4) There are no leakages of fuel, coolant, oil, or gas.

(5) There are no abnormal noises from the engine or other sources.

DRIVING NOTES

PROPER OPERATION

· To stop the engine, return the starter key to the “OFF” position.

Stopping the engine immediately after operation without cooling down by idling is not good for the engine. Particularly in the case of engines equipped with turbochargers or an engine that has been operated under great load, the various parts of the engine are in overheated condition. Therefore, be sure to cool down the engine sufficiently by idling before stopping it.

ADVICE

IDLING BEFORE STOPPING THE ENGINE · Before stopping the engine, idle the engine for five minutes to cool down.

STOPPING THE ENGINE

3-5

INSPECTION OF ENGINE AFTER OPERATION In addition to cleaning the engine after operation, perform the following. · Inspect and repair areas if any faulty had appeared during operation. · Check to see whether there are any loose or damaged parts and any leakage of oil or coolant. · If the coolant is not drained, it can freeze and crack the crankcase or the coolant system or cause other damage.

3-6

·

·

·

PRECAUTIONS TO TAKE DURING FUEL REPLENISHMENT Be sure to fill up the fuel tank after the operation.

In cold weather, if the fuel level is low and there is an increase of the amount of air inside the fuel tank, the vapor contained in the air can turn into drops of water, which may freeze or cause rust in the fuel system, resulting in engine trouble or breakdowns.

Be sure to tighten the fuel tank cap firmly to prevent rain or snow from getting into the tank.

Occasionally remove the drain plug of the fuel tank to drain all the water content from inside the tank.

When the engine is cold, do not race the engine or suddenly impose load to it or rotate it at high speed, because if these are done, they can cause not only engine trouble but also waste of fuel.

ADVICE

The engine needs special care in areas where there is a lot of snow, mountainous regions or extremely cold regions.

PRECAUTIONS TO TAKE WHEN STARTING THE ENGINE · Preheat the engine before starting it. · After starting the engine, warm up the engine by idling at a little higher speed than normal idling.

HANDLING IN COLD WEATHER

PROPER OPERATION

·

·

·

PRECAUTIONS REGARDING THE ENGINE OIL When operating the engine in cold areas, be sure to use the type of oil with the appropriate viscosity because engine oil viscosity increases as outside temperature falls.

FUEL (In winter) If the engine is hard to start-up during winter or in cold climates, fuel maybe frozen.

When in cold climates, please supply the correct fuel to the outside air temperature of the local in advance.

If long-life coolant (LLC) cannot be used for some reason, the drain cocks of the crankcase and the radiator must be opened and the entire coolant must be drained after the shutdown to prevent damage from freezing. If this is not done, the crankcase and the cooling system can be damaged by cracks because of freezing.

ADVICE

When it is extremely cold, remove the battery and store it indoors if it is not being used for an extended period of time.

ADVICE

PRECAUTIONS REGARDING THE BATTERY Battery power declines in cold weather and the battery freezes more easily. Therefore, try to keep the batteries fully charged at all times. · Always charge the batteries by running the engine after replenishing electrolyte, to prevent the batteries from freezing.

·

PRECAUTIONS REGARDINGTHE COOLING SYSTEM Always mix long life coolant (LLC) with the coolant to prevent it from freezing and damaging the engine and radiator.

·

·

·

TM11 - 003A

PRECAUTIONS REGARDING THE COOLANT SYSTEM When it is very hot, scale and rust can form easily in the cooling system (especially in the radiator). For this reason, the coolant should be replaced earlier than the specified change interval (refer to page 4-22) to circulate clean coolant.

The front of radiator or intercooler may get clogged with mud and dust, resulting in decreased cooling efficiency. Therefore, regularly wash off the front of them with water.

PRECAUTIONS REGARDING THE ENGINE OIL Since the engine oil viscosity decreases as outside temperature rises, always use oil with the appropriate viscosity when operating the engine in hot weather.

The engine can overheat more easily in hot weather. Therefore, the handling of the cooling system needs special attention.

HANDLING IN HOT WEATHER

PROPER OPERATION

EC07 - 001A

hot weather, therefore, make sure the battery level checking is always filled up with replenisher or distilled water up to the “UPPER” level.

· Battery electrolyte consumption is higher in

PRECAUTIONS REGARDING THE BATTERY

Never remove the radiator cap until the water temperature has dropped sufficiently. Opening the radiator cap carelessly can lead to burn and other injuries due to spurting out of hot coolant and steam.

WARNING

IS THE TENSION OF THE BELT PROPER?

sure to adjust the tension so that it conforms to the standard value.

· Check the belt for proper tension and make

3-7

DANGER

·

sure not to fill above the “UPPER” level.

Filling above the “UPPER” level may result in the overflow of the replenisher causing the corrosion of terminals, etc.

Always charge the battery by running the engine after adding replenisher. Especially in cold weather, the battery may freeze and be damaged if it is not charged after replenishment.

· When replenishing the battery fluid, be

ADVICE

Battery electrolyte is dilute sulfuric acid and can burn your skin and clothing. If battery electrolyte should contact your clothing, wash the area thoroughly with soap and water. If it should contact your skin or eyes, immediately flush your skin or eyes thoroughly with clean water and get prompt medical treatment.

WARNING

· Since the batteries produce flammable hydrogen gas, keep electric sparks and burning cigarette end away from the batteries. It is very dangerous and could cause hydrogen gas catch fire and cause the batteries to explode. · Do not use the battery when the battery fluid level has dropped to the “LOWER” level or even lower. This accelerates deterioration, and there is the danger of overheating or explosion.

3-8

ENGINE CAN HAVE A NICE REST BY ESTABLISHING NECESSARY MEASURE FOR IMMOBILIZATION

EC08-001A

WHEN THE ENGINE IS NOT OPERATED FOR A LONG TIME When the engine is idle for a comparatively shorter period (approximately less than three months) · Securely cover all fuel, oil, grease, air and coolant related openings, and take care to prevent moisture.

·

WHEN THE ENGINE CAN BE OPERATED WHILE IN STORAGE Run the engine once a week for warm-up operation, so that lubricating oil reaches all parts.

When the engine is going to be idle for a period of time, it should be stored in a dry warehouse according to the procedures described below.

LONG-TERM STORAGE OF THE ENGINE

PROPER OPERATION

1. Rust prevention measures for engine itself a. After removing the oil from the oil pan, replace it with Antirust Oil described on page 3-10, filling in the oil in the same way that engine oil is supplied. b. By using the normal fuel, run the engine at a constant speed for about 15 minutes, then stop it. c. Drain all the fuel from inside the tank, replace it with new fuel and run the engine at idling speed until the antirust oil has spread throughout the fuel system.

Manual”.

· For this work, refer to the “Workshop

ADVICE

When the engine is idle for a long time (approximately for more than three months) be sure to store the engine according to the following procedures.

d. When the engine has cooled down enough, remove the nozzle. After making sure that the upper part of each piston is at the center of the cylinder liner, spray Antirust Oil into the interior of the cylinder liner (until the oil accumulates up to the point above the pistons) and then mount the nozzle. e. Remove the cylinder head cover, and spray Antirust Oil on the rocker arms and other moving parts. After loosening the adjusting screw, install the head cover. f. Drain the coolant completely, and then close all the drain cocks. g. When the rust prevention measures are all completed, be sure to seal all fuel, oil, grease, air and coolant related openings with waterproof tape. h. Touch-up the coat of painted parts and apply a thin layer of antirust oil to processed painted parts.

2. Rust prevention measures for accessories a. After cleaning the air cleaner, seal it with waterproof tape. b. Clean the insides of the alternator, the starter and the relays with dry compressed air and cover them with dustproof, waterproof covers. c. Loosen the tension of the belt. d. Charge the battery fully after filling up with replenisher or distilled water, and disconnect all its cables. Be sure to recharge the battery about once a month.

Manual”.

· For this work, refer to the “Workshop

ADVICE

(1) Drain the antirust oil from the oil pan.

(2) Remove the cylinder head and check the inside of the cylinder liner to make sure it has not rusted. (Corrective measures will be needed, if there is too much rust.) Pour the engine oil on the cylinder liner walls and the top of the piston, and then let the engine rotate a couple of times by hand.

CAUTION NOTES FOR ENGINES WHICH ARE NOT TO BE USED FOR THREE MONTHS OR MORE When reusing an engine that has been idle for more than three month and has not been warmed up periodically, be sure to perform the following inspection and maintenance before using the engine.

If the engine is kept idle for more than a year, perform the above procedures repeatedly.

ADVICE

PROPER OPERATION

(3) Check and adjust the valve clearance.

(4) Fill the oil pan with engine oil up to the specified level.

(5) Replace the oil filters and fuel filters.

(6) Before the test run of the engine, idle the engine with the starter for about 10 seconds to make sure all of the parts are lubricated. Also open the cylinder head cover and make sure the rocker arm bearing and the push rod are sufficiently lubricated.

(7) Drain the anticorrosion oil from the oil pan.

(8) During the test run, check that there are not any leakage of fuel, coolant and gas. During the test run, check that there are not any leakage of fuel, coolant and gas.

(9) After starting the engine, use the fault diagnosis tool (HinoDX) using a personal computer to check if the fault code is detected.

3-9

Mobil Kote 503

Shell Ensis Engine Oil 30

MOBIL

SHELL

P1010 Antirust P1020 P1030

Preservative 30

CALTEX

ESSO

Antirust Oil (for lubrication)

Maker

RECOMMENDED ANTIRUST OILS

3-10

PROPER OPERATION

ADVICE

·

length of service time are mentioned for the intervals of inspection and maintenance, follow whichever comes first.

Items in this section are based on the standard specifications of HINO industrial engines. Depending on the machine model, they may be different for your engine. Please refer to the “OPERATION MANUAL” of your machine.

· In the event that both operation hours and

·

nance can result in serious accidents, or engine trouble. In addition, damages resulting from the lack of maintenance may not be covered by warranty.

Be sure to perform regular inspections even when the engine is not being used for an extended period of time.

· Failing to perform regular mainte-

WARNING

This section contains a description of simple maintenance procedures that can be performed by you. For information on detailed inspection, replacement of parts and adjustments that you cannot perform yourself, please contact the nearest your dealer.

AIR BLEEDING OF THE FUEL SYSTEM ............................... P4- 16

FUEL FILTER .................................... P4- 9

ENGINE OIL FILTER ......................... P4- 6

INSPECTION OF EACH PARTS .......... P4- 6

THE COLOR OF THE EXHAUST GAS .................................................. P4- 6

FUEL LEVEL ..................................... P4- 5

TENSION AND DAMAGE OF THE BELTS ....................................... P4- 4

COOLANT LEVEL AND LEAKAGE FROM THE COOLING SYSTEM .................. P4- 3

ENGINE OIL LEVEL .......................... P4- 3

DAILY (BEFORE STARTING THE ENGINE) INSPECTION.. ............ P4- 3

PRECAUTIONS OF SAFETY .............. P4- 2

4. INSPECTION AND MAINTENANCE

BR(0702)ADD02.PDF

HE00 - 004A

PERIODIC INSPECTION ................. P4- 30

PERIODIC INSPECTION AND MAINTENANCE .. .. ................... P4- 30

SCR SYSTEM ................................. P4- 27

DPR (EXHAUST GAS AFTER TREATMENT SYSTEM) ..... P4- 26

STARTER ........................................ P4- 25

ALTERNATOR ................................. P4- 24

INSPECTION OF THE COOLING SYSTEM ......................................... P4- 21

ADJUSTMENT OF THE BELT TENSION ........................................ P4- 19

FUEL STRAINER ............................ P4- 18

4-1

·

·

·

exhaust system are very hot just after the engine has been stopped. Be sure to let the engine cool down before you start to work, you may suffer burns yourself.

When replacing the various types of oil, oil filters and coolant, be sure to wait until they have cooled down sufficiently. They are very hot just after the engine has stopped and you may suffer burns yourself.

When disposing the oil, coolant and parts that have been replaced, be sure to do so in an environmentally safe manner.

Be sure not to have contact with the revolving parts of the engine while it is running. Your hand and foot or clothing may get caught, resulting in unexpected injury or accidents.

· Engine parts such as the radiator and

WARNING

1. Perform the inspection and the maintenance work in a safe place.

2. Be sure to stop the engine and remove the starter key.

3. Use appropriate tools, machines and measuring devices for the inspection and maintenance work.

4. Wear appropriate clothing during the inspection and the maintenance work.

HE00 - 005A

5. After the inspection and the maintenance, perform a test run of the engine to make sure that all parts are functioning properly.

·

Doing so may cause damage and failures.

When disposing the oil, coolant and parts that have been replaced, be sure to do so in an environmentally safe manner.

· Do not step on pipes and accessories.

ADVICE

WARNING

BE CAREFUL NOT TO LEAVE ANYTHING BEHIND

ED01 - 001A

After finishing the work, be careful not to leave rag, paper and any tool in the engine compartment. Especially, flammable materials can cause fire.

INSPECTION AND MAINTENANCE

PRECAUTIONS OF SAFETY

4-2

HIGH Z404E-02

For details of replenishment of the oil, please refer to “ENGINE OIL” on page 5-2.

MAKE SURE THE ENGINE IS ON THE LEVEL GROUND.

1. Pull out the oil level gauge and wipe off the oil sticking to the gauge by using a rag.

2. Reinsert the gauge fully and pull it out again.

Z404E-01

If the oil is remarkably dirty, or the oil level exceed the X mark in the oil level gauge with full level indicator (X mark), replace the oil.

CAUTION

[LOW],it is normal.

If the oil is insufficient, replenish the oil through the oil filler.

· If the oil sticks to the range of [HIGH]-

LOW

Full Level

WAIT MORE THAN 30 MINUTES AFTER THE ENGINE IS STOPPED.

If the engine has been running, stop the engine and wait at least 30 minutes before checking the oil level.

ADVICE

When checking the oil level or replenishing the oil, make sure the engine is on the level ground.

ENGINE OIL LEVEL

Daily inspection (before starting the engine) is the inspection performed by the operator once a day before the engine is started.

DAILY (BEFORE STARTING THE ENGINE) INSPECTION

4-3

ant from radiator or its hoses.

Also, check to see if there is any trace of coolant leakage under the engine.

If the coolant level is excessively low, there is a danger of coolant leakage from the cooling system. Contact the specified your dealer.

For details of replenishment of the coolant, please refer to “INSPECTION OF THE COOLING SYSTEM” on page 4-21.

· Check whether there is any leakage of cool-

radiator and the reserve tank are sufficient.

· Check to see that the levels of coolant in the

HE02 - 003A

the sub-tank while the coolant temperature is still high. Hot water or steam may spray out, causing burns.

· Never remove the cap of the radiator or

WARNING

COOLANT LEVEL AND LEAKAGE FROM THE COOLING SYSTEM

INSPECTION AND MAINTENANCE

ADVICE

CRANKSHAFT PULLEY

FAN PULLEY

WATER PUMP PULLEY

[P11C]

ALTERNATOR PULLEY

[J08E] A

A

B

HE03 - 014A

IDLER PULLEY

ALTER NATOR PULLEY

HE03 - 009A

CRANKSHAFT PULLEY

FAN PULLEY

· Measure belt tension at point A and B.

Always stop the engine when inspecting the V-belt. Do not touch rotating parts while the engine is running. Hands or clothing may be caught and pulled in, and severe injuries may be caused.

WARNING

MEASURING POSITION OF THE ALTERNATOR BELT AND THE BELT

TENSION AND DAMAGE OF THE BELTS

TL08 - 001A

DEFLECTION

·

·

a pressure to the center of the belt with your finger and if the amount of deflection is within the standard value.

Measure the belt defection by applying a pressure of approximately 98 N {10 kgf, 22 lbf} with your finger or a belt tension gauge, a special tool (Part number: 09444-1210) to the midway between the two pulleys.

If the tension is out of the standard value, make a necessary adjustment of the tension.

For details on the adjustment of the belt, please refer to “ADJUSTMENT OF THE BELT TENSION” on page 4-19.

· Check the belts for proper tension by applying

BELT

MEASURING POSITION (MIDWAY BETWEEN THE TWO PULLEYS)

How to measure the deflection

INSPECTION AND MAINTENANCE

· Check the coolant level and add the coolant while the engine is cold. · When the coolant inspection is performed while the water temperature is high, the water volume appears larger than the actual volume because of the expansion of the water.

4-4

17 - 19 mm {0.67 - 0.75 in}

13 - 15 mm {0.51 - 0.59 in}

When inspected

12 - 14 mm {0.47 - 0.55 in}

When new belt replaced

9 - 11 mm {0.35 - 0.43 in}

Standard Value Measuring Position (B)

4 - 6 mm {0.16 - 0.24 in}

When inspected

When new belt replaced 3 - 5 mm {0.12 - 0.20 in}

them with the new belts if damaged.

· Also check the belts for damage. Replace

P11C

Engine model

P11C

J08E

Engine model

Standard Value Measuring Position (A)

STANDARD DEFLECTION OF THE BELT The items mentioned here are based on the standard specifications of HINO industrial engines. Depending on the machine model, they may not be the same for your engine. Please refer to the “OPERATION MANUAL” of your machine.

ADVICE

FUEL LEVEL

4-5

Leakage of fuel is dangerous (including at the pipe and hose connections) and can cause a fire. If fuel is leaking, replace the gaskets at each connection or retighten them. Always confirm that the leakage has stopped. If the leakage does not stop, turn off the engine immediately and have an inspection performed at the specified service shop.

WARNING

Check to see if there is sufficient fuel in the tank.

Also, make sure that there is no leakage of fuel.

INSPECTION AND MAINTENANCE

Do not operate the engine in a poorly ventilated area. It is dangerous because the exhaust gas can cause carbon monoxide poisoning.

WARNING

If an abnormality is found, have an inspection performed at the specified service shop.

Due to cold weather in winter the smoke may appear white. Be careful not to get confused.

Colorless ........ Complete combustion Black....... Incomplete combustion White...... Oil combustion due to oil loss by way of piston ring or valve guides

HE05 - 001A

ENGINE OIL FILTER

After warming up the engine sufficiently, check the color of the exhaust gas.

Different types of oil filters (full-flow by-pass center bolt type, full-flow by-pass spin-on type) are used for the various types of machine, depending on what the engine is used for.

This section describes the typical oil filters used for HINO industrial engines.

INSPECTION OF EACH PARTS

with the engine oil change. If the oil filter warning lamp lights up, replace the oil filter element regardless of hours of operation.

In case of engines equipped with turbochargers, be sure to use the specified (recommended) brand engine oil to ensure the performance of turbocharger.

· Replace the oil filter element simultaneously

Replacement intervals for the element are different depending on the type of machine. Please refer to the “OPERATION MANUAL” of your machine.

ADVICE

Every 500 hours of operation

Replacement intervals

OIL FILTER ELEMENT REPLACEMENT INTERVALS

INSPECTION AND MAINTENANCE

THE COLOR OF THE EXHAUST GAS

4-6

O-RING

WASHER SPRING

O-RING

ED03 - 001A

DRAIN PLUG

CENTER BOLT

O-RING

FILTER COVER

HE07 - 004A

Spin-on type (full-flow by-pass type)

SEAT

O-RING

ELEMENT

O-RING

Center bolt type (full-flow by-pass type)

REPLACEMENT PROCEDURE

1. Place a container for the oil to be drained under the oil filter and then drain the oil by loosening the drain plug at the lower part of the oil filter.

2. Loosen the center bolt by approximately one turn to facilitate the draining of the oil.

To ensure safety and to prevent the ground from getting dirty, make sure all of the drained oil is drained into a container.

3. After draining, tighten the drain plug securely.

4. After removing the center bolt, remove the element together with the filter cover.

Be careful not to lose the spring and the washer.

When the oil is drained soon after driving, it will be hot, which could cause severe burns; therefore, this should only be done after the temperature has dropped.

WARNING

Center bolt type As dirt may get into the oil filter, be sure to remove all dirt and dust from around the filter before starting to work.

4-7

After replacement of the oil filter, operate the engine for trial to check again to see if there is any oil leakage around the oil filter. Oil leakage can cause a fire.

WARNING

5. Wash all parts except the element and the Oring with commercial diesel fuel.

6. Install new element in the filter cover, in reverse order of disassembling.

Element cannot be washed and reused.

Install new O-rings included in the element kit.

When installing, make sure not to damage the O-rings by twisting. Also, pay attention not to install the element in reverse direction.

7. After replacing the element, run the engine and let the element be fully soaked with oil, then check the engine oil level.

INSPECTION AND MAINTENANCE

1. Place a container for the oil to be drained under the oil filter and then drain the oil by loosening the drain plug at the lower part of the oil filter.

2. Remove the element by turning it to the left using an oil filter wrench, a special tool.

To ensure safety and to prevent the ground from getting dirty, make sure all of the drained oil is drained into a container.

3. Remove all dirt and mud that may be sticking on the sealing face (contact face of the element gasket) of the filter main body.

When the oil is drained soon after driving, it will be hot, which could cause severe burns; therefore, this should only be done after the temperature has dropped.

WARNING

After replacement of the oil filter, operate the engine for trial to check again to see if there is any oil leakage around the oil filter. Oil leakage can cause a fire.

WARNING

4. Apply oil to the gaskets of the new oil filter element and install it by turning it lightly by hand to the right until it comes in contact with the sealing face of the main body.

Be sure to use the new gasket contained in the element kit.

When installing, make sure not to damage the gasket by twisting.

Do not reuse the old element.

5. From this state, tighten the filter element by approximately 3/4 to 1 turn using an oil filter wrench, a special tool.

6. After replacing the element, run the engine and let the element be fully soaked with oil, then check the engine oil level.

INSPECTION AND MAINTENANCE

Spin-on type As dirt may get into the oil filter, be sure to remove all dirt and dust from around the filter before starting to work.

4-8

BOWL

RED COLOR WIRE

PRIMING PUMP

[Type-1]

On machine

DRAIN VALVE

AIR BLEEDER PLUG

HE08 - 014A

AIR BLEEDER PLUG

HE08 - 014B

1. Place a container to receive the drained water under the drain valve.

2. Loosen drain valve and air bleeder plug to drain water gathered in the fuel filter.

DRAIN VALVE

[Type-2]

ADVICE

4-9

CAUTION follow the processing regulation specified in each region, when disposing of it.

· Drained water contains fuel, therefore,

·

·

clean, always collect the fuel in a container.

Keep burning cigarettes etc. away during work. Otherwise there is the danger of parts catching fire.

Never expose the fuel filter to brake fluid and organic solvents (such as parts cleaner and paint thinner) to prevent the drain bowl from cracking resulting in a fire.

· For safety and to keep the ground

WARNING

Drain the water when the float ring of the BOWL reaches the RED COLOR WIRE.

INSPECTION AND MAINTENANCE

DRAINING WATER FROM FUEL FILTER

FUEL FILTER

BR(0702)ADD02.PDF

ADVICE

In the case of Type-2 filter, drain water every 120 hours.

·

spilled water and fuel and check again if there is any leakage of fuel after running the engine.

Leaking fuel may cause a fire.

· After draining water, wipe out all the

WARNING

HE08 - 001A

WATER DRAINING BOLT

AIR BLEEDER BOLT

·

clean, always collect the fuel in a container.

Keep burning cigarettes etc. away during work. Otherwise there is the danger of parts catching fire.

· For safety and to keep the ground

WARNING

1. Place a container to receive the drained water under the drain pipe.

2. Loosen the air bleeder bolt and the water draining bolt of the fuel filter to drain water gathered at the bottom of the fuel filter case.

DRAIN PIPE

JOINT BOLT

On engine

CAUTION

·

work, a thorough bleeding of the pipe must be performed after work completion. (Refer to page 4-16.)

Insufficient air venting can cause an engine malfunction.

· As air enters the fuel piping during

loosened.

· Check to see the air bleeder bolt is

CAUTION

3.Tighten the water draining bolt.

4.Actuate the priming pump and bleed air from the fuel system.

Drained water contains fuel, therefore, follow the processing regulation specified in each region, when disposing of it.

INSPECTION AND MAINTENANCE

3. Make sure to tighten drain valve and air bleeder plug without fail.

4-10

·

spilled water and fuel and check again if there is any leakage of fuel after running the engine.

Leaking fuel may cause a fire.

· After draining water, wipe out all the

WARNING

6.9 2N• m {70 20 kgf• cm}

Tightening Torque

5.Tighten the air bleeder bolt.

ADVICE

Every 500 hours of operation

Replacement Intervals

· Replacement intervals for the element are different depending on the type of machine.

Please refer to the “OPERATION MANUAL” of your machine. · Replacement intervals for the element are different according to the fuel situation in the use region.

·

· ·

between components are free of dirt before starting to install the parts.

Use an original Hino fuel filter element.

As air enters the fuel piping during work, a thorough bleeding of the pipe must be performed after work completion. (Refer to page 4-16.)

Insufficient air venting can cause an engine malfunction.

· Make sure that the contact surfaces

water into the system during work.

· Take care to prevent entry of dirt or

CAUTION

REPLACEMENT OF FUEL FILTER ELEMENT

4-11

Follow the processing regulation specified in each region, when disposing of drained water and fuel.

CAUTION

clean, always collect the fuel in a container. · Carefully wipe off any fuel splashed onto engine parts. Otherwise it may cause a fire. · Keep burning cigarettes etc. away during work. Otherwise there is the danger of parts catching fire.

· For safety and to keep the ground

WARNING

Draining of fuel 1. Place a container to receive the drained fuel under the drain valve.

2. Loosen the air bleeder plug and drain valve to drain the fuel inside the fuel filter.

If water is also gathered, refer to “DRAINING WATER FROM FUEL FILTER (On machine filter)” on page 4-9 to drain water.

On machine <Type-1>

INSPECTION AND MAINTENANCE

DRAIN VALVE

AIR BLEEDER PLUG

HE08 - 014A

HE08 - 011A

Remove dirt around the filter body thoroughly, particularly around the air bleeder plug.

2. Remove the element.

FUEL FILTER WRENCH

3. Turn the bowl about a 3/4 turn after the gasket of the bowl makes contact with the element and then install the bowl on the element.

Do not reuse the gasket.

Before mounting, apply fuel to the gasket surface.

Tighten the element by hand without using any tool.

The following items must be observed as a fire may be caused by fuel leakage. · Do not reuse the element. · Replace old gaskets with new gaskets contained in the element kit. · Be careful not to damage the gaskets by twisting. · Check to see if the gaskets firmly contact to the sealing surface.

WARNING

Installing the fuel filter element 1. Remove any dirt or foreign materials on the fitting surface of the fuel filter element.

2. Install the new element on the filter body by turning it about a 7/8 turn after the gasket makes contact with the filter body.

Before mounting, apply fuel to the gasket surface.

Tighten the element by hand without using any tool.

After installing the fuel element, make sure to wipe out the spilled oil and check to see if there is any leakage of fuel, after running the engine.

Leaking fuel may cause a fire.

WARNING

6. Tighten the air bleeder plug.

loosened.

· Check to see the air bleeder plug is

CAUTION

fluid and organic solvents (such as parts cleaner and paint thinner) to prevent the drain bowl from cracking resulting in a fire.

· Never expose the fuel filter to brake

WARNING

4. Tighten the drain valve.

5. Actuate the priming pump to bleed air from the fuel system.

INSPECTION AND MAINTENANCE

1. Remove the bowl from the filter body using a fuel filter wrench (Part number: 09553-1050A), a specified special tool. Clean the bowl and the groove of the gasket.

Remove dirt around the bowl thoroughly.

Do not damage or throw out the bowl, because it is used again.

BOWL

RED COLOR WIRE

PRIMING PUMP

Removing the fuel filter element

4-12

DRAIN VALVE

ELEMENT

AIR BLEEDER PLUG

HE08 - 011B

CASE

O-RING

Draining of fuel 1. Prepare a container for drain oil.

2. Close the fuel cut valve placed on the halfway of the fuel filter line.

3. Loosen the air bleeder plug and the drain valve, and drain fuel from the fuel filter.

On machine <Type-2>

· Do not reuse the element. Replace old O-rings. · Be careful not to damage the O-rings by twisting. · Check to see if the O-rings firmly contact to the sealing surface.

CAUTION

Installing the fuel filter element 1. Remove dirt and foreign matter from attaching surface.

2. Apply light oil to new O-rings thinly, set it to the case and replace it with new element.

3. Fit the case to the filter head by hand securely and tighten it with specified filter wrench (KOBELCO Parts number: YT01T01008P1).

Removing the fuel filter element 1. Fit the specified filter wrench (KOBELCO Parts number: YT01T01008P1) to the lower side of stiffening ribs and remove the case.

2. Remove the drain valve.

4-13

4. Tighten the air bleeder plug and the drain valve and position the fuel cut valve of the fuel line to "OPEN".

5. Bleed air according to the air bleeding procedure for the fuel system.

INSPECTION AND MAINTENANCE

DRAIN PIPE

CAP

TM04 - 017A

DRAIN VALVE

CENTER BOLT AIR BLEEDER PLUG

·

·

clean, always collect the fuel in a container.

Carefully wipe off any fuel splashed onto engine parts. Otherwise it may cause a fire.

Keep burning cigarettes etc. away during work. Otherwise there is the danger of parts catching fire.

· For safety and to keep the ground

WARNING

Draining of fuel Clean the area around the fuel filter before the start of work. Otherwise dirt may enter.

1. Provide a waste oil container under the fuel filter.

2. After loosening the drain plug, loosen the air bleeder plug and drain the fuel from the drain pipe.

At this time, drain all fuel from the filter. When the element is replaced without draining all of the fuel, unfiltered fuel may remain inside the filter and later may cause engine failure.

CAUTION

TM04 - 023A

ELEMENT

Removing the fuel filter element 1. Loosen the center bolt, remove the cap, and then remove the element.

6.9 2.0 N•m {70 20 kgf•cm}

Tightening Torque

3. Confirm that no more fuel flows from the drain pipe and then tighten the drain plug.

Follow the processing regulation specified in each region, when disposing of drained fuel.

INSPECTION AND MAINTENANCE

<Center bolt type> The fuel filter is an element type. Its purpose is to remove moisture and fine dirt particles from the fuel; the element is made from resin and paper.

Every 500 hours of operation

Replacement intervals

On engine

4-14

6.9 2.0 {70 20}

AIR BLEEDER PLUG

Refer to page 4-16 for bleeding air from the fuel system.

After replacing the element, start the engine, make a test run, and confirm that there are no fuel leaks around the filter. Leaking fuel may cause a fire.

WARNING

2. After installation, bleed the air from the fuel system

Replace the gasket by the new gasket included in the element kit.

Do not reuse the element.

29.4 4.9 {300 50}

CENTER BOLT

(N•m {kgf•cm})

Tightening Torque

Installing the fuel filter element 1. After replacing the element by a new one, install the cap and tighten the center bolt and the air bleeder plug.

Follow the processing regulation specified in each region, when disposing of drained fuel.

CAUTION

· For safety and to keep the ground clean, always collect the fuel in a container. · Carefully wipe off any fuel splashed onto engine parts. Otherwise it may cause a fire. · Keep burning cigarettes etc. away during work. Otherwise there is the danger of parts catching fire.

WARNING

Draining of fuel 1. Place a container to receive drained fuel under the drain pipe.

2. Loosen the air bleeder bolt to drain the fuel.

<Spin-on type>

INSTALL HE08 - 013A

·

container to ensure safety and keep the ground clean.

If fuel is spilled on engine parts, wipe it off entirely. It is dangerous since it can cause a fire.

· Be sure to drain the fuel into a

WARNING

Dirt may enter the fuel filter. Before working, be sure to clean around the fuel filter.

1. Remove the element by turning it counterclockwise with the special tool – fuel filter wrench.

REMOVE

4-15

AIR BLEEDER BOLT

Removing the fuel filter element

INSPECTION AND MAINTENANCE

After replacing the element, start the engine for test run and check that there is no fuel leakage around the filter. Fuel leakage may be a dangerous fire hazard.

WARNING

DRAIN VALVE

AIR BLEEDER PLUG

HE08 - 014A

1. Place a container to receive drained fuel under the fuel filter.

2. Loosen the air bleeder plug and send fuel pumping the priming pump.

Put the rag to the air bleeder plug to absorb drained fuel.

3. Pump the priming pump until the fuel without bubbles comes out from the air bleeder plug.

4. Tighten the air bleeder plug 1.69-2.26 N•m {17.2-23kgf•cm, 1.2-1.6 lbf•ft} if the fuel without bubbles comes out from the air bleeder plug.

5. After air bleeding is completed, wipe off any leaked fuel. Run the engine and check for fuel leakage.

PRIMING PUMP

On machine

AIR BLEEDING PROCEDURE

After replacing the fuel filter or if you have run out of fuel, air might have entered the fuel system and a simple supply of fuel cannot start the engine. Bleed the air according to the following procedure:

AIR BLEEDING OF THE FUEL SYSTEM WARNING

CAUTION

WARNING Never expose the fuel filter to brake fluid and organic solvents (such as parts cleaner and paint thinner) to prevent the drain bowl from cracking resulting in a fire.

·

first attempt, wait for recovery of battery function approximately 30 seconds before attempting your second trial.

Do not turn the starter key for more than 15 seconds consecutively at a time.

· If you cannot start the engine at your

·

container to ensure safety and keep the ground clean.

If fuel is spilled on engine parts, wipe it off entirely. It is dangerous since it can cause a fire.

· Be sure to drain the fuel into a

INSPECTION AND MAINTENANCE

Installing the fuel filter element 1. Clean the dirt and mud on the seal surface (contact surface of the element gasket) of the fuel filter body.

2. Apply fuel to the gasket of a new element and install the element by lightly turning clockwise by hand until it touches the seal surface of the body.

Be sure to use a new gasket contained in the element kit.

When installing, be careful not to damage the gasket by twisting.

Do not reuse the element.

3. In this state, additionally tighten the element about a 2/3 turn by using the special tool – fuel filter wrench.

4. After installation, bleed the air from the fuel system.

4-16

HE11 - 004A

DRAIN PIPE

AIR BLEEDER BOLT

(Spin-on type)

TM04 - 017A

DRAIN VALVE

CENTER BOLT AIR BLEEDER PLUG

1. Place a container to receive drained fuel under the drain pipe.

2. Loosen the air bleeder bolt.

3. Turn the priming pump to the left and move it up and down with floating it.

HE11 - 003A

PRIMING PUMP

DRAIN PIPE

CAP

On engine (Center bolt type)

CAUTION

·

first attempt, wait for recovery of battery function approximately 30 seconds before attempting your second trial.

Do not turn the starter key for more than 15 seconds consecutively at a time.

· If you cannot start the engine at your

·

container to ensure safety and keep the ground clean.

If fuel is spilled on engine parts, wipe it off entirely. It is dangerous since it can cause a fire.

· Be sure to drain the fuel into a

WARNING

6. Pump the priming pump again more than 20 times.

7. Tighten the priming pump to the right fully with pressing it down.

8. Make sure there is not any fuel leakage.

6.9 2 N•m {70 20 kgf•cm}

Tightening Torque

4. Pump the priming pump until the fuel without bubbles comes out from the drain pipe.

5. Tighten the air bleeder bolt.

ADVICE

4-17

· It is dangerous since fuel leakage (including connections of each pipe and hose) can cause a fire. If fuel is leaking, replace the gaskets at each connection or retighten them. · Always confirm that the leakage has stopped. If the leakage does not stop, turn off the engine immediately and have an inspection performed at the specified service shop.

WARNING

INSPECTION OF FUEL PIPE AND HOSE Fuel pipes and hoses are important for safety.

Inspect them as follows: · Check connections and clips for looseness and tighten firmly if loosened. · Check for scratches, rust, wear and hose deterioration. Replace if necessary.

Do not entwist the priming pump piston forcibly when housing it, since it may be jammed and damaged.

INSPECTION AND MAINTENANCE

FUEL STRAINER

TM05 - 005A

Be sure to replace with a new gasket.

bolt of the fuel pipe of the feed pump. Wash the strainer in light oil.

· Take out the fuel strainer by removing the joint

STRAINER

As air enters into the fuel piping during the work, air venting must be performed after fuel strainer washing. (Refer to page 4-16.)

·

·

·

engine for test run and check that there is no fuel leakage around the joint bolt. Fuel leakage may be a dangerous fire hazard.

Be sure to drain fuel into a container for securing safety and avoiding contamination of the ground.

If any part of the engine gets fuel, thoroughly clean off. There is the danger of supporting a flame.

Do not bring a burning cigarette close to this area while working. There is the danger of catching fire.

· After installing the strainer, start the

WARNING

CAUTION At the time of installation of the fuel strainer, install it after confirming that the contact surfaces between parts are free of dirt. Entering dirt into the strainer may cause failure of the engine.

INSPECTION AND MAINTENANCE

JOINT BOLT

Every 120 hours of operation

Washing interval

Applies to P11C engine

WASHING THE FUEL STRAINER

4-18

·

·

a lack of initial adaptability of the belt. Run the engine at idling speed for about three to five minutes. After that, adjust the belt tension again.

New belts get complete initial elongation after being run about two hours.

When you replace belts which are two in one set, make sure to replace both of them.

· When replaced with a new belt, there is

ADVICE

Every 120 hours of operation

Tension adjustment intervals

BELT TENSION ADJUSTMENT INTERVALS

Looseness or excessive tension of the belts can cause an improper charging or failure of the alternator or water pump.

Always adjust the tension of the belts to ensure correct tension.

CAUTION

There are different types of belts used for the machine, depending on what the engine is used for. Typical belts are described here.

ADJUSTMENT OF THE BELT TENSION

CRANKSHAFT PULLEY

FAN PULLEY

WATER PUMP PULLEY

[P11C]

ALTERNATOR PULLEY

[J08E]

· A

A

B

HE03 - 014A

IDLER PULLEY

ALTER NATOR PULLEY

HE03 - 009A

CRANKSHAFT PULLEY

FAN PULLEY

MEASURING POSITIONS OF THE ALTERNATOR BELT AND THE BELT Measure belt tension at point A or B.

P11C

Engine model

P11C

J08E

Engine model

17 - 19 mm {0.67 - 0.75 in}

13 - 15 mm {0.51 - 0.59 in}

9 - 11 mm {0.35 - 0.43 in}

When new belt replaced

12 - 14 mm {0.47 - 0.55 in}

When inspected

Standard Value Measuring Position (B)

4 - 6 mm {0.16 - 0.24 in}

When inspected

4-19

When new belt replaced 3 - 5 mm {0.12 - 0.20 in}

Standard Value Measuring Position (A)

STANDARD TENSION OF THE BELT

INSPECTION AND MAINTENANCE

BOLT a

[P11C]

BOLT AND NUT b

ALTERNATOR PULLEY

ADJUSTING BOLT c

[J08E]

·

A

A

HE13 - 007A

BOLT AND NUT b

ALTERNATOR PULLEY

ADJUSTING BOLT c

BOLT a

TM13 - 001A

3. After adjusting the tension, tighten the bolt a and then tighten the bolt and nut b securely.

4. Tighten the adjustment bolt c and fix securely.

When moving the alternator pulley, be careful not to damage the stator coil located between the front and rear parts and the through bolt.

ADVICE

1. Loosen the bolt a and the bolt and nut b.

2. Measure the belt deflection of the point A (midway between the pulleys) by applying and holding a pressure of about 98 N {10kgf, 22 lbf} to the point A with your finger, or by using a belt tension gauge (part number: 09444-1210) of a special tool. If the deflection is out of standard, adjust it by turning the adjusting bolt c so that the deflection comes to within the standard. · The tension of the belt can be increased by turning the adjusting bolt c to clockwise.

B

HE13 - 011A

LOCK NUT a

ADJUSTING BOLT b

IDLER PULLEY

1. Loosen the lock nut a.

2. Turn the adjusting bolt b and adjust the deflection of the belt so that it comes to within the standard.

3. After the adjustment, securely tighten the lock nut a.

CRANKSHAFT PULLEY

FAN PULLEY

[P11C]

· Measure the belt deflection at point B.

FAN BELT ADJUSTMENT PROCEDURE

INSPECTION AND MAINTENANCE

ALTERNATOR BELT ADJUSTMENT PROCEDURE Measure the belt deflection at point A.

4-20

When using an LLC other than HINO’s genuine LLC, refer to the “OPERATION MANUAL” of the machine being checked by you.

Use tap water (soft water) to mix with long life coolant (LLC).

Hard water from rivers or from the well will cause the formation of water stain and rust.

ADVICE

Hino genuine Long Life Coolant (LLC density: 50%) · Pink type · Blue type

THE COOLANT TO BE USED

INSPECTION OF THE COOLING SYSTEM

50

50

·

·

tirust.

When you replenish LLC, use the same brand and same density of LLC. If you replenish water only, density of LLC becomes low and efficiency of anti-rust and anti-freeze will be decreased.

· Do not use together with Anti-freeze, An-

ADVICE

WATER %

LLC %

PREPARATION OF COOLANT LLC-WATER MIXING TABLE

4-21

CAUTION

ADVICE If the LLC gets on a painted surface, immediately rinse it with water.

·

clothes, immediately rinse with water and then wash with soap and water.

When storing the LLC, make sure to cover it and store it out of reach of the children.

· If the LLC gets on your skin or

away from fire.

· LLC is flammable. Keep the LLC

·

If you drink it by mistake, immediately vomit it and get a medical treatment.

If the LLC enters your eyes, immediately wash your eyes with clean water and get medical treatment.

· LLC is poisonous. Never drink it.

WARNING

HANDLING OF LLC

INSPECTION AND MAINTENANCE

When using an LLC other than HINO’s genuine LLC, refer to the “OPERATION MANUAL” of the machine being checked by you.

Replace the coolant when it is sufficiently cool.

Every 4 years (Blue type)

Every 3 years (Pink type)

Replacement interval

OPEN

[J series engine]

[P series engine]

CLOSE

TM11 - 006A

HE14 - 006A

DRAIN PLUG (PART OF OIL COOLER)

HE15 - 010A

DRAIN PLUG (PART OF OIL COOLER)

DRAIN PLUG (INJECTION PUMP SIDE)

1. Open each drain plug of the engine and drain the coolant.

Never operate the engine without refilling the coolant after draining. This will cause a failure of the water pump and an engine seizure.

ADVICE

Dispose of LLC and antifreeze with a method that is environmentally sound.

Failing to comply with may be a violation of the law.

CAUTION

2. After completing draining, close each drain plug.

INSPECTION AND MAINTENANCE

REPLACEMENT OF THE COOLANT INSIDE THE ENGINE Replacement interval Hino genuine Long Life Coolant · Pink type · Blue type

4-22

Fill in coolant slowly, as air may get trapped in the system.

TM11 - 050A

3. Coolant replenishing method a. Slowly (7 minutes or more) fill in coolant (long-life coolant + tap water) up to the filling port of the radiator.

TM11 - 051A

UPPER HOSE

SQUEEZE THE RADIATOR UPPER HOSE TWO OR THREE TIMES

b. Fill coolant up to the filling port, and squeeze the radiator upper hose two or three times.

Squeezing the hose lets the air in the hose escape, lowering the coolant level and making room for more coolant.

4-23

d. Fill in coolant until the liquid level of the reserve tank is at "FULL", and then tighten the cap.

When the cap is not closed securely, hot coolant may spurt out when the engine starts to overheat.

ADVICE

c. Tighten the radiator cap securely after ensuring that coolant has been filled up to the filler neck; check to make sure that the level has not dropped (5 seconds).

INSPECTION AND MAINTENANCE

TM11 - 009A

Interfusion of air into the coolant can cause overheating and coolant leakage from the water pump.

ADVICE

BLEED AIR AFTER IDLING ABOUT 10 MINUTES

When the cap is not closed securely, hot coolant may spurt out should the engine overheat.

ADVICE

g. After refilling, close the reserve tank cap securely.

Never remove the radiator cap until the water temperature has dropped sufficiently. If the cap is opened too early, hot water or steam may spurt out, which may cause severe burns.

WARNING

f. Stop the engine and after the engine has cooled down, remove the radiator cap again and check if the coolant is filled up to the cap opening level and close the radiator cap securely.

Then check the amount of coolant in the reserve tank and refill it to bring the coolant to the proper level (refill proportionally to the decreased quantity by air bleeding).

ALTERNATOR

·

the engine is running. Turning these switches off while the engine is running will generate high voltage and can damage the diode.

Always turn the starter switch off when the engine has been stopped.

· Never turn off the starter switch while

CAUTION

The alternator can be damaged by high temperature, excess voltage and over current.

Observe the following precautions to prevent damage to the alternator.

INSPECTION AND MAINTENANCE

e. To ensure correct venting of the air in the engine and the piping, run the engine at a slightly higher speed than normal idling, bring the needle of the water temperature gauge close to the center of the gauge, and continue idling for another 10 minutes.

4-24

ED17 - 002A

· If you want to fast charge, please remove the battery terminal. The diode may burnout if you do not remove it. · When cleaning (including high-pressure washing), do not pour water on the alternator. Do not aim steam directly to the alternator when using steam cleaner. · Always use the specified type of fuse and make sure it is installed securely.

Please refer to the operation manual of your machine.

DO NOT MAKE MISCONNECTIONS.

tions of alternator, relays, battery, etc.

Particularly when the polarity of the battery is reversed, an excessively large current will flow, which can burn the diodes or the wiring; also, this may cause an electric shock or a fire.

· Take care not to confuse the connec-

WARNING

·

·

·

Every 1,000 hours of operation

Inspection interval

INSPECTION INTERVALS In case of alternators equipped with brushes Inspect and clean the brushes and the slip rings.

Measure the brush length and replace it with a new one, if necessary.

Refer to workshop manual for detail.

STARTER

4-25

Every 1,000 hours of operation

Inspection interval

INSPECTION INTERVAL

1. Each of the terminal is marked with an inscription. Be sure not to make any error of connecting mark and connect the terminal correctly.

2. Inspect and clean the commutator and the brush. If the commutator surface deteriorates or gets burned, it will result in bigger sparks.

Polish the surface with a No. 400 sandpaper and wipe clean with a dry cloth.

If a brush is worn by more than 2/3, replace it with a new one. · Refer to workshop manual for detail.

INSPECTION AND MAINTENANCE

WARNING

·

amperage.

In addition, please do not use copper wire and wire instead of the fuse.

If you use another type of fuse other than ones specified, it may cause fire due to overheating of the wiring.

Please refer to the operation manual of your machine.

Please never wash at high-pressure the zone around the engine.

The connector around the engine is designed to be a waterproof structure, but high-pressure washing will make the waterproof rubber deform and water will enter the connector inside it. Since it is a waterproof structure, water that enters the interior once can no longer go out and may cause rust and electrolytic corrosion.

Let the nearest your dealer replace the sensor hoses approximately every 3 years (2 years with general purpose use).

ADVICE

DPR filter every 4,500 hours.

Please consult about the DPR maintenance and inspection in the nearest specified service shop.

Check the body of the exhaust gas purification device, the sensor wiring and hoses attached to the body for damage.

If damage (cracking etc.) of the sensor hose surface is found at the time of inspection, replace the hose immediately. Please consult your nearest specified service shop.

· Please execute cleaning or exchanging the

Every 4,500 hours of operation

Maintenance interval

MAINTENANCE INTERVAL

DPR (EXHAUST GAS AFTER TREATMENT SYSTEM)

WARNING

DPR

SCR

· If the inspect or maintenance is not done, the engine and the DPR (exhaust gas after treatment system) might become in a slump. Check the exhaust pressure while the engine is running.

Please consult your nearest specified service shop for inspection of the exhaust pressure and for maintenance of the DPR (exhaust gas after treatment system).

ADVICE

Do not inspect the sensor wiring and hoses directly after driving. The exhaust pipe and the muffler surroundings will be hot and there is the danger of burns.

INSPECTION AND MAINTENANCE

· Please use a fuse of the specified

4-26

WHAT IS AdBlue/DEF? AdBlue/DEF serves as a carrying agent for the ammonia needed to reduce nitrogen oxide (NOx) emissions from diesel engines. When AdBlue/ DEF is injected into the engine exhaust gas upstream of the SCR catalyst, it will be rapidly hydrolyzed producing the oxidizing ammonia needed by the SCR system to lower the level of NOx emissions. · AdBlue/DEF is crystallized as white powder when it is dried. If you find the crystallized AdBlue/DEF on the surface of the AdBlue/ DEF tank, wipe it off with clean cloth. · Keep your face away from AdBlue/DEF and do not sniff the AdBlue/DEF when you open the filter cap of the AdBlue/DEF tank. AdBlue/ DEF may produce an odor when it is warmed up.

WHAT IS SCR? SCR is an abbreviation for “Selective Catalytic Reduction”, a general term for after treatment system which promotes a chemical reaction by using a catalyst for eliminating or detoxifying particular chemical ingredients. By mixing the NOx with the ammonia contained in AdBlue/ DEF, NOx will be separated into water and nitrogen.

This vehicle is equipped with SCR (Selective Catalytic Reduction) system for reduction of NOx (nitrogen oxide) emission.

SCR SYSTEM

·

of SCR system and your safety, always follow the instructions below.

If you need to replace any parts related to SCR system, genuine parts are required. Contact an authorized nearest your dealer for the replacement of parts and repair of SCR system.

· In order to maintain proper function

WARNING

SCR SYSTEM PRECAUTIONS

Use if AdBlue/DEF is required for the reduction of pollutant emissions.

Operation of this vehicle without use of AdBlue/DEF may be a criminal offence under the local regulation.

WARNING

· If you dispose of the AdBlue/DEF follow your local regulations. · The AdBlue/DEF in the AdBlue/DEF tank freezes at -11°C (12°F). If the AdBlue/DEF in the AdBlue/DEF tank is frozen, do not warm the AdBlue/DEF tank by using the burner and heater. The vehicle is equipped with the defrost device, and frozen AdBlue/DEF will be defrosted while driving.

4-27

·

modification to the AdBlue/DEF supply pump, AdBlue/DEF injector, AdBlue/DEF tank and AdBlue/DEF pipes.

Be sure to wait for at least ten minutes after the key is turned to the “OFF” position before you disconnect the battery terminals from the battery, as the vehicle data is recorded on the ECU and DCU starts working for the exhaust gas after treatment after the key is turned to the “OFF” position.

Otherwise, the vehicle data will not be recorded on the ECU properly and the DCU will not work properly, which may result in the malfunction of the DPR and the AdBlue/DEF-SCR system.

· Never reposition nor make any

INSPECTION AND MAINTENANCE

· ·

surface on the housing is no acceptable.

Wrench size: 27mm When removing the filter cover, the AdBlue/ DEF will spill over. Prepare the container and waste cloth for spilled AdBlue/ DEF.

· Contamination or damage of the sealing

CAUTION

FILTER COVER

FILTER REMOVAL TOOL

INSERT THIS SIDE IF FILTER IS BLACK

DP125113ZA

INSERT THIS SIDE IF FILTER IS GREY

4. Select "BLACK(B)" side of the filter removal tool.

3. Check that the end face of the filter is black.

Prying forcefully with a screwdriver when replacing the filter may cause damage to the AdBlue/ DEF pump body and urea leakage.

CAUTION

EQUALIZING ELEMENT

2. Remove the equalizing element from the AdBlue/ DEF pump.

CAUTION

FILTER

contamination. · The sealing surface on the housing must be clean. No contamination or particles acceptable.

· Protect the filter area in the housing from

FILTER REMOVAL TOOL

5. Remove the filter from the AdBlue/ DEF pump using filter removal tool.

INSPECTION AND MAINTENANCE

AdBlue/DEF PUMP FILTER Replacement 1. Turn the filter cover counter-clockwise and remove it from the urea solution pump.

4-28

FILTER COVER

7. Tighten the filter cover.

DP125116ZA

For the mounting process, oil the Oring with the Mobile Verocite No.6 or equivalent.

CAUTION

O-RING

6. Apply oil to the O-ring and replace with the new filter and new equalizing element.

·

·

·

INSPECTION OF AdBlue/DEF AND COOLANT LEAKAGE Check there is no AdBlue/DEF leakage from the AdBlue/DEF tank, AdBlue/DEF pump, AdBlue/DEF injector or AdBlue/DEF pipes.

Check there is no coolant leakage from the AdBlue/DEF tank, AdBlue/DEF pump, AdBlue/ DEF injector or coolant pipes.

If you find any leakages of the AdBlue/DEF and coolant, have your vehicle checked and repaired by your dealer.

20 to 25 N • m {204 to 254 kgf • cm, 15 to 18 lbf • ft}

Filter Cover Tightening Torque

tamination or particles are not acceptable. · It must be checked if there are cracks around the area of the filter cover. No cracks in the material are allowed. If there are cracks in the housing, the entire supply module must be exchanged. If there are cracks in the filter cover, the filter cover must be exchanged. · Wrench size: 27 mm

· All sealing surface must be clean. Con-

CAUTION

·

·

·

·

WARNING

4-29

Do no inspect the AdBlue/DEF and/or coolant leakage just after the engine stop. The exhaust pipe, muffler and coolant temperature is high. Doing so cause burn injury.

WARNING

INSPECTION OF AdBlue/DEF AND COOLANT TUBES AND HOSES Check the crack, damage, bentness of the AdBlue/DEF and coolant tubes and hoses.

Inspect the connector of the tubes and hoses are securely connected.

Inspect the fixing clips of the tubes and hoses are not loosen.

If you find any leakages of the AdBlue/DEF and coolant tube and hoses, contact your dealer.

Do no inspect the AdBlue/DEF and/or coolant leakage just after the engine stop. The exhaust pipe, muffler and coolant temperature is high. Doing so cause burn injury.

INSPECTION AND MAINTENANCE

3. Checking and cleaning of air cleaner and replacement of element

○

2. Checking tightening condition of oil pan and related accessorie mounting area

○

New engine with 30 hours of operation

○

OPERATION HOURS 120

○

250

○

500

INSPECTION INTERVALS (OPERATION HOURS)

1. Checking tightening condition of intake and exhaust manifolds

AIR INTAKE AND EXHAUST SYSTEM

2. Checking of compression

1. Checking of valve clearance

MAIN BODY

ITEM

PERIODIC INSPECTION

The table lists items requiring daily and periodic inspection.

To get maximum performance from the engine and extend its service life, be sure to carry out inspection and maintenance in accordance with the periodic inspection and maintenance tables.

PERIODIC INSPECTION

◎

○

○

○

1000

(

NOTES

: Check,

(Continued)

: Replace)

Note: (1)Inspection intervals are based on the standard specifications of HINO industrial engines. Depending on the machines, they may be different from your engine. Please refer to the "OPERATION MANUAL" of your machine.

(2)More frequent inspections may be required, depending on the conditions under which the engine is used.

INSPECTION AND MAINTENANCE

PERIODIC INSPECTION AND MAINTENANCE

4-30

5. Replacement of fuel hose

○

Every 2 years

Daily inspection

4. Checking of fuel tank strainer

: Replace)

(Continued)

Refer to "OPERATION MANUAL" of your machine

3. Draining of water from fuel filter

◎

NOTES

: Check,

4-31

Refer to "OPERATION MANUAL" of your machine. ＊: In case of using oil other than HINO's genuine oil.

Every 500 hours

○

○

1000

(

2. Replacement of fuel filter element (on engine)

1. Replacement of fuel filter element (on machine)

FUEL SYSTEM

4. Checking of leakage of lubricant system of turbocharger

◎

◎＊

○

500

3. Replacement of by-pass oil filter and oil filter element

○

250

◎

○

○

120

◎＊

○

New engine with 30 hours of operation

2. Replacement of oil filter element

1. Checking whether water and diesel fuel get mixed in the oil pan interior

LUBRICATION SYSTEM

3. Checking play of rotor

2. Checking rotating condition of rotor and impeller

1. Checking tightening condition of each parts of turbocharger

TURBOCHARGER

ITEM

OPERATION HOURS

INSPECTION INTERVALS (OPERATION HOURS)

INSPECTION AND MAINTENANCE

OPERATION HOURS

○

1000

Every 2 years

Every 3 years (Pink type)＊ Every 4 years (Blue type)＊

Daily inspection

○

Check performance before the start of winter. (Check for broken wires, etc.)

: Replace)

Hino genuine Long Life Coolant (Pink type or Blue type). When using an LLC other than HINO’s genuine LLC, refer to the “OPERATION MANUAL” of the machine being checked by you.

(Continued) When using biodiesel fuel, the maintenance interval maybe changed.

4. Checking performance of heater plug and intake air heater (start assistance device)

3. Checking electric wiring

NOTES

: Check,

P series, E series engine

Once a year ○

○

○

500

2. Checking battery electrolyte specific gravity and voltage

250

Daily inspection

○

○

120

(

1. Checking battery electrolyte level

ELECTRICAL EQUIPMENT

7. Cleaning radiator and inter-cooler fins

6. Replacement of rubber hose of coolant pump

5. Checking performance of thermostat

4. Cleaning cooling system

○

○

2. Checking tightening condition of fan mounting bolt

3. Replacement of coolant

○

1. Checking of belt tension and damage

COOLING SYSTEM

7. Washing of fuel strainer

New engine with 30 hours of operation

INSPECTION INTERVALS (OPERATION HOURS)

INSPECTION AND MAINTENANCE

6. Draining of sediments and water from fuel tank interior

ITEM

4-32

Every 4,500 hours

7. DPR

Every 2 years Every 7 years

1. AdBlue/DEF filter

2. NOx sensor

SCR SYSTEM

Daily inspection

○

5. Checking exhaust pipe and muffler

NOTES

: Check,

6. Checking meters, gauges and lamps

○

Daily inspection

3. Checking leakage of fuel system related parts

4. Checking air suction rubber hose

Daily inspection

○

Daily inspection

(

2. Checking engine oil leakage

1. Retightening pipe joints

OTHERS

2. Functional inspection of the compressor, the pressure regulator and the unloader valve

1. Inspection for water in the air tank

AIR COMPRESSOR

○

1000

8. Checking performance of regulator

○

500

○

250

7. Checking and cleaning alternator brush

○

120

○

New engine with 30 hours of operation

6. Checking and cleaning starter brush and commutator

5. Checking performance of starter

ITEM

OPERATION HOURS

INSPECTION INTERVALS (OPERATION HOURS)

INSPECTION AND MAINTENANCE : Replace)

4-33

INSPECTION AND MAINTENANCE

◎

◎ 1 ◎

INSPECTION INTERVALS (OPERATION HOURS) New engine with 30 hours 30 120 250 500 of operation

1 : In case of using oil other than HINO's genuine oil.

2. Star ter

1. Engine

ITEM

INTERVALS, ETC.

"OPERATION MANUAL" of your machine.

1000

When disassemble it

Refer to the "GREASING" on page 5-4

: Replace)

Before star ting the engine

REMARK

(

Refer to the "ENGINE OIL SELECTION" on page 1-4

USING OIL & GREASES

· Depending on the machines, the requirements for your engine may be different. Please refer to the

with the standard specifications.

· Inspection, refilling and replacement intervals shown here are recommended for HINO industrial engines

POINTS OF LUBRICATION AND LUBRICATION INTERVALS

4-34

5. LUBRICATION

HF00 - 003A

GREASING ......................................... P5- 4

ENGINE OIL ...................................... P5- 2

RECOMMENDED LUBRICANTS ........ P5- 2

Items contained in this section are based on the standard specifications of HINO industrial engines. Depending on the machine model, they may not be the same as your engine. Please refer to the “OPERATION MANUAL” of your machine.

ADVICE

5-1

When inspection and replacement intervals are indicated in both hours of operation and length of time, perform inspection and replenishment according to whichever comes first.

ADVICE

Handle the disposal of drained oil and grease with a method that is environmentally sound.

· After replenishment or replacement of oil, wipe off the oil deposited around the oil filter cap or filler plug and drain plug and be sure to check to see if there is any oil leakage. · Be sure to wipe off the oil scattered around. Leaving it may result in catching fire, which is very dangerous.

WARNING

PRECAUTIONS DURING OIL REPLENISHMENT AND REPLACEMENT When changing the oil, be sure to use a container for the drained oil.

Engine oil must offer stable performance in high temperature and resist oxidation. The oil viscosity must remain consistent in a wide range of temperature. Hino genuine engine oils have been made to satisfy such performance and you are recommended to use proper oil according to your condition of usage.

It is necessary to use engine oils of different viscosity values in summer and winter. Select an appropriate oil type in accordance with your engine operating condition.

Periodical replenishment and replacement of oil and grease play an important role in the maintenance of performance quality, prolongation of service life and prevention of accidents. Be sure to follow the recommendations.

Hino genuine lubricants have been made to satisfy such engine performance and you are highly recommended to use Hino genuine lubricants when you replenish or replace lubricants periodically.

ADVICE

ENGINE OIL

LUBRICATION

RECOMMENDED LUBRICANTS

5-2

ADVICE

When replenishing the oil, be sure not to spill any oil. If the oil sticks to the exhaust pipe, it may catch fire due to its high temperature. Be careful when replenishing.

WARNING

REPLENISHMENT 1. If the oil level is insufficient, replenish engine oil through the oil filler.

In order to maintain a trouble-free functioning of the DPR (exhaust gas after treatment system) for a long time, it is recommended to use the specified (recommended) brand of engine oil.

OIL FILLER CAP

HF02 - 004A

2. Check the oil level 10 minutes after replenishing.

For details of checking the oil level, please refer to the “ENGINE OIL LEVEL TABLE” on page 5-4. The position of the oil filler cap may be different depending on the machine.

Please refer to the “OPERATION MANUAL” of your machine. placement intervals may be different from your engine. Please refer to the “OPERATION MANUAL” of your machine. · If the engine is used frequently at high revolutions and under high loads, oil deteriorates quickly.

Change the engine oil early regardless of the specified intervals. When the oil is notably dirty at the time of oil level inspection, or when the oil level exceeds the “FULL LEVEL” (Xmark) (refer to page 4-3), change the oil earlier, independent of the operation hours. · Simultaneously with oil replacement, make sure to replace the oil filter element.

· Depending on the machine model, oil re-

ADVICE

Every 500 hours of operation

Replacement intervals

REPLACING OF ENGINE OIL

LUBRICATION

2. After the oil is completely drained, tighten the drain plug securely.

3. Fill the oil through the oil filler. (For the specified oil level for each engine model, refer to “ENGINE OIL LEVEL TABLE” on page 5-4.)

4. About 10 minutes after filling the oil, check the oil level with the oil level gauge. (Refer to page 4-3.)

5. Start the engine and run it in idling.

6. Stop the engine. Wait more than 30 minutes and after that, check the oil level with the oil level gauge. If the oil level is low, replenish the oil. Also check the drain plugs for leakage.

When the engine oil is drained soon after driving, it will be hot and there is the danger of burns; therefore, this should be done when the temperature has dropped sufficiently.

WARNING

1. Remove the oil filler cap and drain plug of the oil pan to drain oil. Also drain oil from the oil filter. · The oil can be drained more easily if the engine is warm.

5-3

Bathtub type

Deep-set

Oil pan shape

23

26

17

20

31.5

28.5

Total oil

Max. Min. capacity

Oil level (L)

PRECAUTIONS DURING GREASING Shortage of grease may result in an excessive play, abnormal noises and seizure due to premature wear of different parts. Always maintain correct greasing to prevent it.

Remove mud or dirt from grease nipples, bleeders and places to be greased before you start greasing.

After greasing, be sure to wipe off the excessive grease.

P11C

J08E

Engine model

Items contained here are based on the standard specifications of HINO industrial engines. Depending on the machine model, they may not be the same as your engine.

Please refer to the “OPERATION MANUAL” of your machine.

ADVICE

ENGINE OIL LEVEL TABLE

5-4

To ensure long service life of engine, you must perform the required lubrications according to the specified schedule. Points to be lubricated may be different depending on the machines.

Please refer to the “OPERATION MANUAL” of your machine.

GREASING

LUBRICATION STARTER (Reference)

5

7 6 2

HF03 - 004A

1

Starter grease (N.L.G.I. No.2 Lithium-soap) Bearing grease (N.L.G.I. No.2 Lithium-soap)

4

3

[POINTS TO BE LUBRICATED ON THE STARTER]

locations shown in the illustration.

1. Metal A (front) 2. Metal B (pinion) 3. Bearing A (center) 4. Bearing B (rear) 5. Reduction gear 6. Shift lever 7. Engage switch tip

· Whenever disassembled, lubricate the seven

To ensure a long service life of Hino industrial vehicles, drive and operate them correctly; daily inspections, maintenance, and periodic inspections must be performed to prevent breakdowns. In case of a malfunction, perform correct servicing to avoid damage to the vehicle or an accident.

When any of the following problems appear, check and repair according to the following tables. If a problem is unclear or if repair is not possible, have the nearest your dealer check and repair the engine.

6. TROUBLESHOOTING

HF00 - 004A

ENGINE OIL CONSUMPTION IS EXCESSIVE ...................................... P 6- 3

FUEL CONSUMPTION IS EXCESSIVE ..................................... P 6- 3

EXHAUST GAS IS BLACK ................ P 6- 3

ENGINE OVERHEATS ...................... P 6- 3

ENGINE LACKS IN POWER ............. P 6- 3

ENGINE STALLS AT LOW SPEED .............................................. P 6- 2

ENGINE DOES NOT STOP ............. P 6- 2

ENGINE DOES NOT START ............ P 6- 2

6-1

Follow the proper preheat procedure.

Contact the nearest your dealer.

Malfunction of preheating device

Engine stalls at low speed

Engine does not stop

4-16 ― ― ―

Bleed air.

Remove the sheet, etc.

Clean or replace the element.

Replace the hose.

Contact the nearest your dealer.

Accumulation of air in the fuel system

Air cleaner air inlet is stopped up by sheet, etc

Clogged air cleaner element (Dust indicator shows red signal.)

Crushed intake air hose

Possible switches related trouble

1-2

―

4-9

Fill fuel in the tank.

―

―

Replace the element.

Contact the nearest your dealer.

Engine stop lever is engaged

Idling speed is too low

―

―

Lack of the fuel in the tank

Contact the nearest your dealer.

Crushed intake air hose

―

―

―

4-16

4-9

1-2

―

3-3

―

Dir ty fuel filter

Clean or replace the element.

Replace the hose.

Clogged air cleaner element (Dust indicator shows red signal.)

Remove the sheet, etc.

Air cleaner air inlet is stopped up by sheet, etc

Water in the fuel tank

Bleed air.

Warm up the fuel line with hot water (below 60° C {140°F}).

Drain water.

Replace the element.

Replace with proper oil.

Engine oil viscosity is too high

Improper operation of the preheat

Dir ty fuel filter

Contact the nearest your dealer.

Malfunction of the star ter and the electric system

Fill fuel in the tank.

5-2

Connect the ground wire properly.

Disconnected ground wire

Lack of fuel in the tank

―

Tighten securely after cleaning corroded par ts.

―

Charge or replace the batter y.

Page to refer ―

The batter y terminal is off, loosened, or corroded

Remedies

Discharged batter y

Possible cause

TROUBLESHOOTING

Accumulation of air in the fuel system Star ter operates normally Frozen fuel line

Star ter does not operate or operate slowly

Probleme

Engine does not star t

6-2

Clean the radiator with detergent.

Check the actuation of the thermostat.

Remove the sheet, etc.

Crushed intake air hose

Clogged front of the radiator

Radiator is clogged with scale

Thermostat faulty (Closed)

Air cleaner air inlet is stopped up by sheet, etc

5-2 5-4

Replace the filter element.

Warm-up the engine properly.

Clogged oil filter

Omission of engine warm-up

3-4

4-6

5-3

Oil level is too high

Replace at proper inter vals.

Drain excessive oil and make it proper level.

Use of unsuitable oil

―

―

―

Replace with proper oil.

Crushed intake air hose

―

―

―

―

―

―

―

―

4-21

―

―

―

―

4-16

Page to refer 4-9

6-3

In case of looseness of bolts and nuts, retighten them.

Clean or replace the element.

Replace the hose.

Clogged air cleaner element (Dust indicator shows red signal.)

Check the fuel system and retighten if loose.

Remove the sheet, etc.

Air cleaner air inlet is stopped up by sheet, etc

Crushed intake air hose

Fuel leakage

Clean or replace the element.

Replace the hose.

Clogged air cleaner element (Dust indicator shows red signal.)

Insufficient coolant

Clean or replace the element.

Replace the hose.

Check leakage of coolant and add coolant. Bleed air sufficiently.

Clean the front of the radiator.

Clogged air cleaner element (Dust indicator shows red signal.)

Drain fuel from the tank and refill with diesel fuel.

Remove the sheet, etc.

Air cleaner air inlet is stopped up by sheet, etc.

Bleed air.

Accumulation of air in the fuel system

Remedies

Fuel is not diesel fuel

Replace the element.

Dir ty fuel filter

Possible cause

Engine oil consumption Oil leakage is excessive Replacement inter val is too long

Fuel consumption is excessive

Exhaust gas is black

Engine overheats

Engine lacks in power

Probleme

TROUBLESHOOTING

MEMO

7. TABLE OF DIAGNOSIS CODE FOR TROUBLES

TABLE OF DIAGNOSIS CODE FOR TROUBLES ........................................ P7- 2

7-1

35

76 69,76 18 18 18

35

17 17 25 25

17

17

11

11

74

32

32

14 14

P0016

P0045

P0087 P0088 P0096 P0097 P0098

P00AF

P0101 P0104 P0106 P0108

P0112

P0113

P0117

P0118

P119F

P0122

P0123

P0182 P0183

TCCS

2-DIGT CODE 13

SAE CODE

J series engine

7-2

Fuel system pressure control - low Fuel system pressure control - high Intake air temperature sensor (intake manifold) - rationality Intake air temperature sensor (intake manifold) - out of range (Out of range low) Intake air temperature sensor (intake manifold) - out of range (Out of range high) VNT controller CAN communication (ECM) Power supply failure EEPROM failure Air flow sensor - rationality Air flow sensor - out of range Boost pressure sensor - rationality Boost pressure sensor - out of range (Out of range high) Intake air temperature sensor (air flow sensor built-in) out of range (Out of range low) Intake air temperature sensor (air flow sensor built-in) out of range (Out of range high) Engine coolant temperature sensor - out of range (Out of range low) Engine coolant temperature sensor - out of range (Out of range high) Fuel rail pressure sensor - rationality Intake throttle valve-opening sensor 1 out of range (Out of range low) Intake throttle valve position sensor 1 out of range (Out of range high) Fuel temperature sensor Low Fuel temperature sensor High

Crankshaft position sensor and Camshaft position sensor - rationality Nozzle position sensor failure DC motor open circuit DC motor short circuit Nozzle stuck Nozzle operating range failure Initialization failure

TROUBLE

P0404

P0401

P0191 P0192 P0193 P0200 P0201 P0202 P0203 P0204 P0205 P0206 P0217 P0219 P0234 P0237 P0263 P0266 P0269 P0272 P0275 P0278 P0335 P0336 P0340 P0341

SAE CODE

TROUBLE 2-DIGT CODE Fuel rail pressure sensor (main & sub) - out of range 74 74 Fuel rail pressure sensor (main) - out of range (Out of range low) 74 Fuel rail pressure sensor (main) - out of range (Out of range high) 71 Fuel injector driver charge circuit (circuit high) 61 Fuel injector - disconnection (#1cyl) 62 Fuel injector - disconnection (#2cyl) 63 Fuel injector - disconnection (#3cyl) 64 Fuel injector - disconnection (#4cyl) 65 Fuel injector - disconnection (#5cyl) 66 Fuel injector - disconnection (#6cyl) 6 Engine coolant over temperature condition 7 Engine overspeed condition 34 Overboost 25 Boost pressure sensor - out of range (Out of range low) 61 Injection quantity and timing (#1cyl) 62 Injection quantity and timing (#2cyl) 63 Injection quantity and timing (#3cyl) 64 Injection quantity and timing (#4cyl) 65 Injection quantity and timing (#5cyl) 66 Injection quantity and timing (#6cyl) 13 Crankshaft position sensor - disconnection 13 Crankshaft position sensor - rationality 12 Camshaft position sensor - disconnection 12 Camshaft position sensor - rationality 85 EGR low flow Valve position control failure - DC motor out of range, 81 functional (EGR valve stick failure)

TCCS

TABLE OF DIAGNOSIS CODE FOR TROUBLES

53

27

27

5 5 3 3 3 71 45 73 75 5 5 5 5 51 5 5 23 74 74 74 68 68 68 68

P0545

P0546

P0562 P0563 P0605 P0606 P0607 P0611 P0617 P0628 P0629 P0642 P0643 P0652 P0653 P0686 P06D3 P06D4 P1133 P1197 P1198 P119F P1211 P1212 P1214 P1215

2-DIGT CODE

TCCS

P0540

SAE CODE

81 46 2 57,78 57,78 91 27 27 95 97 95 31 31 31 22 22

P1459 P1530 P1601 P1681 P1682 P200C P2032 P2033 P203F P204F P207F P2100 P2101 P2103 P2120 P2123

81

P1458

Battery failure (Low) Battery failure (High) Flash ROM error Control module processor Control module performance Fuel injector driver charge circuit - circuit (circuit low) Starter switch - rationality Suction control valve for fuel supply pump - circuit (Circuit low) Suction control valve for fuel supply pump - circuit (Circuit high) ECU sensor supply 1 failure (Low) ECU sensor supply 1 failure (High) ECU sensor supply 2 failure (Low) ECU sensor supply 2 failure (High) ECM/PCM Power Relay Control Circuit high Air flow sensor power supply failure Short to GND Air flow sensor power supply failure(High) P.T.O. accelerator sensor (Hi) Fuel rail pressure sensor (sub) - out of range (Out of range low) Fuel rail pressure sensor (sub) - out of range (Out of range high) Fuel rail pressure sensor - rationality Fuel injector driver circuit 1 - circuit (Circuit low) Fuel injector driver circuit 1 - circuit (Circuit high) Fuel injector driver circuit 2 - circuit (Circuit low) Fuel injector driver circuit 2 - circuit (Circuit high)

28

P1428

Exhaust gas temperature sensor (DPR inlet)-out of range (Out of range low) Exhaust gas temperature sensor (DPR inlet)-out of range (Out of range high)

2-DIGT CODE 28

TCCS

P1427

SAE CODE

Air intake heater circuit malfunction

TROUBLE

7-3

Throttle/Pedal Position Sensor/Switch "D" Circuit Accelerator pedal position sensor 1 - out of range (Out of range high)

Intake throttle valve - functional DC motor for intake throttle valve - circuit (Short circuit (circuit high))

Valve position control failure - DC motor out of range, functional Valve link failure Low battery voltage EGR actuator malfunction 2 Engine stop switch malfunction Fuel injector adjustment data error Exhaust brake - Circuit (circuit low) Exhaust brake - Circuit (circuit high) DPR over temperature Exhaust gas temperature sensor (DPR outlet)-out of range (Out of range low) Exhaust gas temperature sensor (DPR outlet)-out of range (Out of range high) Empty reductant tank Reductant System Performance Improper reductant DC motor for intake throttle valve - circuit (Open circuit (circuit low))

Differential pressure sensor - out of range (Out of range high)

Differential pressure sensor - out of range (Out of range low)

TROUBLE

TABLE OF DIAGNOSIS CODE FOR TROUBLES

Engine ECU CAN communication (EGR valve controller)

Engine ECU CAN communication (VNT controller)

15

91

92

93

92

93

76

8

8

8

8

97

9

9

8

8

8

P2229

P244A

P244B

P2458

P2463

P24A2

P2635

U0073

U029D

U029E

U02A2

U0301

U1001

U110A

U1122

U1123

U010E

P0112

DPR filter clogged

P0187 P0188

Engine ECU CAN communication (NOx sensor (SCR downstream))

71

P0193 P0200

Engine ECU CAN communication (Vehicle control ECU)

Engine ECU CAN communication (DeNOx ECU)

74

P0192

74

74

11

Engine ECU CAN communication bus for vehicle control bus off

Software incompatibility with DeNOx ECU

P0191

14

P0118

Engine ECU CAN communication (NOx sensor (SCR upstream))

Engine ECU CAN communication (DEF tank sensor)

14

P0117

Engine ECU CAN communication bus for Emission control system - bus off 11

P0113

Suction control valve for fuel supply pump replacement

17

17

25

P0108

DPR regeneration duration

DPR regeneration incomplete by fuel consumption over

18

69,76

76

P0087 P0088

34

P0096

Incomplete regeneration

Filtering performance (missing substrate)

Barometric pressure sensor - out of range (out of range high)

35

2-DIGT CODE

TCCS

P0049

P0045

Barometric pressure sensor - out of range (out of range low)

15

Accelerator pedal position sensor 2 - out of range (Out of range high)

P2228

SAE CODE

TROUBLE

22

2-DIGT CODE

TCCS

P series engine

Fuel injector driver charge circuit (circuit high)

Fuel rail pressure sensor (main) - out of range (Out of range high)

Fuel rail pressure sensor (main) - out of range (Out of range low)

Fuel rail pressure sensor (main & sub) - out of range

Fuel temperature sensor circuit high input

Fuel temperature sensor circuit low input

Engine coolant temperature sensor - out of range (Out of range high)

Engine coolant temperature sensor - out of range (Out of range low)

Intake air temperature sensor (air flow sensor built-in) out of range (Out of range high)

Intake air temperature sensor (air flow sensor built-in) out of range (Out of range low)

Boost pressure sensor - out of range (Out of range high)

Intake air temperature sensor (intake manifold) - rationality

Fuel system pressure control - high

Fuel system pressure control - low

Turbocharger overrun

Nozzle position sensor failure DC motor open circuit DC motor short circuit Nozzle stuck Nozzle operating range failure Initialization failure

TROUBLE

TABLE OF DIAGNOSIS CODE FOR TROUBLES

P2128

SAE CODE

7-4

62

63

64

65

66

6

7

34

25

61

62

63

64

65

66

13

13

12

12

53

27

27

P0203

P0204

P0205

P0206

P0217

P0219

P0234

P0237

P0263

P0266

P0269

P0272

P0275

P0278

P0335

P0336

P0340

P0341

P0540

P0545

P0546

2-DIGT CODE 61

TCCS

P0202

P0201

SAE CODE

71 45

P0607 P0611 P0617

P1418 P1427 P1428

Exhaust gas temperature sensor (DPR inlet)-out of range (Out of range low)

Exhaust gas temperature sensor (DPR inlet)-out of range (Out of range high)

P1417

P1416

P1266

P1229

P1215

P1214

P1212

P1211

P1133

P1072

P1071

P0686

P0629

28

28

19

19

19,85

76

76

68

68

68

68

23

26

26

51

72

72

3

P0606

P0628

3

P0605

TCCS 2-DIGT CODE 3

SAE CODE

Air intake heater circuit malfunction

Camshaft position sensor - rationality

Camshaft position sensor - disconnection

Crankshaft position sensor - rationality

Crankshaft position sensor - disconnection

Injection quantity and timing (#6cyl)

Injection quantity and timing (#5cyl)

Injection quantity and timing (#4cyl)

Injection quantity and timing (#3cyl)

Injection quantity and timing (#2cyl)

Injection quantity and timing (#1cyl)

Boost pressure sensor - out of range (Out of range low)

Overboost

Engine overspeed condition

Engine coolant over temperature condition

Fuel injector - disconnection (#6cyl)

Fuel injector - disconnection (#5cyl)

Fuel injector - disconnection (#4cyl)

Fuel injector - disconnection (#3cyl)

Fuel injector - disconnection (#2cyl)

Fuel injector - disconnection (#1cyl)

TROUBLE

7-5

Differential pressure sensor - out of range (Out of range high)

Differential pressure sensor - out of range (Out of range low)

EGR coolant temperature sensor fault (High)

EGR coolant temperature sensor fault (Low)

EGR coolant temperature sensor characteristic abnormality

Supply pump malfunction

Supply pump excess forced feed

Fuel injector driver circuit 2 - circuit (Circuit high)

Fuel injector driver circuit 2 - circuit (Circuit low)

Fuel injector driver circuit 1 - circuit (Circuit high)

Fuel injector driver circuit 1 - circuit (Circuit low)

P.T.O. accelerator sensor (Hi)

Turbocharger speed sensor circuit low input

Turbocharger speed sensor circuit high input

ECM/PCM Power Relay Control Circuit high

Pump control valve 1 for fuel supply pump - circuit (Circuit high)

Pump control valve 1 for fuel supply pump - circuit (Circuit low)

Starter switch - rationality

Fuel injector driver charge circuit - circuit (circuit low)

Control module performance

Control module processor

Flash ROM error

TROUBLE

TABLE OF DIAGNOSIS CODE FOR TROUBLES

81

81

46

2

91

27

27

22

22

22

15

P1459

P1530

P1601

P200C

P2032

P2033

P2120

P2123

P2128

P2228

2-DIGT CODE

TCCS

P1458

SAE CODE

7-6

92 93 72 72 8 9 8

P2463 P24A2 P2633 P2634 U0073 U110A U1122

DPR over temperature

Exhaust gas temperature sensor (DPR outlet)-out of range (Out of range low)

Exhaust gas temperature sensor (DPR outlet)-out of range (Out of range high)

Throttle/Pedal Position Sensor/Switch "D" Circuit

Accelerator pedal position sensor 1 - out of range (Out of range high)

Accelerator pedal position sensor 2 - out of range (Out of range high)

Barometric pressure sensor - out of range (out of range low)

Fuel injector adjustment data error

8

93

P2458

Engine stop switch malfunction

U1123

91

EGR actuator malfunction 2

P244F

15

2-DIGT CODE

TCCS

92

P2229

SAE CODE

P244B

Valve position control failure - DC motor out of range, functional Valve link failure Low battery voltage

TROUBLE

Engine ECU CAN communication (VNT controller)

Engine ECU CAN communication (EGR valve controller)

Engine ECU CAN communication (Vehicle control ECU)

Engine ECU CAN communication bus for Emission control system - bus off

Pump control valve 2 for fuel supply pump - circuit (Circuit high)

Pump control valve 2 for fuel supply pump - circuit (Circuit low)

DPR regeneration incomplete by fuel consumption over

DPR filter clogged

DPR regeneration duration

DOC over temperature

Incomplete regeneration

Barometric pressure sensor - out of range (out of range high)

TROUBLE

TABLE OF DIAGNOSIS CODE FOR TROUBLES

MEMO

Pub. No. CT4-001E '15-07

PRINTED IN JAPAN

All rights reserved. This manual may not be reproduced or copied in whole or in part, without the written permission of Hino Motors, Ltd.

2015