HIND INDUSTRIAL ENGINE
MODEL
EPlOOT
CONTENTS
GENERAL INSTRUCTION
ENGINE
FUEL INJECTION PUMP
I
GENERATOR
STARTER
TURBOCHARGER
l:mfi:l
HIND MOTORS. LTU TOK YO .JAPAN
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
FOREWORD This shop manual is a general description of the instructions and repairs required for HINO MODEL EP1 00T industrial diesel engine.
It also covers the constructions and operational
characteristics of the engine. Daily and periodical inspection and maintenance are the most important factors governing the high performance of the engine. The proper sequences and methods outlined should be followed in repairs. It is recommended that the customers make full use of this manual in order to attain the maximum efficiency maintenance and repair
NOTE:
All specifications appearing in this manual are based on the metric system. However. as ready reference, conversion has been made as shown below: mm (in), m (ft), km (mile) cm2 (sq.in) mm3 (cu.in). cc (cu.in), m3 (cu.ft), liter (lmp.gal/U.S.gal) g (oz). kg (lb) kg-cm (lb.ft.), kg-m (lb.ft.), kg/mm (lb/in), kg/cm2 (lb/sq.in) m/s (ft/s), km/h (mph)
1-100E-01
GENERAL INSTRUCTIONS GENERAL INSTRUCTIONS ................................... 1-1 CHASSIS & ENGINE SERIAL NUMBERS .......................... 1-2 SPECIFICATIONS .......................................... 1-3 BOLT TIGHTENING ........................................ 1-7 RECOMMENDED LUBRICANT LIST ............................. 1-9
1-1
GENERAL INSTRUCTIONS
Fig. 1-1
03-2252
1-2 ENGINE SERIAL NUMBER The engine serial number is engraved on the left side of the cylinder block.
ENGINE MODEL
SM3-1035
. Fig. 1-2
1-3
SPECIFICATIONS DIESEL ENGINE FOR INDUSTRIAL USE
EPlOOT
HIND APPLICATION:
e
8.821 liters, 4-cycle, 6-cyl., water-cooled
ELECTRICAL GENERATORS, WATER PUMPS, AIR COMPRESSORS, HYDRAULIC CRANES & SHOVELS, ROLLERS, TOWING TRACTORS, FORK-LIFT TRUCKS, SHUNTING LOCOMOTIVES AND OTHER GENERAL POWER PLANTS
PERFORMANCE & PERFORMANCE CURVE (STD. specs.) GENERAL USE (SAE J1349 Gross)
Max. torque
Output,
Output,
kW (HP) at rpm
kW (HP) at rpm
Nm (lbt·tt) at rpm
127 1170) at 2,200
711 (525) at 1,600
intermittent rating 149 1200) at 2,200
continuous rating
Ambient conditions: Intake air temperature Barometric pressure Water vapour pressure
SAE ° 25 C 100 kPa 1.0 kPa
GENERATOR USE (SAE J1349 Gross) Min. fuel consumption g/kWh (lb/HPh)
at rpm
215 10.353) at 1,600
Prime Power
Stand-by Power Output at 1,500rpm kW (HP)
Output at 1,800rpm kW (HP)
Output at 1,500rpm kW (HP)
Output at 1,800rpm kW (HP)
110 (.148)
129 1173)
94 (126)
110 (1481
DIN °
20 c 736 mmHg 10.5 mmHg
e ENGINE DESCRIPTION
1. Type 2. Combustion system 3. Cylinder Bore x Stroke 4. Piston displacement 5. Compression ratio 6. Direction of rotation 7. Dimensions (L X W x H) 8. Dryweight
e
Diesel, 4-cyc., 6-cyl., in-line, overhead valve, water-cooled, turbocharged Direct injection type 120 x 130 mm (4.72 x 5.12 in) 8.821 liters (538.3 cu. in) 17.0 Counter-clockwise viewed from flywheel Approx. 1,255 x 820 x 1,100 mm (49.4 x 32.3 x 43.3 in) Approx. 770 kg (1,700 lb)
FEATURES
1. Cylinder block 2. Cylinder head 3. Crank shaft
4. Piston and rings 5. Camshaft 6. Valves
Mono block cast iron with replaceable dry type liners Single piece cast iron Induction-hardened die forged special steel with counter weights Heat-resistance aluminum alloy Three compression rings, chrome plated One oil ring, chrome plated with coil expander Induction hardened carbon steel Heat resistance steel
1-4
e
STANDARD EQUIPMENT Flywheel housing Flywheel Fuel injection pump Governor Fuel injection nozzle Fuel filter Water separator Cooling system Lubricating system Oil filter Intake manifold Exhaust manifold with flange plate 13. Generator
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
14. Starter 15. Safety valve 16. Connectors of electrical equipments
e
HI NO own (SAE No.2 type) HINO own (SAE 11-1/2 in. type) BOSCH "P" type Centrifugal, all speed control type BOSCH hole type Paper element type Forced-circulation by volute pump Full-forced pressure feed by gear pump Paper element type (full flow & by-pass flow) Inlet position at front or right side Rearward exhaust Alternator with integral regulator 24V-20A 24V-6KW
OPTIONAL EQUIPMENT 1. Cooling fan (suction or blowout) 2. Main switch 3. Battery switch 4. Battery relay 5. Starter switch with key 6. Ammeter 7. Fuse box 8. Engine shut off solenoid 9. Emergency relay 10. Coolant temperature switch 11. Coolant temperature gauge sender 12. Coolant temperature gauge 13. Oil pressure switch 14. Oil pressure gauge sendet 15. Oil pressure gauge 16. Intake heater 17. Intake heater relay 18. intake heater indicator 19. Tachometer with hourmeter 20. Tachometer cable 21. Muffler ................2-3 type available 22. Air cleaner 23. Air cleaner cap 24. Radiator with cooling fan shroud
1-5
SM3-1033 FRONT SIDE VIEW
LJ SM3-1034 LEFT SIDE VIEW NOTE: 1 i 2) 3) 4)
These specifications are subject to change without notice. These specifications are for export models. All specifications of the products are with normal manufacturing allowances and tolerances. The performance and drawings are for standard specifications.
HIND MOTORS, LTD.
TOKYO, JAPAN
1-7 BOLT TIGHTENING Bolt tightening torque chart-for general purpose
Bolt indentification
0 0 0 0 0 0 e e
:�
Even tightening area. Bolt nut, coating, naked bolt, lubricant, etc. Optimum conditions.
Cast iron or aluminium tightening
surface, Washers. Medium conditions.
Tightening area having black coarse
surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions.
Even tightening area. Bolt nut, coating, naked bolt. lubricant, etc. Optimum conditions.
Unit: kg·cm (lb.ft)
4 10-15 10.8~1.01
14 ~ 20 (1.1~1.41
17
~ 25
(1.3 ~ 1.81
6 36
~ 53
12.7 ~ 3.81
48
~ 71
(3.5 ~ 5.11
60
~ 88
8 88
~ 128
17 ~ 91
117~172
10 174 ~ 255
304~ 445
113 ~ 181
122~ 321
232
~ 340
(9~121
(17~ 241
~ 2·14
290 ~ 425
146
14
12
405
~ 592
(30~421
506
~ 742
486
~ 712
(36 ~ 511
647
~ 950
(47 ~ 681
809~ 1,180
14.4~ 6.31
(11 ~ 151
(21 ~ 301
(37 ~ 531
16 ~ 24
58 ~ 83
138 ~ 201
273 ~ 400
477~700
11.2 ~ 1.7)
14.2 ~ 6.01
(10 ~141
(20 ~ 281
(35 ~ 501
{56 ~ 81)
75 ~ 110
183 ~ 270
364 ~ 533
636 ~ 932
1.020 ~ 1,500
127 ~ 381
147 ~ 671
~ 32
Cast iron or aluminium tightening surface. Washers. Medium conditions.
(1.6~ 2.31
Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions.
(2.0 ~ 2.81
Even tightening area. Bolt nut, coating, naked bolt, lubricant, etc. Optimum conditions.
(1.8 ~ 2.31
Cast iron or aluminium tightening surface. Washers. Medium conditions.
(2.4 ~ 3.0f
Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions.
(2.9
22
27
~ 40
24 ~ 32
32
~ 42
40 ~ 53
~ 3.8)
15.5 ~ 7.91
94
~ 138
114
~ 19)
229 ~ 336
455
~ 667
795~ 1,165
16.8 ~ 9.91
117 ~ 241
133 ~ 481
(58 ~ 841
82 ~ 110
200 ~ 267
397 ~574
694~ 925
(15 ~ 191
(29 ~ 411
(51 ~ 661
(6.0 ~ 7.91
110~146
267
~ 356
529
~ 706
925 ~ 1,230
(59 ~ 851
764 ~ 1.120
174~ 1081
1,270
~ 1,870
192 ~ 1351
1,010 ~ 1,480 (74~1071
16 758 ~ 1,110 155 ~ 801
1,010
~ 1,480
(74~ 107)
1,260~ 1,850 (92 ~ 1331
1,190
~ 1,750
(87 ~ 126)
1,590~ 2,330 1116 ~ 1681
1,990
~ 2,920
(144 ~ 2111
1,730 1126
~ 2,310 ~ 1671
18 1,040
~ 1,530
2,700
~ 3,970
2,560
~ 3,750
1$970 ~ 2,900 (143 ~ 2091
1,740~ 2,540
2,460 ~ 3,620 (178 ~ 2611
~ 4,950
4,260
(126~1831
(245 ~ 3581
1,640~2,400
2,320 ~ 3,410
3,180~4,680
4,020
1119~1731
(168~ 2461
(231 ~ 3381
(291 ~ 3871
2,180
~ 3,200
(196 ~ 2871
3,380
(186 ~ 2711
3,410
~ 5,000
(247 ~ 3611
~ 6,250
1309 ~ 4521
~ 5,360
3,100~ 4,550
4,250 ~ 6,210
5,360 ~ 7,850
(158 ~ 2311
(225 ~ 3291
(308 ~ 4491
1388 ~ 5671
2,730 ~4,000
3,870 ~ 5,680
5,310 ~ 7,800
(198 ~ 2891
(280 ~ 4101
(385 ~ 5641
3,380 ~ 4.510
4,630 ~ 6,170
(244 ~ 3261
(335 ~ 4461
(424 ~ 5631
4.510~ 6,010
6,170 ~8,230
7,790 ~ 10,390
2,380
~ 3,170
(173 ~ 2291
3,170
~ 4,230
2,310~ 3,080
(108~1421
(168~222)
(230 ~ 305)
137 ~ 183
334 ~ 445
662~ 882
1,160 ~ 1,540
1,850 ~ 2,470
2,890 ~ 3,850
3,970~ 5,290
(10,0~ 13.2)
125 ~ 32)
(48~ 631
(210 ~ 2781
(288 ~ 3821
~ 1781
~ 2,980 ~ 2151
1101 ~ 1471
1,480 ~ 1,970
(134
1147
2,030
1,390 ~ 2,040-
(67 ~ BBi
(84 ~ 111)
~ 2,170
24
1108 ~ 1561
(3!J~61)
~ 10.51
1,480
22
(76 ~ 1101
(19 ~ 25)
(8 .0
20
(327
5,640
~ 434)
~ 7,510
1408 ~ 5431
(447 ~ 595)
7,720 ~ 10,290 (559
~ 744)
6, 700
~ 9,850
1485 ~ 7121
5,850
1564
9,740 (705
~ 7,790
~ 751)
~ 12,990 ~ 939)
NOTE: The torque values given in this table should be applilld where bott torque is not IJM(:ifilld.
RECOMMENDED LUBRICANTS FOR ALL HINO ENGINE LUBRICANTS
ATMOSPHERIC TEMP.
POSITIONS
ENGINE OIL Previous Class,fication
32' 190'
IA PI OSI
IMIL•L·2104CI
IA. P.1. CCI Previous Class1f1cat1on IA P.1 DMI IMIL-L-46152I IMIL-L-210481
132'
COOLANT PUMP BEARING GREASE
Coolan! Pump Bearing
(MIL-G-109248)
STARTER GREASE
Bushmg. Clulch. Onve Shah. P1nton Shih lever & Reduction Gear
GENERATOR & STARTER BEARING GREASE
Generator Bearing Si,rter Beanng
INJECTION PUMP TIMER GREASE
lnIact10n Pump Timer
ANTI FREEZE
Engine, Rad11to1
IMIL•G· 1092481
IMIL-H-5559AI
MOBIL
SHELL
TOTAL
Essolube 0-3 40. XD-3 40
Gulf Super Oury Motor 011 40. 1 SW-40
Mobd Oelvac 1 340 Mobil Oelvac Super 15W-40
Myr1na 0.1 40. 20W•40. 1 SW-40 A1mula X Otl 40 R1mula CT 40
TOTAL Aub,a S 40 TOTAL Rubra TM 1 SW40
32'F1
30
Vanellus C-3 30
RPM DELO 400 Oil SAE 30 or 1 5Wt40 RPM DELO 300 Cit SAE 30
Castrol or Otusol CRD 30 Castro, or Deusol AX Super 30. 1 SW/40
Essolube D-3 30. X0-3 30
Gutf Super Dutv Motor Oil 30, 1 SW-40
Mobtt Delvac 1 330 Mobtt Deh,ac Super 15W-40
Myrina Oil 30. 20W•40, 1 SW-40 Atmula X Otl 30. 10W•30 Atmula CTJO
TOTAL Rubia S 30 TOTAL Rubia TM 1 5W40
12'C 10'FI
20
Vanellus C-3 20W
RPM DELO 400 011 SAE 20120W. 1 SW:40 RPM DELO 300 011 SAE 20t20W
Castrot or Oeusol CAD 2ow,20 Castro! or Deusol RX Super 20Wt20. 1SW140
Essolube 0-3 20W. XD-3 1 SW,40
Gutf Super Duty Motor 011 20. 1 SW-40
Mobtl Delvac 1310 Mobtt Oelvac Super 15W-40
Myrina 011 20. 20W-40. 1 SW-40 R1mula X 011 20 A1mula CT20
TOTAL Rubia S 20 TOTAL Rubia TM 15W40
40
Vanellus M
RPM DELO 200 Oil SAE 40 RPM DELO 100 0,1
SAE 40
Castrol or Deusol CRX 40 Cawol or Deusol AX Super 40. 1 5Wt40
Essolube HOX 40. HOX Plus 40
Gulflube Motor 011 XHD 40. 1 SW-40
Mobil Oelvac 1240 Mobtl Oelvac 1 140
Rotella TX40.20W-50 Rotella SX 011 40, 20W·40
TOTAL Rubta H 40
o·c
Above 32'C I90'FI
o·
GULF
Castrol or Deusol CAD 40. Turbomu Castrol or Deusol RX Super 40. 1 SW/40
132'
32' 190'
ESSO
RPM DELO 400 Otl SAE 40 01' 1 5Wt40 RPM DELO 300 011 SAE 40
o·
ENGINE OIL
CASTROL
Vanellus C-3 40
IMIL-L-4519981
Cyhnde, Block tnIect10n Pump Air Cleaner
CALTEX
BP
40
Above 32'C I90'FI
IA PI. COi
S.A.E. NO.
HINO MOTORS. LTD. OVERSEAS OPERATIONS TECHNICAL DIV TOKYO. JAPAN
40
32'F)
30
Vanenus M 30
RPM DELO 200 Oil SAE 30 RPM DELO 100 01! SAE 30
Castro! or Deusol CRX 30 Castro! or Deusol RX Super 30. 15Wi40
Essolube HOX 30 HOX Plus 30
Gulflube Motor 0.1 XHD 30. 1 SW-40
Mobil Delvac 1230 Mobil Oelvac 1130
Rotella TX30.20W·50 Rotella SX Oil 30. 20W-40
TOTAL Rubia H 30
12·c 10-FJ
20
Vanellus M 20W
RPM DELO 200 Q,1 SAE 20t20W RPM DELO 100 Oil SAE 20120W
Castro! or Deusol CRX 2ow.-20 Castro! or Deusol RX Super 20W120. 15W 40
Essolube HDX 20. HOX Plus 20W-20
Gulflube Motor 011 XHO 20. 1 SW-40
Mobil Delvac 1220 Mobd Oelvac 1120
Rotelta TX20,20W-50 Rotella SX 011 20/20W.20W-40
TOTAL Rubia H 20
Energrease L·2
Marfak Multipurpose 2 o, Mar1ak All P\l"lpose 2
Castro! LM Grease
Esso Multipurpose Grease
Gulfle� Poly
Mob1lgrease MP,77.MS
Retina.: A Alvania Grease R2
TOTAL MULTIS 2
o·c
---
Molyt!!l Grease EP2
---
---
---
Mob1lgrease 29
A-,ro Shell Grease 1 7
---
Energrease LT 2
RPM Grease SRI 2
---
---
---
Mob,lgrease 2B
Aero Shell Grease 7
---
Energrease L-2
Mar1ak Multipurpose 2 or Marfak All PurposP. 2
Castrol LM Grease
Essa Mul11pwpose Grease
Gulflel Poly
Mob1lgrease MP.77.MS
Ret1nax A Alvama Grease R2
TOTAL Mult1s EP 1
An11 Fros1
AF Engine Coolant
Casl/OI An11-Freeze Cas11ol Long Lile Cool11nt
esso Anti Freeze Cootani
Cruise Master Antifreeze And Summer Coolant
Mobil Permazone
Shellzone!U S A.) Glycoshetl Plus (Europian Countries! Shellsafe Al'lt1-FrHze P281 CoolQuard
TOTAL ANTIGEL
Note: Lubricants were amended ,ccording to ntW clauifie1t1on by A P.l <Amencan Petroleum Institute)
'82-12-200 rT.S.DH!!I
3-17ESF-01E
ENGINE MOTOR MOTEUR SYMBOL MARKS SIMBOLOS SYMBOLES ............................................. · 3-1-1 A GLOSSARY OF TECHNICAL TERMS GLOSARIO DE TERMINOS TECNICOS LEXIOUE DE TERMES TECHNIQUES ........................... 3-1-2 INTRODUCTION INTRODUCCION INTRODUCTION .......................................... 3-1-5 SPECIAL TOOLS HERRAMIENTAS ESPECIALES OUTILLAGE SPECIAL ...................................... 3-1-12 OVERHAUL REPARACION GENERAL REVISION ENGINE OVERHAUL CRITERIA CRITERIOS SOBRE REPARACION GENERAL DEL MOTOR CRITERE DE REVISION OU MOTEUR ......................... 3-2-1 CYLINDER HEAD AND VALVE MECHANISM CULATA DEL CILINDRO Y MECANISMO DE VALVULA CULASSE ET MECHANISME DE SOUPAPE ...................... 3-3-1 TIMING GEAR AND CAMSHAFT ENGRANAJE DE LA DISTRIBUCION Y ARBOL DE LEVAS PIGNONS DE DISTRIBUTION ET ARBRE A CAMES ................ 3-4-1 CYLINDER BLOCK, PISTON AND CRANKSHAFT BLOOUE DE CILINDROS PISTON Y SIGUENAL BLOC-CYLINORES, PISTON ET VILEBREOUIN ................... 3-5-1
LUBRICATING SYSTEM SISTEMA DE LUBRICACION SYSTE:Mt DU G�lAISS/\G[ ........................... 3-6-1 COOLING SYSTEM SISTEMA DE ENFRIAMIENTO SYSTEM[ Of_ Rf·f·HOIUISSI fv1LNT ...................... 3-7-1 FUEL SYSTEM SISTEMA DE COMBUSTIBLE SYSTE ME. COMfllJS 11 Ill I ............................ 3-8-1 AIR CLEANER FILTRO DE AIRE � I L TR L A A I H .. . .... . . . . . .... ... . .. ..... ..... . .. . 3-9-1 TUNING THE ENGINE PUESTA A PUMTO DEL MOTOR GONFLAGE OE MOTEUR ............................ 3-10-1 TROUBLESHOOTING LOCALIZACION DE AVERIAS RECHERCHE DE LA PANNE ......•...............•... 3-11-1 SERVICE STANDARD NORMAS DE SERVICIO CARACTERISTIQUES DE REPARATION ................. 3-12-1
3-1-1 SYMBOL MARKS The following symbols have been adapted for simplicity and for easy comprehension. SIMBOLOS Se han adoptado las siguientes simbolos para simplidad y facil comprensi6n.
SYMBOLFS
LPs symboles suivants ont ete adoptes ,1fin de simplifier et de faciliter la comprehension.
1..1"1
ASSEMBLY ARMADO MONl!\(;1- IHfMONT/\GE)
l}�I
DISASSEMBLY DESARMADO DE MONTAGE:
B
E1 �
l!t1
INSTALLATION INSTALACION MISE EN PLACE (POSE OU REPOSE) REMOVAL REMOCION DE'POSE INSPECTION INSPECCION CONTROLE MEASUREMENT MEDICION MESURE
EJ E1 Iii 81 [I]
TIGHTENING APRIETE SER RAGE (RESSERRAGE) CLEAN LIMPIEZA NETTOYAGE IMPORTANT IMPORT ANTE IMPORTANT ADJUSTMENT AJUSTE REG LAGE (MISE AU POINT) LUBRICATION LUBRICACION GRAISSAGE
3-1-2 A GLOSSARY OF TECHNICAL TERMS GLOSARIO DE TERMINOS TECNICOS LEXIOUE DES TERMES TECHNIQUES
ENGLISH 1. 2. 3. 4.
5.
6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.
Air compressor gear Approx. (Approximately) Arc welding Assembly standard Bushing inside diameter Cam height: A Case bushing inside diameter Cam gear Clearance Clearance between valve stem and guide Clearance between liner and piston Coolant pump gear Cooling jet Correct Crankshaft gear Crankshaft matching Crank pin Cut-off valve Cylinder block Cylinder liner Cylinder head Cylinder head lower face Deflection Dimension Dimension of fillet R Difference between cylinders Drive shaft Drive gear shaft outside diameter Driven gear shaft outside diameter Driven gear bushing inside dimaeter Engine speed (r.p.m.) End play Exhaust Exhaust manifold 1st ring 1st step Force about Free length Gasket Groove breadth Idle gear Incorrect Injection pump
ESPANOL 1. Engranaje del compresor de aire 2. Approx. (aproximadamente) 3. Soldadula electrica 4. Estandard de armado 5. Diametro interio del casquillo 6. Altura de levas: A 7. Diametro interior del casquillo de caja 8. Engranaje de eje de levas 9. Holgura 10. Holgura entre vastago de valvula y guia 11. Holgura entre camisa y piston 12. Engranaje de la bomba de enfriador 13. Chorro de enfriamiento 14. Correcto 15. E ngranaje del ciguenal 16. Rectificaci6n del ciguenal 17. Codo de ciguenal 18. Valvula cierra 19. Bloque del cilindro 20. Camisa del cilindro
21. Culata del cilindro 22. Superficie inferior de la culata del cilindro 23. Defleci6n 24. Dimension 25. Dimension de filete R 26. Diferencia entre cilindros
FRANCA IS 1. Pignon du cornpresst�ur d'a1r 2. Approx. (Appru>:i1n;Jtivement) 3. Soudure a l'arc electrique 4. Norrne rJe montaqe r· Diametre interipur de la bague 6. Hauteur de la came A
�-
7. Diametre interieur du carter de baque 8. Pignon de l'arbre cames
a
9. Jeu 10. .Jeu entre la tige de soupap1-, et le guide 11. Jeu entre la chemise et le piston 12. Pignon rJ'entraineinent de la pompe eau 13. G icleur de refoidissement 14. Correct
a
�-
p·
Pignon du vilebrequin
16. Equilibrage de vilebrequin 17. Maneton de vilcllrequin 18. Soupape de detente 19. Bloc-cylindres 20. 21. 22. 23. 24. 25.
Chemise de cylindre Culasse Face inferieure de la culasse Flex ion Dimension Dimension de rayons de
27. Eje impulsor 28. Diametro interior del eje de engranaje impulsor 29. Diametro exterior del eje de
raccordement 26. Difference entre les cyl incl res 27. Arbre d'entrainemenl 28. Diametre exterieur de l'arbre de pignon d'entraInement 29. Diametre exterieur de l'arbre de
engranaje impulsion 30. diametro interior del casquillo de engranaje impulsion 31. Velocidad del motor (r.p.m.) 32. Juego longitudinal
30. Diametre interieur de la bague du pignon entralne 31. Regime de moteur ( tr/mn) 32. Jeu axial
33. Escape 34. Multiple de escape 35. Aro 10 a 36. 1 etapa 37. F uerza aprox imadamente 38. Longitud libre 39. Junta 40. Anchura de ranura 41. Engranaje loco
pignon entra1ne
33. Echappement 34. Collecteur d'echappement 35. Segment coup de feu (Segment 1) 36. 1 ere et ape 37. 38. 39. 40.
Effort approximatif Longueur libre Joint Largeur de la rainure
41. Pignon intermediaire
3-1-3 Inner spring Intake Inside diameter Journal kg,cm (lb.ft) kg/cm 2 (lb/sq.in) Less Less than Lower seat More than No.1 - No.5 bearing inside diameter 55. No.1 - No.5 journal outside diameter 56. Not easily measured 57. Nut
44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54.
58. Oil clearance
59. Oil pump drive gear 60. 0-ring 61. Oil ring 62. Oil seal sleere 63. Outer spring 64. Outside diameter
65. Piston pin bore inside
66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76.
77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95.
diameter Piston pin outside diameter Power steering oil pump gear
Regulator valve Relief valve Repair limit Repair limit of bent Repair limit of twist Ring breadth Ring gap Rocker arm bushing inside diameter Rocker arm shaft outside diameter Rotating torque Roundness 2nd ring 2nd step Service limit Setting length Setting load Shim thickness Sleeve Spacer Special tool Standard Stem cap Tappet outside diameter Tappet guide inside diameter 3rd ring 3rd step Tightening torque Unit
45. 46. 47. 48. 49. 50. 51. 52. 53. 54.
55. 56. 57. 58. 59. 60. 61. 62. 63.
64. 65. 66. 67. 68. 69.
70. 71.
72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89.
42. 43. 44. 45. 46. 47.
lncorrect(e) Pompe d'injection Ressort interieur Admission Adomisi6n Diametre int�rieur Diametro interior Tourillon Muiion 48. kg-cm kg-cm (lb.pie) 2 49. kg/cm 2 kg/cm (lb/pul.cuad) 50. Moins Menos 51. lnferieur(e) a Menos de 52. Coupelle inferieure Asiento interior 53. Superieur(e) a Mas de 54. Diametre interieur du coussinet Diametro interior de\ cojinete du palier nOl - n05 No.1 - No.5 exterieur du tourillon Diametre 55. Oiametro exterior de\ muiion n05 n01 No.1 - No.5 56. Difficilement mesurable No puede medido facilmente 57. Ecrou Tuerca 5 8. Film d'huile Holgura de aceite Engranaje impulsor de la bomba 59. Pignon d'entra1nement de la pompe a huile de aceite 60. Joint torique Anillo-0 61. Segment racleur d'huile Aro de aceite 62. Manchon de bague d'etancheite Manquito de\ sello de aceite 63. Ressort exterieur Resorte exterior 64. Diametre exterieur Oiametro exterior 65. Oiametre interieur de l'alesage Oiametro interior de\ oriticio de \'axe de piston de pasador de piston Diametro exterior del pasador de 66. Diametre exterieur de l'axe de piston piston Engranaje de la bomba de aceite 67. Pignon d'entra1nement de la pompe a huile de la direction de la direccion hidraulica assistee Valvula regulador 68. Soupape regulatrice Valvu\a descarga 69. Soupape de surete Limite de reparaci6n 70. Limite de reparation Limite de reparaci6n de comba 71. Limite de reparation de voile flexion Limite de reparaci6n de 72. Limite de reparation de torsion corcedura 73. Largeur du segment Anchura de\ aro 74. Jeu a lacoupe de segment Entre chierro de aro 75. Diametre interieur de la bague Diametro interior de casquillo du culbuteur del brazo de balaci n 76. Diametre exterieur de l'axe de Diametro exterior del eje del culbuteur brazo de balanci n 77. Couple de rotation Par de rotacion 78. Rondite Redondez 79. 1 er segment d'etancheite Aro i2 (Segment 2) 21J. etapa 80. 2e etape Limite de servicio 81. Limite d'utilisation Longitud de ajuste 82. Longueur comprimee Carga de ajuste 83. Sous charge de Espaciador de lamina 84. Epaisseur de la cale Manguito 85. Manchon Espaciador 86. E ntretoise Herramienta especial 87. Outil special Estandard 88. Normal(e) Tapa de\ vastago
42. lncorrecto 43. Bomba de inyeccion 44. Resorte interior
3-1-4 96. 97. 98. 99. 100. 101. 102.
Upper seat Valve clearance Valve guide inside diameter Valve stem outside diameter Wear Within Wrong
90. Diametro exterior de levanta-
valvula
91. Diametro interior del guia de 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102.
levantavalvula Aro 3Q ďż˝ etapa Par de apriete
Unidad Asiento superior Holgura de valvula Diametro interior de la guia de valvula Diametro exterior del vastago valvula Desgaste Dentro de Err6neo
89. Capuchon de queue de soupape couple de serrage 90. Diametre exterieur du poussoir 91. Diametre interieur du guide de poussoir 92. 2 e segment d'etancheite (Segment 3) 93. 3 8 etape 94. Couple de serrage 95. Unite 96. Coupelle superieure 97. Jeu de soupape 98. Diametre interieur du guide de soupape Diametre exterieur de la queue de 99. soupape 100. Usu re 101. a l'interieur 102. Mauvais(e)
3-1-5
ENGINE {Model EP100T) INTRODUCTION Model EP100T industrial diesel engine is 4-cycle, direct injection type diesel engine having 6 cylinder in-line water cooled and overhead valves.
DIFFINITION OF TERMS The terms adopted in this Workshop Manual are defined as follows.
Rotation: This engine rotates clockwise seen from the timing gear side. Nominal dimension: Basic dimension excluding tolerance. Nominal clearance: Space allowed between two parts on account of difference of tolerance when fixed together. Repair limit: Parts which reach this limit should be repaired. The mark (+)or (-) expresses increase or decrease as compared with the nominal dimension. Serviceable: The utmost that can be serviceable and parts which reach this limit should be replaced. The mark (+)or(-) expresses increase or decrease as compared with the nominal dimension.
3-1-6
DATA & SPECIFICATIONS GENERAL Model ........ : ........................ HINO EP100T Model . . . . . . . . . . . . . . . . .. . .. . . . .. . . .. . . . Diesel, 4 stroke cycle, vertical 6 cylinder in-line, overhead valve, water-colled direct injection type Bore and stroke . . . . . . . . . . . . .... . . . . . . . . . . 120 x 130 mm (4.72 x 5.12 in) Piston displacement· . . . . . . . . . . . . .. . . . . . . . . . 8.821 liters (538.3 Cu.in) C ompression ratio. . ...... . . . . .. . ..... . . . . . 17.0 : 1 Firing order ............................. 1-4-2-6-3-5 Compression pressure . . . . . . . . . .. . . . . . . . . ... 2 8-30 kg/cm 2 ( 399-426 lb/sq.in) at 200 rpm Maximum revolution (at full load) . . . . . . . . . . . . . . 2,200 rpm Idling speed . . . . . . . . .. . . . . . . . . . . .. . . . . . . . 700 - 750 rpm Weight ................................ 770 kg (1,700 lb) CYLINDER HEAD Type . . . . . . . . . . .. . . . . . .... . . . . . . . . . . . . Single piece casting Material . . . . . . . . . . . . ... . . . ...... . . .. . . ... C ast iron VALVE MECHANISM ° Valve seat angle; Inlet .................. 30 ° Exhaust ............... 45 ° Inlet .................. 30 Valve face angle; ° Exhaust ... . ...... . .... 45 Inlet.. . . . . . . . . . . . . .. . . Heat-resisting steel Valve material; Exhaust Special heat resistance steel ° Valve timing (flywheel travel); Inlet opens .... . 6 before T.D.C. ° Inlet closes ..... 22 after B.D.C. ° Exhaust opens .. . 32 before B.D.C. ° Exhaust closes .. . 6 after T.D.C. Inlet .......... 0.40 mm (0.0157 in) Valve clearance (when cold) Exhaust ....... 0.50 mm (0.0197 in) Tappet ................................ Special cast iron Push rod . . . .. . . . . . . . . . .. . . . . . . . . . . . . . .. Hollow, carbon steel CYLINDER BLOCK, CYLINDER LINER AND CAMSHAFT Cylinder block ........................... Mono-block, 6 cylinder, cast iron Cylinder liner . . . . . . . . . . . . . . . . . . . . .. . .. . . . Dry type, replaceable, special cast iron, centrifugally cast Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Induction hardened die-forged carbon steel in material Camshaft bearing; Number and material ........7, white metal with carbon steel back metal
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3-1-7 CONNECTING ROD AND PISTON Connecting rod . . .. . . .. . . .. . . .. . . . . . . . . . . 6, carbon steel Small end bearing, Material .. . .. . .. . . . . . . . . . . . Leaded tin bronze Large end bearing, Material . . . . . . . . . . . . . . . . . . . Thin-kelmet with lead alloy Piston . . . ....... . . . . . . . .. . . . . . . . . . . . . . . Heat-resistance aluminum alloy Compression .................. Three with chrome-plated Piston ring; Oil ring ..... . . .... . . . .... . ... One, chrome-plated with coil expander CRANKSHAFT AND CRANKSHAFT BEARING Crankshaft .. . . ... . . . . . . . . . . . . . . . . . . . . . . Induction-hardened die forged special steel with counter weights Crankshaft bearing: Material . . . . . . . . .. . . . . . . . Lead indium and kelmet over steel back metal TIMING GEAR Timing gear drive . . . . . . . .. .... . . . . . . . . . . . . Helical gear FUEL SYSTEM Fuel injection pump Injection timing (flywheel travel) ............... Governor .............. .... . ........... Fuel feed pump Nozzle . .. . . . . . . . . . .. . . . . . . . . . . . . .. . . .. Nozzle holder ........................... Fuel filter . . . . . . . . . .. . . . . . .. . . . . . . . . . . . .
BOSCH line type, driven by engine, 1/2 x engine rpm, clockwise seen from the drive side ° 16 before 1st cyl. T.D.C.(Top dead center) BOSCH type, mechanical all speed control (RSV) Piston type, driven by injection pump camshaft, max. feeding pressure 3.4 kg/cm2 (48.3 lb/sq. in) Multi-hole nozzle type Injection pressure 220 kg/cm 2 (3,125 Ibis.in) Replaceable paper element type
LUBRICATING SYSTEM Type . . . . . . . .. . . . . . . . . . . . . . . . .. . . . .. . . Forced-feed lubrication with oil pump Oil capacity ............................. 26 liters (5.72 Imp. gal/6.87 U.S. gal) Oil pressure ............................. 0.5-5.0 kg/cm 2 (7.11-71.1 lb/sq.in) Oil filter . . . . . .. . . . .. . . . . . .. .. . . . . .. . . . . Full flow type using paper element and bypass type using depth element COOLING SYSTEM Type . . ... . . . .. . . . . . . . . . . . . . . . . . . . . . . . Radiator cap pressure ..... ................. Water boiling temperature . . . . . . . . . . . . . . . . . . . Cooling system water capacity (only cylinder block) .. Coolant pump . . . ..... . . . . .. . . . . . . . .. . . . . Fan: Type . . . . . . ... . . . . . . . . . . . . . . . . . . . Drive . . . . . . .. . . . . . .. . . ... .. . . . . . .
Forced recirculation type 0.5 kg/cm2 (7.11 lb/sq.in) than atmospheric pressure ° ° 106 - 110 C (222.8-230 F) 15.5 liters (3.41 lmp.gal/4.10 U.S.gal) Centrifugal, belt-driven by engine crankshaft Mounted on coolant pump, 2-3 type available 6-blades type, fully shrouded belt-driven by engine crankshaft pulley Radiator: Type .... . ................. .... Corrugate type Mounting .... .. . .. . . . . . .. .. . . .. Rubber shock insulators ° ° Thermostat ............................. Wax type, bottom by pass system, open at 76.5 C (169 F) ° ° max. lift 10.0 mm (0.393 in) at 90 C (194 F) AIR CLEANER Type .... ...... ................. ...... Dry type (paper element), 2-3 type available
3-1-8 PERFORMANCE & PERFORMANCE CURVE
Output, intermittent rating KW (HP) rpm ........... 149 (200) SAE J1349, Gross (without cooling fan) 139 (186) 129 (173) 118 (153)
at 2,200 rpm at 2,000 rpm at 1,800 rpm at 1,600 rpm
Output, continuous rating KW (HP) at rpm .......... 127 (170) SAE J1349, Gross (without cooling fan) 119 ( 159) 110 (148) 100 (134) Max. torque Nm (lb.ft) at rpm .......... 711 (525) NOTE:
Outputs are converted to SAE J1349 standard ambient conditions; ° Intake air temperature 25 C Barometric pressure 100 KPa Water vaper pressure in atmosphere 1.0 KPa
E z
SAE Jl349 (Gross)
�....__
�.,,,,..200 <(
180
150
140
130
Intermittent
160 120 z <( ::::> z (/) a. w 110 l-1-� ::::> 0 ::i 140 0 a.. 100
1-u
t;
at 2,200 rpm at 2,000 rpm at 1,800 rpm at 1,600 rpm at 1,600 rpm
(L
120 100 80
90
80 70
60
/ / ..... 1,000
-
/
/
1,200
\
/
/
\y,... V .. "'/
,
..
/
;1'
1,400
�600
/
/
--..
V
/
.. � .. .. I/
700
+-
550
500
LU W ::::> 0 a: cc ::i <(0 600 450 0 I- a.. u
650
V
w
_j a)
\continuous
1,800
ENGINE SPEED (r.p.m.)
i--
-
240 230 220 210
2,000 2,200
VELOCIDAD DEL MOTOR (r.p.m.) REGIME DU MOTEUR (tr/mn)
Fig. 3-1-1 Engine perfomance curves Curvas caracteristicas del motor Courbes des performances du moteur
_j
(L
04 0 038 l 0·36 0·34
w C/l ..J ::i Ill ro -2 1-Q (/) u Z�z 2�w I-OZ a..uo � I-W ::) Cl> 0 <( Z02 0�2 U::::>o ..J wzz ::::>OO LL (.) U Cl)(/)
SM3-1036
3-1-9 Output, intermittent rating
188 (138.3) at 2,200 rpm
PS (KW) at rpm
180 (132.3) at 2,000 rpm
DIN 62708 (with cooling fan)
166 (122.1) at 1,800 rpm 151 ( 111. 1) at 1,600 rpm Output, continuous rating
160 (117.4) at 2,200 rpm
PS ( KW) at rpm
151 (111.0) at 2,000 rpm
DIN 6270A (with cooling fan)
141 (103.7) at 1,800 rpm 129 ( 94.9) at 1,600 rpm Max. torque
Kgm (Nm) at rpm . . . . . . .
68 (666.8) at 1,600 rpm
NOTE: Outputs are converted to DIN 6270 standard ambient conditions; °
Intake air temperature
20 C
Barometric pressure
735 mmHg
Water vaper pressure in atmosphere
10.5 mmHg
---
DIN 6270 (/)
a.
150
200 I........
14 130
��
t-u z ::> z <! Q. w (/) t-1-� ::> 0 :J 0 Q. a.
120
90
180
60
60
160
627 08
140
120
100
I
V
V
/
y A ,. ..,,
/ /
/ ., ,.,, /'
' ..........
j
80
V 1,000
1,200
-�__..,.l---'"'... 1,400
1,600
� w 600 o � a: cc :J
soo
e 6: s
/
t\6270A
I /
I /
700
400
✓
80 70
70
50
II 0 100
E z
.,,.,,,
I80 I 70 I 60
1,800 2,000 2,200
ENGINE SPEED (r.p.m.) VELOCIDAD DEL MOTOR (r.p.m.) REGIME OU MOTEUR (trs/mn) SM3-1037 Fig. 3-1-2
Engine performance curves
Curvas caracteristicas del motor Courbes des performances du moteur
3-1-10
DESCRIPTION (General views)
SM3-1034
LEFT SIDE VIEW
SM3-1033
FRONT VIEW
Fig_ 3-1-3
3-1-11
(Remarkable tightening torque positions) ¢12P1.75 1,100-1,200 kg·cm
I ¢10P1.5 I 300-500 kg•cm I
¢17 P2.0 c/>10 Pl.5
3,300-3,500 kg•cm 650-750 kg•cm
¢14P2 1,000-1,300 kg-cm
¢16P1 .5 2,600-2,900 kg•cm
c/J22P1.5 5,500-7,000 kg•cm
,,....._--------1 ¢30P1 .5 I 1,000-1,200 kg•cm I
SM3-588
¢8 P1.25
c/>8 P1.25
190-270 kg•cm
q,14 P2.,0 ¢16 P2.0
¢15 P1.5 Fig. 3-1-4
2,200-2,400 kg·cm
190-270 kg•cm
1, 100-1,500 kg•cm
2,700-2,900 kg•cm SM3-1039
3-1-12
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have the following.
Illustration
Tool No.
/ 09442-1200 I / \ ,..____...,,,.,,,...
0
Tool name
./PISTON RING EXPANDER
Usage
For removing and install the piston rings
964507-435 985136-104
O-RING
09470-1022 09433-1061
VALVE SPRING PRESS
For installing or removing valve spring and lifting cylinder head
09420-1442
SLIDING HAMMER
For removing the nozzle holder (Used with nozzle holder puller 09462-1130)
0�402-1140.
PRESS
For camshaft end plug
WRENCH
To tighten the cylinder head bolt
/
)
(Used with 09402-1280) (Used with 09402-1161)
··�-----
0$839-2205
3-1-13
Illustration
Tool No.
w
c,·""
Tool name
Usage
09444-1210
V-BEL T TENSION GAUGE
For V-belt tension
09482-1350 .'
PRESS
For the injection pump drive shaft sleeve
09420-1180/
PULLER
For the injection pump drive shaft sleeve
ADAPTOR
For with drawing the idle gear shaft (Used with 09420-1442)
STOPPER
For tappet hold
09412-1080
WRENCH
For water pump vane puller
_09552-1030
PRESSURE GAUGE ADAPTER
For the compression gauge
Is,
'--
�
-�·""
.� -" ·
_
.. -··
/09462-1410
\
' \
09451-1040
)
3-1-14
Illustration
Tool name
Tool No.
Usage
09420-1450
CYLINDER LINER PULLER
For removing the cylinder liner and measuring the protrusion of the cylinder liner
09402-1290
DUST SI LINGER P�ESS
For pressing the dust slinger to crankshaft pulley
09402-1161
PRESS
To install the front oil seal sleeve
09480-1100
CY,LINDER LINE'ft ) Gl:JIDE I
,
...-····
··---.\
To install the cylinder liner
(
\ i
09441-1051
P,ISTON RING/ HOLDER
09482-1420
,PRESS
09482-1430
.· PRESS
,/
For piston installation
For front oil seal to timing gear cover
For rear oil seal
3-1-15
Illustration
Tool No.
Tool name
Usage
09402-1220
PRESS
To install rear oil seal sleeve
09420-1111
PULLER
For injection pump drive gear
09431-1010
VALVE LAPPING TOOL
For valve lapping
09819-1707
W.RENCH
Tightening or retightening injection pump coupling
09472-1210
NOZZLE SLEEVE BAR
For installing.the nozzle sleeve (Used with 9800-06100)
9800-06100
STEEL BALL
For expanding the nozzle sleeve (Used with 09472-1210)
09408-1010
COMPRESSION ADAPTER
For measuring engine compression pressure (Bolt size PF 3/8)
3-1-16
Illustration
Tool No.
Tool name
/
For with drawing the nozzle holder (Used with 09420-1442)
STEM SEAL PRESS
To install the valve stem seal
ENGINE HANGER
For lifting the engine
09482-1210
PRESS
For pressing the oil seal of water pump
9001-24265
CONNECTOR BOLT
For inspection of the piston cooling jet
TARGET PLATE
For inspection of the piston cooling jet
ADJUSTER BAR
To adjust the jet nozzle
/
./·
· 09472-175(Y
.6�405-1190 ..,.,.....
,
l
)
ADAPTER
//
09462-11JQ/
(
Usage
,,/
,I
··
, , 09470-1090 ·�--., - . .
09472-1620 .· .·
3-2-1 OVERHAUL ENGINE OVERHAUL CRITERIA
1. Factor which determine when an engine overhaul is needed. 1) Lowered compression pressure.
NOTE:
1. 1I 2) 3) 4) 2. 1) 2)
Fig. 3-2-1 09408-1010 09552-1030
Special tool
Before measurement. Correct the valve clearance ° ° Warm up engine (about 80 C, 176 Fl Charge the battery fully Remove the air cleaner Measurement Remove the six nozzle holder Install the gauge adapter
REPARACION GENERAL REPARACION GENERAL DEL MOTOR
Unit: kg/cm 2 (lb/sq.in) Standard value
Limit
Difference between each cylinder
28-30 (399-426)
26 (370)
Less than 3 (43)
Engine speed (r.p.m.) 200
1. Factores que determinan la necesidad de efectuar una reparaci6n general del motor. 1) Presi6n de compresi6n insuficiente.
NOTA: 1. Antes de la medici6n 1) La holgu ra de la val vu la esta correcta ° ° 2) La temperatura del agua es de 80 C (176 F) 3) Cargue la bateria por completo 4) Remueva el filtro de aire
2. Medici6n 1) Remueva los seis portainyectores 2) Revise la revoluci6n del motor
REVISION
REVISION DU MOTEUR
1. Facteurs dont depend la prise de decision sur le moment ou ii faut envisager la revision du moteur. 1) Baisse de la pression de compression.
N.B.: 1. 1) 2) 3) 4) 2. 1) 2)
Avant prise de mesure Le jeu de soupape est correct ° La temperature de l'eau de refroidissement est de 80 C Charger la batterie pleinement Deposer le filtre a air Mesure Deposer les six porte-injecteurs Verifier le regime du moteur
2) Oil pressure decreases.
2) La presi6n de aceite disminuye. 2) La pression d'huile diminue.
Fig. 3-2-2 Service limit
SM3-590 2
0.4 kg/cm (5.7 lb/sq.in)
3-2-2 3. Other factor a. The blow-by explacive gas in the cylinder block will increase. b. The engine will not start easily. c. Engine output decrease. d. Fuel consumption increases. e. Engine makes a larger noise.
3. Otros factores a. Aumento de_ las gases de "blow-by" en el bloque de ci I i_ndros. b. El motor no arranca con facilidad c. La potencia del motor disminuye. d. Aumento del consume de combustible. e. El motor produce un ruido excesivo. 3. D'autres facteurs a. Le gaz explosif par soufflage (blow-by) dans le bloc-cylindres sera augmente. b. Le moteur ne demarrera pas facilement. c. Perte de la puissance du moteur. d. Augmentation de la consommation en carburant. e. Le moteur fonctionne avec un bruit plus mar quant.
3-2-3
,44 ..,
ENGINE COMPONENT PARTS PIEZAS COMPONENTES DEL MOTOR PIECES COMPOSANT DU MOTEUR Disassembly Desarmado De montage 1. Drain the water and engine oil.
NOTE: After drain the ,water and engine oil, retighten the each drain plug.
2. Dismount the following component parts. 1) Remove the cooling fan. 2) Fuel filter 3) Engine oil level gauge 4) Remove the fuel pipes and oil pipes 5) Remove the starter
Fig. 3-2-3
03-1034
.El Fig. 3-2-4
EPIT-046
El Fig. 3-2-5
6) Remove the generator (1) Loosen the belt tension adjusting bolt,@. (2) Remove the nut, G) . (3) Loosen the through bolt, @. (4) Remove the V-belt.
SM3-1040
7) Remove the oil filter with oil cooler.
3-2-4 8) Remove the fuel pipes, oil pipes and fuel leakage pipes. 9) Remove the fuel injection pipes.
Fig. 3-2�
03-2255
10) Di'sconnect the coupling (1) Loosen the through boltG). (2) Remove the coupling bolts and nuts.
Fig. 3-2-7
03-2261
11) Remove the injection pump.
Fig. 3-2-8
04-1322
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3-3-1 HINO EP100 EP100T CYLINDER HEAD AND VALVE MECHANISM CULATA DEL CILINDRO Y MECANISMO DE VALVULA CULASSE ET MECHANISME DE SOUPAPE HE11-087-00X01 (1320)
INTAKE AND EXHAUST MANIFOLD 1. 2. 3. 4. 5. 6. 7.
Intake manifold Intake manifold gasket Exhaust manifold Exhaust manifold gasket Seal ring Intake pipe Air hose
MULTIPLE DE ADMISION Y ESCAPE
1. 2. 3. 4. 5. 6. 7.
Multiple de admision Junta del multiple de admision Multiple de escape Junta del multiple de escape Aro reten Tubo de admisi6n Manguera de aire
Fig. 3-3-1
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3-3-2
HE11-087-00x01 (1000)(2/2) â&#x20AC;¢ 8
CYLINDER HEAD & RELATED PARTS 1. 2.
Cylinder head cover Cylinder head cover gasket
3.
Cylinder head gasket
4.
Oil filler cap
5.
Ventilator
6.
Cylinder head bolt
7.
Cylinder head bolt
8.
Vent pipe
CULATA DEL CILINDRO Y PIEZAS RELACIONADAS
1. Cubierta de la culata del cilindro 2. Junta de la cubierta de la culata del cilindro 3. Junta de la culata del cilindro 4. Tapon de relleno de acei te 5. Ventilador 6. Perno de la culata del cilindro 7. Perno de la culata del cilindro 8. Tubo de ventilacion
CULASSE ET PIECES CONNEXES
1. Couvercle de culasse 2. Joint du couvercte de cu tasse 3. Joint de culasse 4. Bouchon de remptissage d"huile S. v.,11tilateur 6. Bouton cJe fixation cle cutasse 7. Bou Ion de fixation de culasse 8. Rer,iflard
Fig. 3-3-2
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3-3-3
HE11-094-00X02 (1310)â&#x20AC;˘
HINO EP100 HINO EP100T VALVE SYSTEM 1. Inlet valve 2. Exhaust valve 3. Valve stem cap 4. Valve spring lower seat 5. Valve spring outer 6. Valve spring outer seat 7. Valve stem key 8. Tappet 9. Push rod 10. Rocker arm support 11. Rocker arm 12. Adjusting screw 13. Adjusting screw nut 14. Support bolt 15. Rocker arm shaft
SISTEMA DE VALVULA 1. 2. 3.
4.
5. 6.
7. 8.
9. 10. 11. 12. 13. 14. 15.
Valvula de admisi6n Valvula de escape Tapa del vastago de la valvula Asiento inferior de resorte de la valvula Resorte de la valvula exterior Asiento exterior de resorte de la valvula Chaveta del vastago de la valvula Levantavalvula Varilla de empuje Soporte del brazo de balancin Brazo de balanci n Tornillo de ajuste Tuerca del tornillo de ajuste Perno de soporte Eje de brazo de balancin
MECANISME DE SOUPAPES Soupape d'admission Soupape d'echappement 3. Capuchon de tige de soupape 4. Siege inferieur de ressort de soupape 5. Ressort de soupape exterieur 6. Siege exterieur de ressort de soupape 7. Demi-cone de soupape 8, Poussoir 9. Tige-poussoir 10. Support de culbuteur 11. Culbuteur 12. Vis de reglage 13. Ecrou de vis de reglage 14. Bou Ion de support 15. Axe de culbuteurs 1. 2.
Fig. 3-3-3
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3-3-4
HE11-087-00X01 (1000)(1/2)â&#x20AC;¢
CYLINDER HEAD 1. 2. 3.
4. 5,
6.
7.
Cylinder head Valve guide Inlet valve seat Exhaust valve seat Nozzle seat (copper sleeve) O-ring Expansion plug
CULATA DEL CILINDRO 1. Culata del cilindro 2. Gu ia de valvula 3. Asiento de la valvula de admisi6n 4. Asiento de la val vu la de escape 5. Asiento de inyector (manguito de cobre) 6. AnilloO
CULASSE 1. Culasse Guide de soupape 3. Siege de soupape d'admission 4. Siege de soupape d'echappement 5. Siege d'injecteur (chemise en cuivrel 6. Joint torlque
2.
Fig. 3-3-4
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
3-3-5
El Fig. 3-3-5
1. Cylinder head. 1) Remove the intake manifold.
SM3-1048
El Fig. 3-3-6
2) Remove the exhaust manifold.
SM3-1041
El
El J:J���K�/'.: � Fig. 3-3-8
Disassembly
SM3-1042
3) Remove the coolant pump.
4) Remove the thermostat case.
3-3-6
13 -----L
Fig. 3.3.9 Special tool
SM3-356 09462-1130, 09420-1442
6) Remueva la cubierta del balancin. 6) Deooser le couvre culbuteurs.
7) Remove the rocker arm shaft assembly. Remove the valve stem cap. Remove the push rod.
7) Remueva el conj unto de eje de balanci n. Remueva la tapa del vastago de la valvula. 7) Deposer !'ensemble axe de c,iltuteurs. Deposer le capuchon de la tige de soupape.
03-1826
13 Fig. 3-3-12
6) Remove the rocker arm cover.
03-1825
13 Fig. 3-3-11
5) Remueva el inyector. 5) Deposer les injecteurs.
i,
13 Fig. 3-3-10
5) Remove the injection nozzle.
03-1827
8) Loosen the cylinder head bolts.
8) Afloje los pernos de la culata del cilindro. 8) Desserrer les boulons de fixation de culasse.
3-3-7 9) Loosening sequence of cylinder head bolts.
9) Orden de aflojamiento de los pernos de la culata de cilindro. 9) Ordre de deserrage des boulon de culasse.
Fig. 3-3-13
SM3-506
El Fig. 3-3-14
1.
Chisel
2.
Cylinder block
A
Place the chisel only at this
B
Hit up and down
10) Remueva el conjunto de la culata del cilindro. 10) Deposer I 'ensemble culasse.
SM3-552
1. Cincel 2. Bloque de cilindros A Coloque el cincel solo en este angulo B Golpee arriba y abajo
corner
El Fig. 3-3-15 Special tool
10) Remove the cylinder head assembly.
SM13-425
09433-1061
1. 2. A B
Ciseau Bloc-cylindres Placer le ciseau uniquement ace coin Frapper ve,s le haut et vers le bas
11) Lift the cylinder head from the block.
3-3-8 2. Remove the valve spring. 2. Remueva el resorte de valvula. 2. Deposer le ressort de soupape.
SM3-824
Fig. 3-3-16 09470-1022
Special tool
! ! ! ! ! 11 !1 !1 !1 !11 !1
IN � �
A�I
·� :iJ
.,.
i,
�
�
� iJ ·� �
IAl"
.
:t��i:!:J ;:_ e
lves and springs arranged in the sequence
. 3 Conserve las valvulas y los resortes dispuestos en la misma secuencia que los cilindros. 3. Disposer les soupape et les ressorts suivant l'o,·dre des cylindres.
EX
2
Fig. 3-3-17
3
4
5
6
SM3-598
4. Disassemble the rocker arm shaft. 4. Desarme el eje de balanci n. 4. Demonter l'axe de culhuteurs
Fig. 3-3-18
03-2034
5. Remove the valve guide. 5. Remueva la gu[a valvula. 5. Deposer la guide de soupape.
Fig. 3-3-19
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C:1 c::.J
O=
3-3-9 6. If necessary, replace the valve seat.
/1
__J_
2 8
SM3-553
Fig. 3-3-20
1. Valve seat 2. Valve A Arc welding points Grinding portion
1. Siiige d,, soupaµ,i
1. Asiento de val vu la
2. Valvula
A Soldadula electrica B Corte estas porciones
2. Sour,ap8
A Souuer a I ·arc Fl MP.ulez ici
7. If ne,,e,sa,y, ,epl"" the nmle "''· , .... ,
Fig. 3-3·21
03-677
3-3-10 Inspection and repair
1. Cylinder head and valve 11 Clean the mounting surface of cylinder head. I nspecci6n y reparaci6n
1. Culata del cilindro y valvula 1) Limpie la superficie de montaje de la culata del cilindro.
Controle et reparation
1. Culasse et soupape 1) Nettoyer la surface de montage de la culasse.
Fig. 3-3-22
SM3-825
2) lnsepect for cracks and damage.
21 I nspecione en cuanto a grietas y dafios. 2) Controler la culasse a la recherche des felures et de l'endommagement.
Fig. 3-3-23
SM3-832
3) Check the cylinder head surface for flatness.
03-667
Fig. 3-3-24 Standard
Repair limit
0-0.05 mm (0-0.0019 in) 0.1 mm (0.0039 in)
4) Measuring process and situation. B C
E'
F'
G'
A' -f---""1-ďż˝-----+-------:;rl"'---t-C'
Fig. 3-3-25
SM3-554
3-3-11 Inspect the valve contact surfaces for contacting
r::;;]5) condition.
1:::1
Fig. 3-3-26
If necessary, hand-lap the valve and valve seat.
NOTE: Lightly apply lapping compound to the valve face. Install the valve with a special tool, tap and rotate the valve against the seat.
SM3-364
I Special tool
09431-1010
6) Measure the valve sink. 6) Mida el sumidero de la valvula. 6) Mesurer le fonc;:age de la soupape
03-535
Fig. 3-3-27
A
Fig. 3-3-28 Standard Service limit
SM3-236 A
0-0.2 mm (0-0.0078 in}
7) Correct the valve seat. 7) Corrija el asiento de la valvula. 7) Rectifier le siege cle soupape
Fig. 3-3-29 Standard
SM3-708
Inlet Exhaust
째
째
30 -30 15' 45째 -45째 15'
3-3-12 8) Correct the valve face. 8) Corrija la cara de la valvula. 8) Rectifier la face de la soupape.
SM3-707
Fig. 3-3-30
Standard
Inlet Exhaust
° ° 29 45'-30 ° ° 44 45'-45
u 45° INLET Fig. 3-3-31
EXHAUST
SM3-555
9) Measure the oil clearance between valve stem and guide.
Fig. 3-3-32
SM3-834
Fig. 3-3-33
SM3-835
3-3-13 10) Measuring position of valve guide and valve stem.
2 A
B
C
UNIT: MM Fig. 3-3-34
SM3-556
1. Inlet 2. Exhaust
1. Admisi6n 2. Escape
Standard 9.938-9.950 mm (0.3913-0.3917 in) 9.921-9.943 mm (0.3906-0.3914 in)
Inlet valve stem outside diameter Exhaust valve stem outside diameter
� Inlet Exhaust
1. Admission 2. Echappement Service limit 9.88 mm (0.389 in) 9.88 mm (0.389 in)
Repair limit mm (in) A&B C
Clearance mm (in) 0.040-0.077 (0.0016-0.0030) 0.057-0.094 (0.0023-0.0037)
0.12 (0.0047) 0.14 (0.0055)
0.18 (0.0071) 0.20 (0.0079)
Valve spring 1) Check the valve spring for straightness. NOTE: Runout maximum should be less than 7 mm (0.275 in). Straightness should be less than 3.5 mm (0.137 in)
Fig. 3-3-35 Limit
SM3-303 A (max.)-A (min.) � 7 mm (0.275 in) B (max.)-B (min.) �7 mm (0.275 in) 2) Measure the free length.
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com SM3-557
Fig. 3-3-36 Free length 77 (3.03)
mm(in) Service limit 7.5 (2.953)
J-3-14 3) Measure the valve spring force.
3) Mida la fuerza del resorte de la valvula_ 3) Mesurer l'effort du ressort de soupape
-------
Fig. 3.3.37
Setting length mm (in) Setting load kg(lb) Service limit kg (lb)
03-680
Outer spring Intake Exhaust 54.3 52.8 (2.077) (2.136) 46.9-51.5 43.2-47.8 (95.26-105.4) (103.4-113.5) 45.5 41.8 (92.17) (100.3)
4) Check the valve spring seat for wear (upper and lower).
4) I nspeccione el asiento del resorte de la valvula en cuanto a desgaste (superior e inferior.) 4) Verifier le siege de ressort de soupape a la re cherche d'usure. (superieur et inferieur)
Fig. 3-3-38
SM3-371
3. Rocker arm and rocker arm shaft 1) Measure inside diameter of the rocker arm.
3. Brazo de balanci n y eje del brazo de balanci n 3. Culbuteur et axe de culbuteur
Fig. 3-3-39
SM3-291
3-3-15 2) Measure outside diameter of the rocker arm shaft.
Fig. 3-3-40
03-682
3) Measuring position.
----
Fig. 3-3-41
Outside diameter Inside diameter Clearance
SM3-558
Standard mm (in)
24.16-24.18 (0.9512-0.9519) 24.21-24.26 (0.953-0.955) 0.03-0.101 (0.0012-0.0039)
Repair limit mm (in)
Service limit mm (in)
0.15 (0.0059)
-
-
24.12 (0.9496) 24.28 (0.9559)
4) Inspect the valve stem contact point of the rocker arm for wear. 4) I nspeccione el pu/lto de contacto del vastago de la valvula del brazo de balancf n en cuanto a des gaste.
� � 1:::::7
Fig. 3-3-42
SM3-930
4) Controler I 'usure de la partie de contact de la tige de soupape avec le culbuteur.
3-3-16
Fig. 3-3-43
SM3-292
Service limit
0.5 mm (0.0196 in)
Check the adjusting screws and push rod for wear, or damage.
I _.,./)
, Fig. 3-3-44
SM3-419
Intake manifold. 1) Measure the flatness of flange face.
Fig. 3-3-45
03-1829
Standard 0.1 mm (0.004 in)
Service limit 0.5 mm (0.02 in)
Exhaust manifold 1) Measure the flatness of flange face.
Fig. 3-3-46
03-1830
Standard Service limit 0.1 mm (0.004 in) 0.5 mm (0.02 in)
3-3-17
Hino EP100 EP100T Exhaust Seal Rings ©OJ 45•
Fig. 3-3-47
2) Inspect the wear or damage of seal ring.
SEAL RING
SM3-943
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3-3-18
El Fig. 3-3-48
SM3-826
Assembly
1. Install the valve seat Heat the cylinder head in boiling °water and put the valve seat in liquid nitrogen (-196 C).
Armada 1. Montaje del asiento de la valvula Caliente la culata del cilindro en agua hirviendo y ponga el asiento de la valvula en nitr6geno liquido ° (-196 C). Remontage 1. Montage du siege de soupape Chauffer la culasse dans l'eau bouillante et mettre le ° siege de soupape dans le liquide nitrogene (-196 C).
Install the nozzle sleeve. 1) Set the O-ring into the cylinder head Apply adhesive (Super Three Bond No. 1210 or equivalent) to the lower part of the new copper nozzle sleeve and carefully insert the nozzle sleeve into the cylinder head. NOTE: A damaged 0-ring may cause leaks and lead to over heating or cracked heads.
SM3-390
Fig. 3-3-49 Special tool A
09472-1210
Special tool B
9800-06100
2) Measure the protrusion of nozzle from the cylind er surface.
• CYLINDER HEAD
Fig. 3-3-50
SM3-391
Tightening torque 130-190 kg·cm (10-13 lb.ft) Protrusion
2.75-3.25 mm (0.1083-0.1279 in)
3-3-19 Install the valve guide 1) Setting position of the valve guide.
2
B
SM3-562
Fig. 3-3-51
1. Inlet
2. Exhaust
Cylinder head upper face Cylinder head lower face
1. Admisi6n 2. Escape A Superficie superior de la culata del cilindro B Superficie inferior de la culata del cilindro
1. Admission
2. Echappement
A Surface superieur de la culasse B Surface ,nferiP.ur de la culasse
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E3
4. Install the valve stem seal.
4. lnstale el sello del vastago de valvula. 4. Poser I 'etanchei te de tige de soupape.
Fig. 3-3-52 I Special tool
SM3-984 09472-1750
El Fig. 3-3-53
03 G87
5. Install the valve.
5. I nstale la valvula. 5. Poser la soupape.
3-3-20
El
6. I nstale el re so rte de valvula. 6. Poser le guide de ressort rle soupape.
SM3-824
Fig. 3.3.54
Special
6. Install the valve spring.
09470-1022
tool
PAINT MARK CYLINDER HEAD
INTAKE Fig. 3.3.55
EXHAUST
SM3-402
El
8. Mount the cylinder head assembly.
NOTE: Replace the c"l'.linder head gasket with new one.
8. lnstale el cojunto de la culata del cilindro.
NOTA: Reemplace la junta de la culata del cilindro con otra nueva.
8. Monter !'ensemble culasse.
N.B.: Remplacer le joint de culasse par une piece neuve.
Fig. 3-3¡56
SM3-425
El
9. Install the cylinder head bolt and tighten them temporarily. NOTE: Applying the engine oil.
9. lnstalelos pernos de la culata del cilindro y apriete los temporalmente. 9. Poser les boulons de fixation de culasse et serrer les temp ore I lement.
Fig. 3.3.57
03-689
3-3-21 10. Install the valve push rod. 0 NOTE: Applying engine oil. �10. I nstale el empujador de la valvula. NOTA:
10. Poser la tige-poussoir. N.B.:
Fig. 3-3-58
B 03-690
Fig. 3-3-59
··•:.\l.·.. 1 I .I t::rit:a:sr:irif
p:
. ,. .
12. Assemble the rocker arm. 12. Arme el balanci6n. 12. Ensemble le culbuteur.
I
i . . 1:; .;;;;;;..;:c;;
03·664
Fig. 3-3-60
UP
m 1£=.1
�
TIMING-+ GEAR SIDE Fig. 3-3-61
11. Install the stem cap. 11. lnstale la tapa del vastago de valvula. 11. Poser le capuchen de la tige de soupape.
SM3-938
13. Make sure that the rocker arm shaft is installed with the "UP" mark the shaft upward. NOTE: Lubricate the rocker arm shaft and arm bush.
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 SM3-357 website: www.HeavyEquipmentRestorationParts.com
3-3-22
El
El
14. Poser l'ensemtJle axe de c:ulln1teurs.
,s.
Tightening sequence of rocker arm support. NOTE: Tightening sequence 3-4·5·2· 1 ·6
03-322
Fig. 3·3·63
1, 100-1,200 kg-cm (80-86 lb.ft) 2,400-2,600 kg-cm (174-188 lb.ft)
El Fig. 3.3.54 Special tool
14. lnstale el conjunto del eje de balancin.
03-1826
Fig. 3·3·62
Tighting torque
14. Install the rocker arm shaft assembly.
16. Tighten the cylinder head bolt and rocker arm support bolt.
03-1831 09839-2205
17. Tightening sequence of Hino EP100 Hino EP100T cylinder head bolts. 17. Orden de apriete de los pernos de la culata de cilindro. 17. OrcJre de serrage des I.Joulons de r:t1lassri.
INTAKE
Fig. 3.3.55 Outside diameter 16 1.1m 10 mm
SM3-506 Hino EP100 T Tightening torque 3,300-3,500 i<g•cm (239-253 lb.ft) 650-750 kg-cm (47-54 lb.ft)
3-3-23 18. Install the injection nozzle. 18. lnstale la tobera del inyector. 18. Remettre l'injecteur en place.
03-2159
Fig. 3-3-66 I Tightening torque I
130-190kg.cm(10-13Ib.ft)
[BJ'"·
Adjust the valve clearance. 1) Set the each piston at top dead center of the compression stroke and adjust the valve clear ance. Firing order: 1-4-2-6-3-5
19. Ajuste la holgura de la valvula.
1) Coloque cada piston en el punto muerto superior de la carrera de compresion y ajuste la holgura de la valliula. Orden de encendido: 1-4-2-6-3-5
19. Regler le jeu de soupape.
1) Regler chaque piston au point mort haut de la phase de compression et regler le jeu de soupape. Ordre d'allumage 1-4-2-6-3-5
SM3-519
Fig. 3-3-67 Valve clearance
0.40 mm (0.157 in) 0.50 mm (0.0197 in)
Inlet Exhaust
2) 2-time adjustment Set the No.1 piston to top dead center of com pression stroke, adjust the valve clearance and set the No.6 piston to top dead center, adjust the other valves. 2) Ajuste de 2-tiempos Coloque el piston N °, 1 en el punto muerto superior de la carrera de compresion y ajuste la holgura de la valvula, luego coloque el piston N °, 6 en el punto muerto superior y ajuste las demas valvulas. 2) Reglage en deux reprises Regler le piston N ° 1 au point mort haut de la phase de compression et regler le jeu de soupape et regler le piston N ° 6 au point mort haut et regler d'autres soupapes.
Fig. 3-3-68
Valve arrangement With No. 1 piston at T.D.C. on compression stroke With No. 6 piston at T.D.C. on compression stroke
2
1
Cylinder No.
I
4
3
I
I
I
E
1
2 3 4 5 6 7
E
E
• •
• • 0
0
I
E
I
E
8 9 10 11 12
• 0
6
5 E
•
0
0
0
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3-4-1 HINO EP100 EP100T TIMING GEAR AND CAMSHAFT ENGRANAJE DE LA DISTRIBUCION Y ARBOL DE LEVAS PIGNO NS DE DISTRIBUTION ET ARBRE A CAM ES HE11-094-00X01 (1110)
1. Timing gear cover
2. Timing gear cover gasket 3. Oil seal
4. 0-ring
5. Seal plate 6. Timing gear plate
1. Cubierta de! engranaje de la distribuci6n 2. Junta de la cubierta del engrenaje de la distribuci6n 3. Sella de aceite 4. Anillo-O 5. Placa retenadora
Fig. 3-4-1
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1. Couvercle du carter de distribution 2. Joint du couvercle du carter de distribution 3. Rondelle de retenue d'huile 4. Joint torqieu 5. Plaque d'etancheite
3-4-2
3
4
5
SM3-593
HINO EP100 EP100T GEAR TRAIN
1. Crankshaft gear 2. Idler gear 3. Camshaft gear 4. Injection pump drive gear 5. Oil pump drive gear 6. Coolant pump gear 7. Match mark
GREN DE ENGRANAJES
1. Engranaje del cigi.ienal
2. Engranaje loco
3. E ngranaje del arbol de levas 4. Engranaje impulsor de la bomba de inyeccion
5. Engranaje impulsor de la bomba de aceite
6. Engranaje de bomba del
enfriador
7. Marcas de Alimeati6n
Fig. 3-4-2
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PIGNONS DE DISTRIBUTION 1. Pignon du vilebrcquin Pignon intermediaire de distribution 3. Pignon de I 'arbrn a carnes 4. Pignon d'entrainement de la pompe a injection 5. Pignon d'entrainement de la 6. Pignon de pompe a eau 7. Marques d'appariement 2
3-4-3
HE11-087-00X01 (1300)
1. Camshaft
2. 3. 4. 5. 6.
7.
8.
9.
10.
Camshaft gear Idler gear Injection pump drive gear Spacer Thrust plate Plain washer Idler gear shaft Bushing Thrust plate
1.
Arbol de levas Engranaje del arbol de levas 3. Engranaje loco 4. Engranaje impulsor de la bomba de i nyecci6n 5. Espaciador 6. Placa de empuje 7. Arandela plana 8. Ene del engranaje loco 9. Casquillo 10. Placa de empuje
2.
1.
Arbre
a cames
2. Pignon dentrainement de
3. 4. 5.
6. 7.
8. 9.
10.
Fig. 3-4-3
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
a
l'arbre cames Pignon intermediaire de distribution Arbre d'entrainement de la pompe d'injection Cale d' epaisseur Plaque de butee Rondelle plate E'.nsemble axe de pignon intermediaire de distribution Bague Plaque de butee
3-4-4 Disassembly
1. Remove the crankshaft pulley.
1. Remueva la polea del ciguefial. 1. Deposer la poulie d'arbre a cames.
Fig. 3-4-4
SM3-935
2. Râ&#x20AC;˘mo,o th, 0;1 pan. ,.... ,
Fig. 3-4-5
03-1835
t;;I ďż˝: c:J
Remove the timing gear cover.
Remueva la cubierta del engranaje de la distribuci6n.
3. Deposer le couvercle de pignons de distribution.
Fig. 3-4-o
03-1836
Fig. 3-4-7
03-2058
3-4-5
El Fig. 3-4-8
I Special tool
5. Remove the idler gear. 5. Remueva el engranaje intermedio. 5. Deposer le pignon intermediaire.
03-571
09420-1442, 09462-1410
•· Remove the ;n;,ct;on pump dd,e .,., and ,halt. ,...... ,
Fig. 3-4-9
03-1840
03-1841
Remove the camshaft. 1) Remove the valve lifter (tappetI chamber cover.
El
2) Install the tapper holder and remove the camshaft. 3) Using a special tool, lift up the tappets and sus pend them above the camshaft. 4) Lubricate all journals of the camshaft and insert the camshaft assembly into the cylinder block.
NOTE: 0 Insert the camshaft, slowly turning while insert ing so that the bearing will not be damaged.
Fig. 3-4-11
I Special tool
SM3-952
SM3-839
09451-1040
3-4-6
E3
5) Remove the tappets (1) Remove the special tool (stopper). (2) Remove the tappets.
NOTE: Be sure to arrange the tappets in correct order.
03-2066
Fig. 3-4-12
8. If nooo,,a,y, ,omo,o tho oam,hoft d,;,. goa,. .
... , ..
03-1845
Fig. 3-4-13
I
,
Special tool
09420-1111
•· Romo" tho ;n;,ct;on pump d,;,. ,hoft boa,;ng. ,
Fig. 3-4-14
I
Special tool
..
... ,
03-1847
03-1846 09420-1180
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3-4-7 Inspection and repair 1. Measure the clearance between the idler gear shaft and the idler gear bushing.
03-1848
Fig. 3-4-15
Fig. 3-4-16 Standard Repair limit
03-1849 0.030-0.090 mm (0.0012-0.0035 in) 0.20 mm (0.0079 in)
2. Measure the idler gear end play. 2. Mida el juego longitudinal del engranaje intermedio. 2. Measurer le jeu en bout du pignon intermediaire.
Fig. 3-4-17 Standard Repair limit
03-578 0.049-0.140 mm (0.0019-0.0055) 0.30 mm C0.0118 in)
lu 1 Fig. 3-4-18 Camheight Service limit
SM3-347 54.85 mm (2.1594 in) 54.05 mm (2.1280 in)
SM3-563
··
MeHure th• cam h,;ght.
3-4-8
l!tl Fig. 3-4-19
4.
Measure the clearance between the camshaft journal and the bearing. (Refer the table of page 3-118, 3-119).
03-575
03-574
0.03-0.12 mm (0.0012-0.0047 in) 0.3 mm (0.0118 in)
ltJ
Fig. 3-4-20 Repair limit
I
0. Mea'"'eth, <amshaft ,un out.
03-573
0.10 mm (0.0039 in)
g-
Fig. 3-4-21
6. Measure the camshaft end play. 6. Mida el juego longitudinal del arbol de levas. G Mes11rtcr le jeu en 110111 de l'arhre a ra111es.
03-576
0.10-0.23 mm (0.004-0.009 in) 0.30 mm (0.0118 in)
IÂŽ I
Fig. 3-4-22
03-1850
7. ln,peot thâ&#x20AC;˘ ;njoot;on pump d,;,.,haft beadng.
3-4-9
�� ,�irF.,
/.'.o• ... ,,
•/'
0) ,
I
lg:]
8. Measure the clearance between the tappet and' the tappet guide.
.
-..:2./' '\.. '
l
....___,"--2.,,_,'...'
'..___ / Fig. 3-4-23 Standard Repair limit
SM3-325
SM3-420
0.020-0.066 mm (0.0008-0.0025 in) 0.10 mm (0.0039 in)
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3-4-10
El Fig. 3-4-24
I
Pre-road
Assembly
1. Install the injection pump drive shaft and bearing. NOTE: Adjust the bearing pre-load using the shims.
03-1852 4-12 kg-cm (0.29-0.86 lb-ft)
l. Install tho timing goa, plat•. ,....,
I
Fig. 3-4-25 Tightening torque
03-1853 190-270 kg·cm (14-19 lb-ft)
J. Install tho injoction p"mp boa,ing holdo,. ,....,
Fig. 3-4-26 Tightening torque
03-2083 190-260 kg·cm (14-18 lb.ft)
3-4-11 4. Install tho ;nject'•o� pump drive gear . . 1) Align the m1ect1on pump drive gear matching mark with the camshaft ·,di er gear. , ....., NO TE.. Incorrect installation can resu Its in engi ne d amage or lowering of 8ngine • performance b V causing • . . improper inJection timing.
Fig. 3-4-27
SM3-575
5. Install the tappet.
El
6. Install th e camshaft and tighten the bolts of thrust plate.
03-1856 Special tool Tightening torque
0 9451-1040 190-260 kg·cm (14-18 lb.ft)
03-1857 Tightening torque .
1 , 100
450
1, 200 kg·cm (1 00 -861b.ft) 5 kg·cm (33-36Ib.ft)
oo
l••.,I
'·
ln,tall tho 0;1 pump.
3-4-12 8. Install th• ;do, ,,.,. ,.....,
Fig. 3-4-31
03-1858
Be sure that matching marks of the crankshaft gear, camshaft gear, injection pump drive gear, and idle gear aligned correctly.
I L--
Fig. 3-4-32
SM3-593
9. Hghtoo tho ;o;,ct;oo pump d,;,. ,.., out. IJ
Fig. 3-4-33 J Tightening torque
rl
03-1859 2,000-2,200 kg•cm (145-159 lb-ft)
El Fig. 3-4-34 J Tightening torque
03-1860 1,800-2,000 kg·cm (130-144 lb.ft)
10. Tighten the idle gear bolt.
lu I
Backlash
Unit: mm (in)
Gears
Assembly allowance
Crank gear - idle gear
0.08 - 0.23 (0.0032-0.0090)
Camshaft drive gear - Idle gear
0.08 - 0.23 (0.0032-0.0090)
Idle gear - Injection pump drive gear
0.08 - 0.23 (0.0032-0.0090)
Camshaft drive gear - Oil pump drive gear
0.14 - 0.32 (0.0055-0.0125)
Fig. 3-4-36
Service limit
A
,C.,,. , �
"·
3-4-13 M,asure the tim;ngg,.. backla,h.
12. Standard gear backlash and service limit.
�
0.30 (0.0118)
0.35 (0.0138)
03-2058 200-250 kg·cm ( 15-18 lb.ft)
El
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 03-587 website: www.HeavyEquipmentRestorationParts.com
Fig. 3-4-37 I Special toi;,I
13. Install the timing gear cover oil seal.
09482-1180
3-4-14
03-1862
Fig. 3-4-38
1•••1
�I
••·
Install tno oH pan.
-=-----
Fig. 3-4-39
SM3-393
1•·•1
Fig. 3-4-40 Tightening torque
03-2259 5,500-7,000 kg•cm (398-506 lb.ft)
'"·
Install tho o,ank,haft pulley.
3-5-1
HINO EP100 EP100T CYLINDER BLOCK, PISTON AND CRANKSHAFT
BLOOUE .DE Cl LIND ROS, PISTON Y SIGUEl'JAL BLOC-CYLINDRES, PISTON ET VILEBREOUIN HE11-087-00X01
( 1100) (2/2)
4
2
1. Cylinder block 2. Oil level gauge guide 3. Oil level gauge
4. Valve push rod cover 5. Gasket 6. Oil pan
7. Gasket
8. Drain plug 9. Gasket
1. Bl oque de ci Ii ndros 2. Gu ia del indicador de nivel de aceite 3. lndicador del nivel de aceite 4. Cubierta de la varilla de empuje de la valvula 5. Junta 6. Colector de aceite 7. Junta 8. Tap6n 9. Junta
Fig. 3-5-1
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
1. Bloc-cylindres
2. Guide de jauge a huile 3. Jauge d'huile 4. Couvercle de la tige-poussoir r·0. Joint 6. Carter d'huile 7. Joint 8. Bouchon 9 Joint
3-5-2
LE17-094-00X05X06X07 (1100) (1/2)
CYLINDER BLOCK
1. 2. 3. 4. 5. 6. 7.
Hino EP100 EP100T Cylinder liner
Cylinder block Bearing cap Bearing cap bolt Strai ght pin Camshaft bearing Oil jet
BLOOUE DE CILINDROS 1. 2. 3. 4. 5. 6_ 7.
Camisa del cilindro Bloque de cilindros Tapa del cojinete Perno de la tapa del cojinete Pasador recto Cojinete del arbol de levas Injector de aciete
BLOCCYLINDRES 1. Chemise de cylindre 2. Bloc-cylindres 3. Chapea,J de palier 4. Boulon de fixation du chapeau de paliP.r !:°L GoupillP. 6. Pdli,•r r1"arbre a cames 7. Gicleur d'huile
Fig. 3-5-2
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3-5-3
HE11-087-00X01 (1200)
2!;}
7
17��,.
16
8
15 From Engine No. EP100T 00012570
2
HINO EP100 HINO EP100T CRANKSHAFT AND RELATED PARTS 1. 2. 3. 4. 5. 6. 7.
8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Crankshaft Crankshaft gear O-ring Crankshaft sleeve, front Dust slinger Crankshaft pulley center Pulley Bolt Collar O-ring Bolt Key O-ring Crankshaft sleeve Oil seal Gasket Retainer Flywheel dust cover Crankshaft bearing set Thrust bearing set Piston Piston ring Piston pin Retainer ring Connecting rod assembly Piston pin bushing Connecting rod bolt Ring gear Flywheel
Fig. 3-5-3
SM3-1043 CIGUENAL Y PIEZAS RELACION ADAS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Cigi.ieiial Engranaje del cigi.ieiial Anillo 0 Mangu ito del cigi.ieiial, delantero Deflector de polvo Centro de la polea del cigi.ieiial Polea Perno Collar in Anillo 0 Perno Chaveta Anillo 0 Manguito del cigi.ieiial Selle de aceite Junta Retenedor Cuvierta de contra del volante Juego de cojinete del cigi.ieiial Juego de cojinete de empuje Piston Arcs de piston Pasador de piston Anillo retenedor Cojunto de biela Casquillo del pasador de piston Perno de la,biela Engranaje angular Volante
VILEBREOUIN ET PIECES CON NEXES 1. 2. 3. 4. C,. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Vilebrequin Pignon de vilebrequin Joint torique Manchon de vilebrequin, AV deflecteur de poussiere Cone epaule de poulie de vilebrequin Poulie Boulon Collier Joint torique Boulorr Clavette Joint torique Manchon de vilebrequ in Rone.Jelle de retenue d'huil<, Joint Support de joint Couvercle pare-poussiere de volan t Jeu de coussi,1ets Jeu de flasques Piston Segment de piston Ax,; de pisto11 Circlip Ensemble biellP. Bague de l'axe de piston Boulorr r:le fixation de bielle Couronne de volant Vol11nt
3-5-4
E1
Disassembly 1. Remove the flywheel assembly.
Desarmado
1. Remueva el conj unto de volante.
Demontage 1
Fig. 3-5-4
03-2169
E1 Fig. 3-5-5
2. Remove the flywheel housing. 2. Remueva el carter del volante. 2. Deposer le carter de volant.
03-1865
E1 Fig. 3-5-6
3. Remove the oil seal retainer. 3. Remueva el retenedor de sello de aceite. 3. Deposer la rondelle de retenue d'huile.
03-1866
E1 Fig. 3-5-7
Deposer. I 'ensemble vol ant.
03-727
03-1867
4. Remove the piston with connecting rod. 4. Remueva el piston con la biela. 4. Deposer le piston avec la bielle.
3-5-5
E)
Fig. 3-5-8
5. Remueva el ciguenal. 5. Deposer le vilelJreqLJin.
03-556
E)
Fig. 3-5-9
6. Remove the connecting rod. 6. Remueva la biela. 6. Deposer la bielle.
SM3-294
El
7. Remove the piston rings. 7. Remueva los aros de piston. 7. Deposer les segments de piston.
SM3-295
Fig. 3-5-10 Special tool
5. Remove the crankshaft.
09442-1190
Remove the cylinder liner.
NOTE: Put the line-up marks on the cylinder block and I iner flange.
Remueva la camisa del cilindro. NOTA: Ponga les marca de coincidencial bloque de cilindros y el reborde de la camisa del cilindro.
Deposer la chemise de cyl incJre. N.B. ¡ Faire les marques d'alliance sur le bloc-cylindres et la col lerette de la chemise de cylindre.
Fig. 3-5-11
SM3-851
3-5-6
a.
Romo,e tho oyhndo, 1;no,.
,......,
Fig. 3-5-12
03-539
Special tool
09420-1430
Inspection and repair
1. Measure the clearance between the small end bushing and the piston pin.
Fig. 3-5-13 Pin diameter Clearance
SM3-296
SM3-297
47.0 mm ( 1.850 in) I Service limit 46.95 mm ( 1.8485 in) Standard I 0.025-0.043 mm (0.0010-0.0016 in) 0.10 mm (0.0039 in) Repair limit I
Measure the spread dimension of the connecting rod bearing. Mida la dimension de la amplitud del cojinete de pie de biela. 2. Mesurer la dimension d'ecartement du conssinet de hielle.
Fig. 3-5-14 I Standard
SM3-298 80.75-81.75 mm (3.1792-3.2184 in)
3-5-7 3. Measurement of oil clearance between connecting rod and crank pin. 1) Measure the connecting rod inside diameter. 3. Medici6n de la holgura de aceite entre la biela y el codo de cigueiial. 1) Mida el diametro interior de la biela. 3. Prise cJe rnesure du jeu de passa[.)e cJ'huile entre hielle et rnaneton de vilehrequin. 1) Mesurer le diarnetre interieur de la bielle.
Fig. 3-5-15 SM3-300 SM3-564 Tightening torque 2,200-2,400 kg¡cm (160-173 lb.ft) Oil clearance 0.041-0.092 mm (0.0017-0.0036 in) Repair limit 0.30 mm (0.0118 in)
2) Measure the crank pin outside diameter. 2) Mida el diametro exterior de\ codo de cigueiial. 2) Mesurer le c.Jiametre exterieur c.Ju maneton c.Je vilebreljuin.
Fig. 3-5-16
SM3-430
Standard Repair limit Service limit
03-739
74.95-74.97 mm (2.9508-2.9515 in) 74.80 mm (2.945 in) 73.80 mm (2.906 in)
3) Check to ensure that this hole is not clogged up, by blowing air through it or inserting a piece of wire into it.
Fig. 3-5-17
SM3-424
4. Measure the connecting rod end play. 4. Mida el juego longitudinal de la bila. 4. Mesurer le jeu en bout c.Je la bielle.
Fig. 3-5-18 Tightening torque End play Service limit
SM3-576 2,200-2,400 kg¡cm (159-174 lb-ft) 0.15-0.32 mm (0.0059-0.013 in) 0.6 mm (0.0236 in)
I I I
3-5-8
lu 1
/
M .. , ... th, connooting rnd maightn,...
SM3-330
Fig. 3-5-19 I Service limit
··
0.1 mm (0.0039 in) for each 200 mm (7.87 in)
lu 1
··
Mea,u .. th, connooting rnd twist.
Fig. 3-5-20 I Service limit
0.1 mm (0.0039 in) for each 200 mm (7.87 in)
(;}��
I![) ��
_____l
lf----41----·__J_�
Fig. 3-5-21 Standard Service limit
SM3-313
7.
Measurement of the clearance between cylinder liner and piston. 1) Measure the cylinder liner inside diameter.
7. Medici6n de la holgura entre la camisa del cilindro y el piston. 1) Mida el diametro interior de la camisa del cilindro. 7. Prise de mesure du jeu entre chemise et piston. 1) Mesurer le diametre interieur de la chemise de cylindre.
SM3-432
120 mm (4.724 in) 120.15 mm (4.730 in)
2) Measure the piston outside diameter.
2) Mida el diametro exterior del piston. 2) Mesurer le diametre exterieur du piston.
Fig. 3-5-22 I Clearance
SM3-433 0.134-0.166 mm (0.0053-0.0065 in)
3-5-9 Measure the clearance between the piston pin hole and the piston pin.
Fig. 3-5-23
SM3-297
SM3-585
Outside diameter Clearance
Standard Standard Service limit
47 mm ( 1.850 in) 0.002-0.016 mm (0.00008-0.00063 in) 0.05 mm (0.0020 in)
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
Measure the clearance between the piston ring groove and the piston ring.
--
Fig. 3-5-24
Top ring, 2nd ring 3rd ring Oil ring
SM3-301
Clearance
Service limit
0.04-0.08 mm (0.0016-0.0031 in) 0.02-0.06 mm.(0.0008-0.0023 in}
0.2 mm (0.0079 in) 0.1 mm (0.0039 in}
-
-
3-5-10
lu I
--
Fig. 3-5-25
Top ring 2nd ring 3rd ring Oil ring
Service limit
M, ..... th, p;,ton ,;ng •nd """""·
SM3-302 Clearance 0.35-0.50 mm (0.0138-0.0196 in) 0.35-0.47 mm (0.0138-0.0185 in) 0.35-0.47 mm (0.0138-0.0185 in) 0.35-0.55 mm (0.0138-0.0217 in)
Service limit 1.5 mm (0.0590 in) 1.2 mm (0.0472 in) 1.2 mm (0.0472 in) 1.0 mm (0.0393 in)
lu I Fig. 3-5-26
'"·
"·
Meamoth, c,ank,hofnunout.
SM3-577 0.09 mm (0.0035 in)
12. Measure the spread dimension of the main bearing. ✓
----
12. Mida la dimension de la amplitud del cojinete prin cipal. 12. Mesu rer la dimension d 'ecartemen t du coussinet principal.
Fig. 3-5-27 Standard
SM3-298 96.75-98.00 mm (3.8091-3.8582 in)
3-5-11
,$,
l!tl
0
y
y
/
JOURNAL'
SM3-431
Fig. 3-5-28 Standard Repair limit Service limit
89.91-89 .93 mm (3.5398-3.5405 in) -0.2 mm (-0.0079 in) -1.2 mm (-0.0472 in)
rll
�
Tightening torque Oil clearance Repair limit
B
2) Measure the main bearing inside diameter. If the oil clearance is larger than repair limit, regrind or replace the crankshaft.
1{
00 00
Fig. 3-5-29
13.
Measure the oil clearance between crankshaft jour nal and main bearing. 1) Measure the crankshaft journal outside diameter.
,\
-
.
I
H
H
.- •- t -SM3-440
2,700-2,900 kg-cm (196-209 lb.ft) 0.050-0.106 mm (0.0020-0.0041 in) 0.30 mm (0.0118 in)
Machining dimension of crankshaft Under size bearing
Crank pin outside diameter
Journal outside diameter
0.25 mm (0.0098 in)
74.69-74.71 mm (2.9405-2.9413 in)
89.69-89.71 mm (3.5310-3.5319 in)
0.50 mm (0.0197 in)
74.44-74.46 mm (2.9307-2.9315 in)
89.44-89.46 mm (3.5212-3.5220 in)
0.75 mm (0.0295 in)
74.19-74.21 mm (2.9208-2.9216 in)
89.19-89.21 mm (3.5114-3.5122 in)
1.00 mm (0.0394 in)
73.94-73.96 mm (2.9110-2.9118 in)
88.96-89.94 mm (3.5024-3.5409)
Standard
74.950-74.970 mm (2.9508-2.9515 in)
89.910-89.930 mm (3.5398-3.5405 in)
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
3-5-12 3) Method of the crankshaft regrinding for fillet R.
�·J��. :::--.�
CORRECT
I
WRONG
I
SM3-441
Fig. 3-5-30
Dimension of C_ra_n_k_:;p_in_+-_4 _.5_-_5_.0_m_m 0 ( _._17_7_-_0_._196_in l � � fillet R Journal 4.5-5.0 mm (0.177-0.196� in).,... ----l
14. Measure the cylinder block surface evenness.
14. Mida la superificie del bloque de cilindros para comprobar su uniformidad. 14. Verifier la regularite de la surface du bloc-cylindres.
SM3-578
Fig. 3-5-31
15. Measure the crankshaft end play.
15. Mida el juego longitudinal del cigueiial. 15. Mesurer le jeu en bout du vilebrequih.
SfVl3-362
Fig_ 3-5-32 Standard Repair limit
0.110-0.240 mm (0.0043-0.0094 in) 0.50 mm (0.0197 in)
1) Measure the distortion of flywheel friction surface.
1) Mida la distorsi6n de la superficie de fricci6n del volanete. 1) Mesurer la distorsion de la surface de friction du volant.
03-858
Fig. 3-5-33 Repair limit
0.20 mm (0.0078 in)
3-5-13 Inspection and repair
1. Inspect the piston cooling jet positioning 1) Remove the piston cooling jet connector bolt and install a special tool.
Fig. 3-5-34
03-2092
Special tool
9001-24265
A
2) Use a commercially available oil pump [pressure about 2 kg/cm2 , flow rate about 2.5Q/min (0.66 US.gal)]. 3) Prepare new engine oil. 4) Connect the oil lines. Connect the oil pump outlet to a special tool (con nector bolt).
B
Fig. 3-5-35
SM3-579
A. Coling jet B. Bolt for inspection C. Oil hose for inspection
SPECIAL TOOL
COOLING JET
Fig. 3-5-36 j Special tool
SM3-942 09470-1090
5) Install a special tool on the cylinder block with locating pins. 6) Operate the oil pump, and with pressure at about 2 kg/cm2 (28.44 lb/sq.in), pump new oil from the jet, and perform a spray test. Conditions are nor mal if the center of stream hits a target plate of cj>10mm (0.39 in).
3-5-14 2. Adjust the direction of oil jet stream 1) Inspect the hitting position of oil spout on the target plate. NOTE: Operate the oil pump, and with pressure at about 2 kg/cm 2 (28.44 lb/sq.in), pump new oil from the jet, and perform a spray test. Conditions are normal if the center of stream hits a target plate of ¢10 mm (0.39 in).
TARGET
WARNING
Diesel oil is flamable. This spray test should be done in a well ventilated room and away from any open flames or electric sparks.
SPRAY
-$- $ ®-
-E!(TARGET ¢10 � '--v--' ABNORMAL NORMAL Fig. 3-5-37
SM3-923 SM3-581
2) Adjust the nozzle direction using a special tool, if the spray of the cooling jet messes the circle on the target plate.
Fig. 3-5-38
Special tool
09472-1620
SPRAY PATTERN
lll (d)
(cl
ABNORMAL
(b)
'------,.v-----
Fig. 3.5.39
SM3-953
VSPRAY
�OLINGJET NORMAL (a)
SM3-582
3) Inspect the spray pattern ( 1) When inspecting the piston cooling jet posi tioning, check that the spray is dispersed as shown in (a) and not as in (b), (c), or (d) in the illustration at left. (2) Check that the spray is not a thin muddy color.
NOTE: If the tip of the jet is damaged so that the spray pattern is bad, replace the jet wfth a new one. When replacing the cooling jet, always inspect the new piston cooling jet's positioning.
3-5-15 4) After inspecting the piston cooling jet positioning. Remove the special tool (connector bolt), then install the cooling jet on the cylinder block using the correct mounting bolt. 5) After installing the piston, make sure that there is no interference between the cooling jet and the piston when the piston is at bottom dead center.
NOTE: Do not remove the cooling jet except when per forming overhauls or when otherwise necessary. In the event that the cooling jet is removed, be sure to replace it on the cylinder.
Fig. 3-5-40
Tightening torque
200-250 kg¡cm (15-18 lb.ft)
03-2092
3. Inspect the pilot bearing. 3. lnspeccione el cojinete piloto. 3. Controler le roulement-guide.
Fig. 3-5-41
03-756
SPECIAL TOOL
(FRONT SIDE)
Fig. 3-5-42
SM3-565
Special tool
SPECIAL TOOL
(REAR SIDE) 09420-1560
SM3-566
09420-1570
E1
4.9-5.1 mm
SPECIAL TOOL
Fig. 3-5-43
I Special tool
Inspect the crankshaft sleeve for wear. If excessive worn, replace its. Replacement of crankshaft sleeve. 1) Remove the crankshaft sleeve (Front and rear).
SM3-985
(REAR SIDE) 09402-1161 09402-1220
SM3-568
2) Install the crankshaft sleeve (Front and rear).
NOTE: To prevent the oil seal lip from-dropping off, drive in the sleeve to a distance of 4.9 to 5.1 mm from the edge of the pulley center.
3-5-16
EJ
SPECIAL TOOL
TIMING GEAR CASE
Fig. 3-5-44 Special tool
5. Replacement of oil seal and dust slinger 1 I Front oil seal 5. Reemplazo del sello de aceite y del deflector de polvo 1) Sella de aceite delantero 5. Remplacement cle la rondelle de retenue cfhuile et le deflecteur cJ'huile 1) Rondelle cJe retenue cJ'huile AV.
SM3-569
09402-1161
SPECIAL TOOL
EJ
2) Front dust slinger. 2) Deflector de polvo delantero. 2) Detlecteur cl'huile AV.
PULLEY
Fig. 3-5-45
I
Special tool
SM3-570
09402-1290, 964507-435
EJ Fig. 3-5-46
I
Special tool
3) Rear oil seal. 3) Sella de aceite trasero. 3) Rone.Jelle de retenue cJ'huile AR.
SM3-966
09482-1420
E3
4) If necessary, remove the ring gear. a. Heat the ring gear with a blow torch in a uniform ° ° manner [Approx. 100 C (212 F)). b. Strike all around the ring gear in a uniform manner and remove it. 4) Si es necesario, remueva la corona dentada. a. Caliente la corona dentada con un soplete oxi ° acetilenio etc., de manera uniforme [Aprox. 100 C ° (212 F)]. b. Golpee de manera uniforme alrededor de la corona dentada y remuevala.
Fig. 3-5-47
SM3-787
a
3-5-17 Assembly and adjustment
1. Install the cylinder liner. Apply engine oil to the liner.
Armado y ajuste 1. I nstale la camisa del cilindro. Aplique aceite de motor en la camisa.
Remontage et reglage
1. Remonter la chemise de cylindre. Enduire la chemise de cylindre d'huile pour moteur.
Fig. 3-5-48 I Spacial tool
09480-1110 NOTE: When install the cylinder liner to be fit the same make with cylinder block (A or Bl.
IA A or B
I
'I
A or B
Fig. 3-5-49
SM3-583
2. Align the line-up marks of cylinder liner and block. 2. Alinee las marcas de coincidencia de la camisa del
cilindro y el bloque. 2. Faire aligner les marques d'alliance sur la chemise et le bloc-cylindres.
Fig. 3-5-50
SM3-851
3-5-18 3. Measure the protrusion of the cylinder liner flange.
3. Mida la saliente de la brida de la camisa del cilindro. 3. Mesurer la protrusion de la collerette de la chem,se de cylindre.
Fig. 3-5-51 Special tool Tightening torque Protrusion
03-546 09420-1450 100 kgâ&#x20AC;˘cm (7.23 lb.ft) 0.04-0.10 mm (0.0016-0.0039 in)
PRESSURE: 500kg (1,100 lb)
Fig. 3-5-52
SM3-572
rrr
Mounting the crankshaft 1) Apply engine oil to the bearing.
NOTE: Do not forget to install the thrust bearing.
4. Montaje del ciguefial 1) Aplique aceite de motor en el cojinete.
NOTA: No olvide de instalar el cojinete de empuje.
4. Remontage du vilebrequin 1) Enduire le coussinet d'huile pour moteur. N.8.: Ne pas oublier de remonter les flasques.
Fig. 3-5-53
03-762
El Fig. 3-5-54
03-556
2) Install the crankshaft.
2) lnstale el ciguefial. 2) Remonter le vilebrequin.
3-5-19
ARROW MARK
El
3) Install the bearing cap and thrust bearing.
TIMING GEAR SIDE
Fig. 3-5-55
SM3-855
El Fig. 3-5-56 Tightening torque
4) Tightening the main bearing cap bolt. NOTE: Make sure that crankshaft rotates smoothly. Tightening sequence: 4-3-5-2-6-1-7
03-564
2,700-2,900 kg-cm (195-209 lb.ft)
El
5.- Assembling the piston and connecting rod. 1) Assemble the piston and connecting rod.
5. ¡ Armado del piston y la biela. 1) Arme el piston y la biela. 5. Assemblage du piston et de la biel le. 1) Assembler le piston et la bielle.
Fig. 3.5.57
03-214
m l=:I INJECTION PUMP SIDE
Fig. 3-5-58
SM3-407
2) Piston and connecting rod fitting position.
3-5-20 3) Position of ring gap seen from piston top. OMARK
3) Posicion de la holgura del aro vista de la parte superior del piston. 3) Position de la fente du segment vue au dessus du piston.
RING UPPER FACE
IDENTIFIÂ CATION NO.
SM3-573
Fig. 3-5-59
El Fig. 3-5-60
SM3-383
Special tool
09441-1051
m
ďż˝
Tightening torque
2) Direction of the piston head.
NOTE: When installing the piston and connecting rod assembly, be careful that the cooling jet is not struck by the connecting rod.
SM3-967
El Fig. 3-5-62
6. I nstale el conjunto del piston 1) Lubrique el piston y la camisa del cilindro. 6. Monter !'ensemble piston 1) Graisser le piston et la chemise de cylindre.
03-857
PISTON O-MARK IDENTIFICATION MARKS OF LINER AND BLOCK
Fig. 3-5-61
6. Install the piston assembly 1) Lubricate the piston and cylinder liner.
03-547 2,200-2,400 kg-cm (160-173 lb.ft)
7. Tightening the connecting rod bolt.
7. Apriete las biela perno. 7. Serrer les l>ielle IJoulon.
3-5-21
El
8. Instate el retenedor de sello de aceite. 8. Monter la rondelle de retenue d'huile.
03-1868
Fig. 3-5-63 Tightening torque
8. Install the oil seal retainer.
190-260 kgâ&#x20AC;˘cm (14-18 lb.ft)
B
9. Install the flywheel housing.
9. Instate el carter del volante. 9. Monter le carter de volant.
Fig. 3-5-64 Tightening torque
Fig. 3-5-65 Tightening torque
1,000-1,300 kg-cm (73-93 lb.ft)
B
10. Install the flywheel.
10. Instate el voltante. 10. Monter le vol ant.
03-2169
2,600-2,900 kg¡cm (189-209 lb.ft)
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MEMO
3-6-1 HINO EP100 HINO EP100T LUBRICATING SYSTEM SISTEME DE LUBRICACION SYSTEME OE REFROIOISSEMENT �1
, a :
"
24
2 3
26 5
25
21
9 +----23 SM3-1044
LUBRICATING SYSTEM 1. Piston 2. Cooling jet 3. Sub oil hole 4. Crankshaft 5. Main hole 6. Camshaft 7. Injection pump 8. Fuel injection pump drive gear 9. Turbocharger 10. Check valve 11. Pressure gauge (OPT.) 12. Safety valve 13. Oil filter warning switch Fig. 3-6-1
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Oil filter (Full-flow) Oil filter (By-pass) Low cut off valve Oil cooler Safety valve Regulator valve Safety valve Oil pump Oil strainer Oil pan Check valve To valve system To jet
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3-6-2
HE11-094-00X00 (1400)
1. Oil pump 2. 3.
4. 5.
O-ring Suction strainer Oil cooler O-ring
1.
Bomba de aceite
2. AnilloO
1.
2.
3. Colador de aspiraci6n
3.
4. Enfriador de aceite 5. AnilloO
4.
5.
Pompe a huile Joint torique Crepine d'aspiration Refroidisseur d'huilf. Joint torique
Fig. 3-6-2
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3-6-3
1420D I-NO.20
�
4
.1·
��
7
""
�
L/
1. Oil cooler case
2. Regulator valve 3. Safety valve
4. Safety valve
5. Element
6. Cover 7. Bolt 8. co·ver 9. Gasket 10. Element
7
i�
6
L_/
10 6
1. Caja de enfriador de aceite
1.
Carter de refroidisseur a huile
2. Valvula de regulaje
2. Soupape de regulatrice
3.
Valvula de seguridad
4. Valvula de seguridad
5.
6.
Elemento Cubierta Perno Cubierta Junta Elemento
3. 4. 6.
7.
8. 9.
10.
5. 7. 8. 9. 10.
Fig. 3-6-3
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Soupape de securite Soupape de securite Cartouche de filtre Couvercle Bou Ion Couvercle Joint Cartouche de fi ltre
3-6-4
1458S I-N0.21
HINO EP100 HINO EP100T Engine Oil Pump
1. 2. 3. 4. 5. 6. 7. 8.
Oil pump body Oil pump cover Driven gear Drive gear Drive shaft Bushing Drive gear Safety valve
a huile a huile
1. Caja de bomba de aceite
1. Corps de pompe
2. Cubierta de bomba de aceite
2. Couvercle de pompe
3. Engranaje impulsado 4. Engranaje impulsor 5. Eje impulsor
6. Casquillo
7. Engranaje impulsor
8. Valvula de seguridad
3. Piynon entraine
4. Pignon d"entraine,nent 5. Arure d"entrainernent 6. Bague 7. Pignon d'entrairiement 8. Soupape de securite
Fig. 3-6-4
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3-6-5 Inspection and repair 1. Oil pump and oil cooler 1) Measure the clearance between the pump case and gear teeth.
Fig. 3-6-5
Standard Repair limit
03-581
0.033-0.10 mm (0.0013-0.0039 in) 0.13 mm (0.0051 in)
2) Measure the end play of the driven gear. 2) Mida el juego longitudinal de! engranaje impul sado. 2) Mesurer le ieu en liout du pignon entraine.
Fig. 3-6-6
Standard Repair limit
SM3-927
0.040-0.092 mm (0.0016-0.0036 in) 0.15 mm (0.0059 in)
3) Measure the oil clearance between the drive gear shaft and the inside diameter of pump cover.
Fig. 3-6-7
Standard Repair limit
SM3-929
0.04-0.083 mm (0.0016-0.0032 in) 0.15 mm (0.0059 in)
4) Mesure the gear backlash. 4) Mida el contragolpe de los engranajes. 4) Mesurer le batternenr des engrenages.
Fig. 3-6-8
Standard Repair limit
03-584
0.15-0.28 mm (0.006-0.011 in)_ 0.4 mm (0.0157 in)
3-6-6 �. �
2. Oil cooler Inspect the oil cooler for cracks and any other damage. 2. Enfriador de aceite lnspeccione el enfriador de aceite en cuanto a grietas y cualquier otro dafio. 2. Refroidisseur d'huile Controler le refroidisseur d'huile a lil rH:herche cJe fissures et ci'autres deteriorations
Fig. 3-6-9
03-597
Cooler-element 150-250 kg·cm ( 11-18 lb.ft) Tightening torque t--------+-----=----------l Cooler assembly 130-180 kg•cm (10-13 lb.ft)
�r
Oil filter 1) Inspect the safety valve, regulator valve and springs for wear and any other damage.
3. Filtro de aceite 1) I nspeccione la val vu la de seguridad, valvula de regulaje y el resorte en cuanto a desgaste y cual quier otro dafio. 3. Filtreahuile 1) C:ontroler la soupape cJe sec:urite, soupapc cJc regulatrice et le ressort a la recherche cl'usure et cJ'autre deterioration
Fig. 3-6-10
03-595
Regulator valve 300-400 kg·cm (22-28 lb.ft) Tightening torque t-=--c------+-----=---'----'---'-....:....--1 Safety valve 250-350 kg•cm (19-25 lb.ft)
2) Inspect the oil filter element and • 0' -ring for clog and any other damage.
Fig. 3-6-11
03-591
3) Wash the element in clean diesel fuel to allow no foreign matter to enter. 3) Lave el elemento el combustible diesel limpio a fin de impedir la infiltracion de cuerpos extrafios. 3) Laver la cartouche dans le combustible diesel propre afin de ne pas permettre !'introduction des substances etrangeres.
Fig. 3-6-12
03 776
3-7-1 HINO EP100 HINO EP100T COOLING SYSTEM SISTEME DE ENFRIAMIENTO SYSTEME DE REFROIDISSEMENT HE11-094-00X01 (1600)
1. Coolant pump out let pipe
2. Coolant pump
3. Hose 4. Thermostat case cover 5. Thermostat case 6. Thermostat 7. Gasket 8. Cooling fan
1. Tuba de salida de la bomba 2. 3. 4. 5. 6. 7. 8.
del enfriador Bomba del enfriador Manguera Cubierta de la caja del thermostato Caja del termostato Termostato Junta Ventilador del radiador
1. Canalisation de debouche de pompe eau 2. Pompe eau 3. Du rite 4. Couvercle de la cage de thermostat 5. Cage de thermostat 6. Thermostat 7. Joint 8. Ventilateur
Fig. 3-7-1
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a
a
3-7-2
1659J I-N0.21
2
COOLANT PUMP
BOMBA DEL ENFIADOR
Case Shaft Vane Coolant seal Spacer 6. Plate 7. Gasket
1. Caja
1. 2. 3. 4. 5.
Fig. 3-7·2
2. Eje 3. Paleta 4. Sello del enfriador 5. Espaciador 6. Placa 7. Junta
POMPE A EAU 1. Carter Arbre Ailette 0 Bague d etancheite EntretoisP. 6. Plaque de fermeture 7. Joint
2. 3. 4. 5.
3-7-3
El
Coolant pump Disassembly 1. Remove the plate and vane.
Bomba de enfriador
Desarmado 1. Reml)eva la placa y el alabe.
Pompe a eau
Demontage 1. Deposer la plaque de fermeture el l'ailette. SM3-954
Fig. 3-7-3 I Special tool
09412-1080
El Fig. 3-7-4
2. Remove the retainer ring. 2. Remueva el anillo retenedor. 2. Deposer le circlip
SM3-964
3. Remo,e the d,;., shaft, wam seal aad oH seal. , .... ,
Fig. 3-7-5
SM3-994
Inspection and repair 1. Inspect the disassembled parts for wear, cracks and any other damage. I nspecci6n y reparaci6n 1. I nspeccione las piezas desarmadas en c_uanto a des gaste, grietas, y cualquier otro dano.
Controle et reparation
1. ConIroler 1es pieces desassernblees a la recherche cl'usure, de felures et d'autres deteriorations.
Fig. 3-7-6
03-1876
3-7-4
r=1
2. Clean the water drain hole.
L:J
Fig. 3-7-7
SM3-932
El Fig. 3-7-8
Special tool Tightening torque
2. Install the retainer ring. 2. lnstale el anillo retenedor. 2. Remonter le circlip
SM3-964
El Fig. 3-7-10
1. Install the oil seal, water seal, and drive shaft.
SM3-963
El Fig. 3-7-9
Assembly
SM3-954 09412-1080 1,150-1,250 kgâ&#x20AC;˘cm (83-90Ib.ft)
3. Install the vane to the shaft. 3. lnstale la paleta en el eje. 3. Remonter l'ailette sur l'arbre.
B Fig. 3-7-11
3-7-5 Thermostat
1. Disassembly 1) Loosen the 4 bolts attaching the thermostart cover and case, then remove the thermostat from within the case.
SM3-366
Inspection 1) Inspect the thermostat case. Check to see whether there is deterioration or damage to the thermostat attachment section. Replace any worn or damaged parts.
Fig. 3-7-12
SM3-370
3-7-6
a
Assembly
1. Replace the gasket without fail if it is corroded, damaged or flattened. 2. Before installing the thermostat, apply sealing com pound to the thermostat gasket and the hose installa tion portion of the thermostat case cover.
Armado
1. Reemplace sin falta la junta en caso que este corroida, danada o aplastada. 2. Antes de instalar el termostato, aplique empaque• tadura liquida en la junta del termostato, y en la porci6n de instalaci6n de la manguera en la cubierta del termostato.
Fig. 3-7-13
Gasket Plate Cover Thermostat 5. Case
1. 2. 3. 4.
SM3-791
1. Junta 2. Placa 3. Cubierta 4. Termostato 5. Caja
El Fig. 3-7-14 I Tightening torque
SM3-807 190-270 kg.cm (14-19 lb.ft)
3. Tighten up the clamp bolts of the case and thermo stat cover.
3. Apriete los pernos de fijaci6n de la caja y de la cubierta del termostato.
3-7-7 2) Check the valve lift in hot water. ° Valve opening temperature: 76.5 C Maximum valve lift: 10.0 mm 2) lnspeccione el alzado de la valvula en agua caliente. ° Temperatura de apertura de la valvula: 76,5 C Alzado maximo de la valvula: 10,0 mm
2) Verifier la levee de la soupape dans l'eau chaude. ° Temperature d'ouverture de la soupape: 76,5 C Levee maxi. de soupape: 10,0 mm
Fig. 3-7-15
SM3-805
10 MM
t
A
° 0 C
°
f--10 C•--; °
76.5 C
I I
°
90 C
Fig. 3-7-16
1. Stirring rod
2. 3. 4. A. B.
Thermometer Thermostat Heater Lift Temperature
SM3-638
1. Varilla de mezcla
1. Agitateur
2. Term6metro
2. Thermometre 3. Thermostat
3. Term6stato
4. Calentador
A. Alzado B. Temperatura
4. Chau ff age A. ·Levee B. Temperature
3-7-8
El 03-793
Fig. 3-7-17
Pressure
Radiator
1. Inspect the radiator cap pressure.
0.4-0.6 kg/cm
2
(5.64-8.53 lb.sq.in)
2. Inspect the radiator for crack and clogging of tube. 2. lnspeccione el radiador en cuanto a grietas y obtura ci6n el tubo. 2. Contr61er le racliiiteur ;'1 lil reclierche cle fissures r.t de IHlLICiicll.jP cill tllytltJ
Fig. 3-7-18
03-794
3-8-1 HINO EP100 HINO EP100T FUEL SYSTEM SISTEMA DE COMBUSTIBLE SYS TEME DE COMBUSTIBLr
-
t
t
(Automatic timer is optional) 5
SM3-595 HINO EP100 HINO EP100T FUEL SYSTEM
SISTEMA DE COMBUSTIBLE
SYSTEME DE COMBUSTIBLE
1. 2. 3. 4. 5.
1. Filtro de combustible (secundario) 2. Portainyector 3. Bomba de alimentaci6n 4. Separador de agua 5. Tanque de combustible
1. 2. 3. 4. 5.
Fuel f ilter (seocndary) Injector Feed pump Water separator Fuel tank
Fig, 3-8-1
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Filre a carburant lsecondaire) Porte-injecteur Pompe d'alimentation Separateur d'eau Reservoir de carburant
3-8-2
HE11-087-00X01 (1500)
5 HINO EP100 HINO EP100T RELATED PARTS OF FUEL SYSTEM
1.
2. 3. 4. 5. 6.
7.
8.
9.
10. 11.
Fuel injection pump assembly Fuel feed pump Automatic timer (OPT.) Coupling Fuel injection pump drive gear Nozzle holder Fuel filter High pressure pipe Fuel pipe (inlet) Fuel pipe (return) Fuel pipe (return)
PIEZAS RELACIONADAS CON EL SISTEMA DE COMBUSTIBLE 1.
2. 3.
4.
5.
6.
7.
8. 9.
10. 11. Fig. 3-8-2
Conjunto de la bomba de inyecci6n del combustible Bomba de alimentaci6n del combustible Dispositivo de avance automatico (OPC.) Acoplamiento Engranaje impulsor de la bomba de inyecci6n del combustible Portainyector Filtro de combustible Tubo de alta presi6n Tubo de combustible (admisi6n) Tubo de combustible (retorno) Tubo de combustible (retorno)
PIECES CONNEXES AU SYSTEME D'ALIMENTATION EN COMBUSTIBLE 1.
2, 3. 4, 5,
6. 7. 8.
9.
10. 11.
a
Ensemble pompe injection Pompe d'alimentation de carburant Dispositif d'avance automatique (sur demande) Accouplement Pignon d'entrainement de la pompe injection Porte-i njecteu r Filtre carburant Tuyau a haute pression Tuyau de carburant (admission) Tuyau de carburant (retour) Tuyau de carburant (retour)
a
a
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3-8-3
1530R I-NO.20
�
10 9
6
8
\+
5
4
7
�
3---'
2 1
HINO EP100 INJECTOR HINO EP100T INJECTOR
1. 2. 3. 4.
5. 6. 7. 8. 9.
10. 11.
Nozzle holder assembly Gasket Inlet connector Nozzle holder press pin Pressure spring Adjusting screw Gasket Retaining nut Gasket Joint bolt Nozzle holder cap nut
PORT Al NY ECTOR 1. Conjunto de portainyector
2. Junta
3. Conector de admision
4. Pasador de presion del portainyector 5. Resorte de presion 6. Tornillo de ajuste 7. Junta 8. Tuerca retenedora 9. Junta 10. Perno de union 11. Tuerca de combrerete del po rta in yector
PORTE-INJECTION 1.
Ensemble porte-injecteur
2. Joint
3. Connecteur d'admission
4. Tige de pression du porteinjecteur
5. Ressort depression 6. Vis de reglage
7. Joint 8. Ecrou de retenue
9. Joint 10. Bou Ion d'articu lat ion 11. Ecrou a chapeau de porte-
Fig. 3-8-3
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injecteur
3-8-4
1518M I-N0.22
-2
�-10 '----11
FUEL FILTER
1. Body
2. Center bolt 3.
4. 5. 6. 7. 8. 9. 10. 11.
O-ring Element spring Element spring seat Element kit O-ring Body cover Bleeder plug Gasket Drain plug
Fig. 3-8-4
FILTRO DE COMBUSTIBLE 1. Cuerpo 2. Perno central 3. Anillo 0 4. Resorte del elemento 5. Asiento del resorte del elemento 6. Juego de elemento 7. AnilloO 8. Cubierta del cuerpo 9. Tap6n de purga 10. Junta 11. Tap6n de vaciado
Fl L TRE A CAR BU RANT 1. 2.
3.
4. 5.
6. 7. 8.
9.
10. 11.
Corps Bou Ion central Joint torique Ressort de cartouche Siege de ressort de canouche Ensemble cartouche Joint torique Couvercle de corps Bouchon de trop-plein Joint Bouchon de vidange
3-8-5
1571 B I-NO.20
4-0
3
�·
�--··---7 �
SEDIMENTER 1.
Cover 2. Body 3. Float 4. O-ring 5. Nut 6. Drain plug 7. O-ring 8. Bolt 9. Gasket Fig. 3-8-5
SEDIMENTADOR 1. Cubierta 2. Cuerpo 3. Flotador 4. Anillo 0 5. Tuerca 6. Tap6n de vaciado 7. Anillo 0 8. Perno 9. Junta
0------------
6
SEDIMENTEUR 1. 2. 3.
Couvercle Corps Flotteur 4. Joint torique 5. Ecrou 6. Bouchon de vidange 7. Joint torique 8. Bou Ion 9. Joint
3-8-6 Disassembly
1. Disassemble the injection nozzle.
03-786
Fig. 3-8-6
Inspection and adjustment 1. Inspect the injection pump coupling for cracks and any other damage.
lnspecci6n y ajuste 1. I nspeccione el acoplamiento de la bomba de inyec ci6n en cuanto a grietas y cualqu ier otro daii o.
Controle et reglage
a
injection Controler l'accouplernent de la pompe la recherche de felure et d'autres deteriorations.
Fig. 3-8-7
a
03-796
2. Inspect the nozzle for wear and damage. 2. lnspeccione el inyector en cuanto a desgaste y daiios. 2. Controler l'injecteur a la recherche de l'usure et de la deterioration.
Fig. 3-8-8
03-797
3. Adjusting the injection pressure. 1) Assemble the injection nozzle. 3. Ajuste la presi6n de inyecci6n. 1} Arme la tobera de inyecci6n. 3. Reglage de la pression d'injection. 1) Assembler l'injecteur
Fig. 3-8-9
I Tightening torque I
03-798 600
~
800 kg.cm (44
~
57 lb.ft)
3-8-7 2) Adjust the injection pressure.
2) Adjuste la presion de inyeccion. 2) Regler la pression d'injection
Fig. 3-8-10
03-799
Injection pressure I 220 kg/cm l (3,128 lb/sq .in)
3) Checking the spray profile. 4) In the spray profile is unsatisfactory, clean or replace the nozzle.
r 1
GOOD DEFECTIVE DEFECTIVE Fig. 3-8-11
DEFECTIVE SM3-450
ASSEMBLY
_,.
CLOCK WISE
C)
Fig. 3-8-12
Adjusting the injection timing
°
1. Rotate the crankshaft clockwise to a position 16 before top dead center of the compression stroke of the No.1 cylinder as seen in the inspection hole of the flywheel housing.
___ 16___ SM3-1047
2. Match the injection timing marks on the pump body side and the coupling side.
Fig. 3-8-13
EP1T-037
3-8-8 3. Check the rocker arms on No.1 cylinder are loose and rockers on No.6 are tight. NOTE:
Fig. 3-8-14
If not, turn the crankshaft one complete revolution and align marks as above.
SM3-338
Match the injection timing marks on the automatic timer. NOTE: Align the timing marks by turning the automatic timer to clockwise by hand. The automatic timer is optional.
Fig. 3-8-15
SM3-339
Fig. 3-8-16
SM3-340
Tighten the coupling bolt.
NOTE: There should not be any gap between the laminated plates or by any deformation of the flange due to pressure the laminated plates.
Fig. 3-8-17
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3-9-1 AIR CLEANER FILTRO DE AIRE FILTRE A AIR 2502E I-N0.23
-
/((\� /
J·
�--�
AIR CLEANER
FILTRO DE AIRE
1. Air cleaner body sub-assembly 2. Hook bolt
1.
3. Air cleaner cover sub-assembly
4. 5. 6. 7. 8.
Dust pan sub-assembly Filter element Gasket Wing nut Dust indicator
Fig. 3-9-1
2. 3. 4. 5. 6. 7. 8.
Sub-conjunto del cuerpo del filtro de aire Perno de gancho Cubierta del filtro de aire Sub-conjunto del colector de polvo Elemento del filtro Junta Tuerca de aletas I ndicador de polvo
FILTREAAIR 1. 2. 3.
a
4.
Sous-ensemble corps de filtre air Boulon-crochet Sous-ensemble couvercle du filtre air Sous-ensemble carter de poussiere
5. 6. 7. 8.
Cartouche de filtre Joint Ecrou a oreilles lndicateur de poussieres
a
3-9-2 Inspection
• ·1·
1. Inspect the rubber packing for damage .
lnspecci6n
. .
'
1. 1 nspeccione la empaquetadura de goma en cuanto a dai'ios
.
Cont role 1
Fig. 3-9-2
03-802
E]
Fig. 3-9-3
2. Element 1) Clean the element with compressed air. 2. Elemento 1) Limpie el elemento con a ire comprimido. 2. Cartouche 1) Net toyer la cartouche avec d'air comprime.
E024
E]
Fig. 3-9-4
Controler le joint caoutchouc a la recherche de sa deterioration.
Washing the element (only primary element) which is dirty with soot and oil. 2) Wash the element by soaking it in a non-sudsing detergent solution for about 30 minutes. Rinse it with clean water.
E025
Air dry the element completely. Do not apply fire or compressed air.
Fig. 3-9-5
03-808
3-9-3 4. Inspection Check the element for rupture or pin holes by plac ing a light inside the element after cleaning. Check for a damaged gasket. Replace if necessary.
Fig. 3-9-6
E087
3-9-4
13 Fig. 3-9-7 Tightening torque
ENGINE COMPONENT PARTS PIEZAS COMPONENTES DEL MOTOR PIECES COMPOSANT DU MOTEUR Assembly Armada Remontage 1. Installment of component parts Installment should be done in the opposite order of disassembly. Pay attention to the following points. 1) Install the inspection pump.
04-1322
NOTE: Adjust the injection timing refer to fuel system page 3-8-7.
380-500 kg·cm (28-36 lb.ft)
2. Install the intake manifold. , ....,
Fig. 3-9-8 HINO EP100 EP100T Tightening torque
SM3-1046
190-270 kg•cm (14-19 lb.ft)
3. ln,tall the exhau>t manifold. , ....,
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com Fig. 3-9-9 HINO EP100 EP100T Tightening torque
SM3-1041
450-500 kg·cm (33-36 lb.ft)
1•••1
130-180 kg•cm (10-13 lb.ft)
1•·•1
J. Install tho ooolant pomp and tho,momt '"'·
03-1886
Fig. 3-9-11 HINO EP100 EP100T Tightening torque
ln'1all th, oH coolo, (w;th on tut,,>.
03-2258
Fig. 3·9-10 HINO EP100 EP100T Tightening torque
•·
3-9-5
350-500 kg•cm (26-36 lb.ft)
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
3-10-1
TUNING THE ENGINE
PUESTA .A PUMTO DEL MOTOR
GONFLAGE DE MOTEUR
El Fig. 3-10-1
1. Coloque el conjunto del motor sabre un banco de pruebas.
SM3-810
OJ Fig. 3-10-2
1. Set the engine assembly on the test bench.
SM3-414
2. Fill the engine oil, power steering oil and coolant. 2. Rellene refrigerante, aceite de motor y de direcci6n de potencia.
3-10-2
m l:=I
Fig. 3-10-3
SM3-475
m l:=I
Fig. 3-10-4 j Tightening torque
3. Bleeding the air from the fuel filter (Secondary filter). 1) Loosen the bleeder plus of the fuel filter. 2) Loosen the priming pump handle. 3) Operate the priming pump handle and bleed the air from the filter until no air comes out through the bleeding plug. 4) Insert the priming pump handle, turn it to the right, and lock it. 5) Tighten the bleeder plug. 3. Purgue el aire del filtro de combutible (Filtro secundario). 1) Afloje el tap6n de purga del filtro de combustible. 2) Afloje la manivela de la bomba de cebado. 3) Opere la manivela de la bomba de cebado y prugue el filtro hasta que deje de aslir aire a traves del tap6n de purga. 4) lnserte la manivela de la bomba de cebado, girela hacia la derecha y enclavela. 5) Apriete el tap6n de purga.
03-2260 40-60 kg.cm (3-4 lb.ft)
A
Turn the engine stop lever to the engine stop position and crank the engine till the oil flows to each parts.
4. Gire la paranca de parada del motor al posici6n de "�4.
Fig. 3-10-5
03-2255
parada y dar vueltas al cigi..iefial hasta que el aceite circula hacia cada partes.
3-10-3 5. Start the engine. 1) Check the oil feed to rocker arms. Within one minute after starting the engine, oil should flow to the head ( Face A) of all push rods and the head ( Face B) of all valves. 2) Check the contact of the rocker arm and valve stem caps. After running the engine, contact of 7 to 11 mm (0.276 to 0.433 in) should be obtain ed at the cap contact face of the rocker arm. 3) Operate the engine for 30 to 40 minutes so that the cylinder head gasket is warmed and stabilized in dimension.
B
SM3-399
Fig. 3-10-6 A: B:
Face A Face B
A: B:
Cara A Cara B
NOTE: Check for water and gas leaks, and noise.
5. Arranque el motor 1) Revise de un minuto despues de poner en marcha el motor, el aceite circulara hacia la cabeza (cara A) de todos los empujadores, y la cabeza (cara B) de todas las val vu\as. 2) Revise el contacto de las tapas de\ balancin y de\ vastago de la valvula. Despues de arrancar el motor, se debe obtener un cojntacto de 7 a 11 mm (0,276 a 0,433 pul.) en la cara de contacto de la tapa de! balanci n. 3) Opere el motor durante 30 a 40 minutos, de manera tal que se caliente la junta de la culata del cilindro, y se estabilicen sus dimensiones. NOTA: Revise si hay ruidos o perdidas de agua o gas.
6. Check the injection timing ° 1) Rotate the crankshaft clockwise to a pos1t1on 15 before top dead center of the compression stroke of the No.1 cylinder as seen in the inspection hole of the flywheel housing. At the same time, check that the timing marks of the injection pump are aligned.
Fig. 3-10-7
SM3-413, SM3-1047
3-10-4 7. Adjust the valve clearance 1) Set each piston in firing order at top dead center of the compression stroke and adjust the valve clearance. Firing order: 1-4-2-6-3-5
--
03-1526
Fig, 3-10-8
Inlet Exhaust
Valve clearance, when cold 0.40 mm (0.0157 in) 0.50 mm (0.0197 in)
Set the No.1 piston to top dead center of compres sion stroke and adjust the valve clearance of the valves indicated in the table below. Then set the No.6 piston to top dead center and adjust the remaining valves. Firing order:· 1-4-2-6-3-5 Valve clearance, when cold; Inlet: 0.40 mm (0.0157 in) Outlet: 0.50 mm (0.0196 in)
SM3-519
Fig. 3-10-9
Cylinder Valve arrangement With No. 1 piston at T.O.C. on compression stroke With No. 6 piston at T.D.C. on compression stroke
1 I
•
3
2
E
•
I
0
E
•
I
•
4
E
I
()
0
6
5
E
•
I
•
E
I
E
()
()
()
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
3-11-1 TROUBLESHOOTING LOCALIZACION DE AVERIAS RECHERCHE DES PANNES
1. ENGINE OVER HEATING 1. RECALENTAMIENTO DEL MOTOR 1. SURCHAUFFE DU MOTEUR
OPERATION
OPERACION FONCTIONNEMENT
1-----
Over load
Sobrecarga Surcharge
Loosening or slipping fan belt
Flomedad o patinaje de la correa del ventilador Courroie de ventilateur desserree ou glissante Insufficient coolant water
I nsuficiencia de agua de enfriamiento Eau de refroidissement insuffisante
COOLING SYSTEM
SISTEMA DE ENFRIAMIENTO SYSTEME DE REFROIDISSEMENT
Clogged radiator
Radiador obstruido Radiateur bouche
Defective thermostat
Termostato defectuoso Thermostat defectueux Damaged coolant pump impeller
Rotor de la bomba de! refrigerante danado Turbine de pompe a eau de refroidissement endommagee
Engine oil level too low
N ivel de aceite de motor demasiado bajo Niveau d'huile de moteur trop bas Engine oil deteriorated
LUBRICATING SYSTEM
SISTEMA DE LUBRICACION SYSTEME DE LUBRIFICATION
Aceite de motor deteriorado Huile de moteur deterioree Defective oil cooler
Enfriador de aceite defectuoso Radiateur d'huile defectueux Defective oil pump
Bomba de aceite defectuosa Pompe a huile defectueuse
3-11-2
Improper injection pump timing Reglaje inadecuado de la bomba de inyeccion Reglage de la pompe d'injection incorrecte Defective nozzle injection I nyeccion defectuosa lnJection d'injecteur defectueuse ABNORMAL COMBUSTION COMBUSTION ANORMAL COMBUSTION ANORMALE
Injection pressure deteriorated Presion de inyeccion deteriorada Pression d'in1ection deterioree Excessive fuel volume Volumen de combustibole excesivo Volume de combustible excessif Poor quality fuel Combustible de calidad deficiente Combustible de mauvaise qualite
3-11-3 2.
EXCESSIVE OIL CONSUMPTION
2. CONSUMO EXCESIVO DE ACEITE 2. CONSOMMATION D'HUI LE EXCESSIVE
Oil leakage from head cover
Fuga de aceite de la cubierta de la culata Fuite d'huile du couvercle de culasse
Oil leakage from oil filter
Fuga de aceite del filtro de aceite Fuite d'huile du filtre a huile
OIL LEAKAGE
FUGAS DE ACEITE FUITE: O'HUI Le
Oil leakage fro� oil cooler
Fuga de aceite del enfriador de aceite Fuite d'huile du radiateur d'huile
Oil leakage from front oil seal
Fuga de aceite de! sello de aceite delantero Fuite d'huile de la bague d'etancheite avant
Oil leakage from rear oil seal
Fuga de aceite de! sello de ace\te trasero Fuite d'huile de la bauge d'etancheite arriere
Excessive oil flow on rocker arm
Flujo de aceite excesivo sobre el balanci n Debit excessif d'huile sur le culbuteur Valve guide worn VALVE, VALVE GUIDE
VALVULA, GUIA DE LA VALVULA SOUPAPE, GUIDE. DE SOUPAPE
Guia de la valvula gastada Guide de soupape use Valve stem worn
Vastago de la valvula gastado Tige de soupape usee
Valve seat worn
Aciento de la valvula gastado Siege de soupape use
Piston, liner and ring worn
Piston, c·amisam y aros gastados Piston, chemise et segment uses Shortage ring expanding PISTON, LINER, RING
PISTON, CAMISA, AROS PISTON, CHEMISE, SEGMENT
Expansion deficiente del aro Dilatation d'insuffisance de segment Damaged orsticked ring
Aro danado o adherido Anneau endommage ou colle Incorrectly assembled ring
Aros ensamblados incorrectamente Segment assemble incorrectement
3-11-4
3. BURNT OUT OF PISTON 3. OUEMADURA DEL PISTON 3. BRULURE DE PISTON
Operating under non cooling water OPERATION
OPERACION FONCTIONNEMENT
Operaci6n sin agua de enframiento Fonctionnement sous eau non refrigerante Sudden engine stop
Parada repentina del motor Arret brusque de moteur �Overload
Sobrecarga Surcharge
Insufficient cooling water
Agua de enfriamiento insuficiente Eau de refroidissement insuffisante � Clogged radiator Radiador obstruido Radiateur bouche COOLING SYSTEM
SISTEMA DE ENFRIAMIENTO SYSTEME DE REFROIDISSEMENT
Defective radiator cap
Tapa del radiador defectuosa Bouchon de radiateur defectueux Dirty water
Agua sucia Eau souillee Defective thermostat
Termostato defectuoso Thermostat souille
Insufficient oil
I nsuficiencia de aceite Huile insuffisante Decrease oil pressure
OIL SYSTEM
SISTEMA DE LUBRICACION SYSTEME D'HUI LE
Disminuci6n de la presi6n de aceite Pression d'huile diminuee Dirty oil
Aceite sucio Huile sou ii lee Poor quality oil
Aceite de calidad deficiente Huile de mauvaise qualite
3-11-5
Improper injection timing
Reglaje de la inyeccion inadecuada Calage d'injection incorrecte
ABNORMAL COMBUSTION COMBUSTION ANORMAL COMBUSTION ANROMALE
Excessive fuel injection
I nyeccion de combustible excesiva Injection de combustible excessi f Poor quality fuel
Combustible de calidad deficiente Combustible de mauvaise qualite
Ring broken
Rotura del aro Segment
Intrusion carbon to ring groove
PISTON, LINER, RING
PISTON, FORRO, ARO PISTON, CHEMISE, SEGMENT
Adhesion de carbonilla en la ranura del aro Penetration de carbone dans la gorge de segment Defective rubber ring
Aro de goma defectuoso Joint torique defectueux Improper assembly piston pin
Pasador del piston incorrectamente ensamblado Axe de piston assemble incorrectement
3-11-6
4. ENGINE LACKS POWER
4. EL MOTOR PIERDE FUERZA 4. LE MOTEUR MANOUE DE PUISSANCE
Draw air
Aspiraci6n aire Air de tirage Clogged fuel filter FUEL SYSTEM SISTEMA DE COMBUSTIBLE SYSTEME DE COMBUSTIBLE
Filtro de combustible obturado Filtre de combustible bouche
Worn and burn nozzle
I nyector gastado y quemado I njecteur use et brule
Poor quality fuel
Combustible de calidad deficiente Combustible de mauvaise qualite
Improper adjustment for control lever
Ajuste incorrecto de la palanca de control Reglage incorrect de levier de commande Improper injection timing INJECTION PUMP BOMBA DE INYECCION POMPE D'I NJECTION
Reglaje de la inyecci6n defectuoso Calage d'injection incorrecte
Clogged feed pump strainer
Colador de la bomba de alimentaci6n obturado Crepine de pompe d'alimentation bouchee
Uneven fuel volume
Volumen de combustible irregular Volume inegal de combustible
Improper valve clearance
Holgura de la valvula inadecuada Jeu de soupape incorrect Incorrect valve seat contact
Contacto incorrecto del asiento de la valvula Contact de siege de soupape incorrect ENGINE
MOTOR
MOTEUR
Perished valve spring
Resorte de la valvula defectuoso Ressort de soupape endommage
Worn piston and liner
Piston y forro gastados Piston et chemise uses
Insufficient coolant water
Agua de enfriamiento insuficiente Eau de refroidissement insuffisante
3-11-7 Insufficient coolant water
Agua de enfriamiento insuficiente Eau de refroidissement insuffisante Engine oil deteriorated
OVER HEAT
RECA LENTAM IE NTO SURCHAUFFE
Aceite de motor deteriorado Huile de moteur deterioree Abnormal combustion
Combustion anormal Combustion anormale Worn water pump
Bomba de agua gastada Pompe d'eau usee
3-11-8 5. BLOW OUT OF CYLINDER HEAD GASKET 5. ESTALLIDO DE LA JUNTA DE LA CULATA DEL CILINDRO 5. RUPTURE DE JOINT D'ETANCHEITE DE CULASSE
Incorrect tightening torque
Par de apriete incorrecto Couple de serrage incorrect
Incorrect" tightening sequence
HEAD BOLT
Secuencia de apriete incorrecto Ordre de serrage incorrect
PERNO DE LA CULATA BOULON OE CULASSE
Poor retightening
Deficiencia de reapriete Resserrage mediocre
CYLINDER HEAD GASKET
JUNTA DE LA CULATA DEL CILINDRO JOINT O'ET ANCHE ITE OE CULASSE
-
� Using wrong parts
Empleo de piezas erroneas Usage de pieces errones
� Reuse
Reuso Reusage
Cracked cylinder block and cylinder head CYLINDER BLOCK AND CYLINDER HEAD
BLOOUE DE CILINDROS Y CULATA .__ DEL CILINDRO BLOC-CYLINDRE ET CULASSE
Bloque y culata de cilindro agrietados Bloc-cylindre et culasse feles
>-- Distortion block top face or cracked cylinder head
Superficie superior del bloque deformado o culata del cilindro agrietada Face superieure de bloc deformee et culasse felee Shortage liner protrusion
Protusion deficiente de la camisa Saillie de chemise insuffisante
Improper injection timing
Reglaje de la inyeccion inadecuada Calage d'injection incorrecte Incorrect injection pressure
ABNORMAL COMBUSTION
COMBUSTION ANORMAL COMBUSTION ANORMALE
Presion de inyeccion incorrecta Pression d'iniection incorrecte Incorrect nozzle spray
Pulverizacion incorrecta del inyector Jet d'injecteur incorrecte Over heat
Recalentamiento Surchauffe
3-12-1 HINO EP100 HINO EP100T ENGINE PARTS SPECIFICATIONS Item
..
Flatness
ai -c
Regrinding limit
u
Protrusion of nozzle
-c .s::
.!:
>-
-
2.75-3.25 (0.1083-0.1279 I
Valve seat angle
45 °
xw �
Valve face angle
45
0
0
°
0
0
30 - 30 15' °
29 45' - 30
0
0
0
45 - 45 15' °
44 45' - 45
°
Intake valve
-
0-0.2 ( o .000-0.0078 I
io
>
Exhaust valve
....
a:
.,
.,"'> ::,
io
>
..
0
-
-
-
-
-
-
-
-
Replace gasket or nozzle
0
Regri1,1d with 30 or 45 cutter and finish by lapping
-
-
-
Rocker arm shaft outside diameter
24.2 (0.953)
24.16-24.18 (0.9512-0.9519)
-
24.12 (0.9496)
Replace shaft
Bushing inside diameter
24.2 (0.953)
24.21-24.26 (0.9532-0.9551)
-
24.28 (0.9559)
Replace bushing
-
0.03-0.101 (0.0012-0.0039)
0.15 (0.0059)
-
Replace shaft and/ or bushing
-
-
0.50 (0.0196)
-
Repair by pressing or replace
(0.39)
10
10.000-10.015 (0.3938-0.3942)
-
-
10 (0.39)
9.938-9.960 (0.3913-0.3921 I
-
9.88 (0.3890)
-
0.040-0.077 (0.0016-0.0030)
0.12 (0.0047)
-
10 (0.39)
9.921-9.943 (0.3906-0.3914)
-
9.88 (0.3890)
-
0.057-0.094 (0.0023-0.0037)
0.14 (0.0055)
-
77 (3.03)
-
75 (2.953)
Clearance
., ., ...-="'-"'> ..: >
Valve stem outside diameter Clearance
"'
::, .s;;iij )( ,.
w
Valve stem outside diameter Clearance
In
54.25 (2.1358)
Ex
52.75 (2.0768)
-
In
45.5 (100.3) 49.2 (108.5)
In 43.2-47.8 (95.3-105.3) Ex 48.9-51.5 (103.4-113.5)
Free length
"' .!: a. "' ....,::,
-
Regrind or replace
0.70 (0.0276)
.. ..... .,,.
C
.,>
103.7 (4.083)
0-0.2 Io .000-0 .0078 I
>
-c
-
Corrective method
0.70 (0.0276)
Valve guide inside diameter :-2
Service limit
-
Pushrod bend
>
-
104 (4.09)
...� .....&I
E .,..: " 0
io
0.10 (0.0039)
30
.,>
..
0-0.05 (0-0.0019)
Valve face angle
C
.,"E .,>
-
C "' >
..:
.s::
Repair limit
30
"iii
·c
Assembly standard or clearance
Valve seat angle
"'., .s:: >
E"'
Nominal dimensions
.....
., .,"'., ..: .. > .,._
Unit: mm (inch)
Setting length
Setting load kg (lb)
Ex Straightness
Tappet guide inside diameter Tappet outside diameter Clearance
-
-
-
-
20.0 (0.787) 20.0 (0.787)
20.000-20.021 (0.7874-0.7882) 19.995-19.980 (0.7857-0. 7866)
-
-
0.020-0.066 (0.0008-0.0025)
0.10 (0.0039)
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
-
41.8 kg (92.1 lbl 45.5 kg (100.3 lb) 3.5 (0.137)
Replace valve and valve seat
Replace valve Replace valve guide and/or valve Replace valve Replace valve guide and/or valve
Replace spring seat
Replace spring
20.10 (0.7914)
-
-
Replace tappet
3-12-2 Nominal dimensions
Assembly standard or clearance
Repair limit
Service limit
Intake
-
0.40 (0.0157)
±0.15 (±0.0059)
-
Exhaust
-
0.50 (0.0197)
±0.15 (±0.0059)
-
0.35-0.50 (0.0138-0.0196)
-
1.5 (0.059)
Item II>
g? � ti �
>:
Top ring
...
=c:
2nd ring
.. -c 0. II>
o,:: C: >
·-rx: "C:
-
0.35-0.47 (0.0138-0.0185)
Oil ring
-
0.35-0.55 I0.0138-0.0216)
Ring groove thickness
-
-
3.3 (0.1300)
3.29-3.30 (0.1 296-0.1299)
3rd ring
-�
0.
Ring breadth
Ring groove thickness
-
Ring breadth
2.8 (0.1102)
Clearance
C:
·5. C: 0
t: ·5. -c
= ... C:
C
=
·E
-c C:
N
0
.. .. ·E .. .. C: 0
c:'
·5.
C:
..... -ce.,. .....
... C: CD•-
-5 ti .:.:• C C ID C
... 0 u"
..
-
5.01-5.03 (0.1973-0.1980)
-
-
5.0 (0.1968)
4.97-4.99 (0.1957-0.1964)
-
-
-
0.02-0.06 (0.0008-0.0023)
-
0.10 (0.0039)
Piston pin hole inside diameter
47 (1.850)
47.002-47.008 ( 1.8505-1.8507)
-
-
Piston pin outside diameter
47 (1.850)
46.992-47.000 (1.8501-1.8503)
46.95 (1.8485)
Clearance between piston pin hole and pin
-
0.002-0.016 (0.00008-0.00063)
Connecting rod bushing inside diameter
47 (1.850)
47.025-47.035 (1.8514-1.8517)
-
0.05 (0.0020)
Clearance between piston pin and bashing
-
0.025-0.043 (0.0010-0.0016)
0.10 (0.0039)
Connecting rod big end width
42.85 (1.687)
42.78-42.85 (1.6843-1.6870)
Crankshaft crank pin width
43.0 (1,693)
43.0-43.1 (1.693-1.696)
2 .5 (0.0984)
2.47-2.49 (0.0974-0.0980)
-
Ring groove thickness Ring breadth
Clearance
-
0.15-0.32 (0.0059-0.013)
0 u
Straightness
-
-
Twist
-
-
C C
Replace piston and/or piston ring
-
5.0 (0.1968)
Ring breadth
...." C
-
0.20 (0.0079)
2.53-2.55 (0.0996-0.1003)
Replace piston and/or piston ring
-
-
2.5 (0.0984)
Clearance
C: 0
-
-
0.04-0.08 (0.0016-0.0031)
0
-c -c
-
Replace piston ring
-
-
"E M
-�
C:
-
Adjust at cold engine
1.0 (0.039)
-
.[
Ring gropve thickness
Clearance
C
2.79-2.80 (0.1098-0.1102)
-
-
0
'ii
2.53-2.55 (0.0997-0.1003)
1.2 (0.047)
-
C
0
-
-
Clearance
t: ·5. -c C
-
Corrective method
-
Replace piston and/or piston ring
Replace piston and/or piston ring
Replace piston an and piston pin
Replace bushing and/or piston pin
-
-
-
-
Replace connecting rod
0.6 (0.0236) 0.1 (0.0039) for each 200 (7.87)
Repair or replace
3-12-3 Nominal dimensions
Assembly standard or clearance
Repair limit
Service limit
Connecting rod big end inner diameter
80.0 (3.150)
80.015-80.030 (3.1502-3.1507)
-
-
C
Crank pin outside diameter
75.0 (2.953)
74.95-74.97 (2.9508-2.9515)
74.80 (2.9447)
73.80 (2.9056)
Q) C: C:
Clearance
-
0.041-0.092 (0.0017-0.0036)
0.30 (0.0118)
-
Connecting rod bearing spread
80.75-81.75 (3.1792-3.2184)
-
-
-
Journal outside, diameter
90.0 (3,543)
89.91-89.93 (3.5398-3.5405)
89.8 (3,535)
88.8 (3.496)
-
0.050-0.106 (0.0020-0.0041)
0.30 (0.0118)
-
Replace bearing
96.75-98.00 (3.8091-3.8582)
-
-
Replace bearing
46.00-46.025 (1.8110-1.8120)
-
-
End play
-
0.110-0.240 (0.0043-0.0094)
0.50 (0.0197)
Crankshaft runout
-
-
48.00 (1.890)
47.9-48.1 (1.8859-1.8937)
Item
"'
·;:::
e"'
-0
0
(.)
·;:::
C:
C
0
.. .. CJ
-0 C
,t'.
.s::U)
..ll:
oi
E::,
-,
� C
(.)
Clearance
0
Main bearing spread
Width of thrust face
0.3 (0.0118)
0- 0.05 (0 - 0.0019)
0.10 (0.0039)
-
120.0 (4.724)
-
-
120.15 (4,730)
-
0.134-0.166 (0.0053-0.0065)
-
-
0.04-0.10 (0.0016-0.0039)
-
0.03 (0.0012)
.....
-
Distortion at the top of the cylinder
-
C CJ
:: 0
>-
0.09 (0.0035)
-
Face alignment
-0..i,:
-
50.00 (1.96)
Depth of friction face (OPT.)
0-0.2 (0-0.0078)
Regrind undersize or replace
Regrind undersize or replace
-
-
oi Q) .s::
:::> u::
-
Corrective method
Replace oversize thrust bearing Regrind or replace
Replace or regrind
Regrind
(.) JJ
...
Liner, inside diameter
;
Piston clearance
Q)
.!:
·>-= -0
(.)
....
,._ .s:: Ill
.. E
u
Height (protrusion) No.1
65.00 (2.5591)
65.00-65.07 (2.5591-2.5618)
-
65.15 (2.5649)
No. 2
64.60 (2.5433)
64.60-64.67 (2.5433-2.5460)
-
64.75 (2.5492)
E
No. 3
.,
64.20 (2.5276)
64.20-64.27 (2.5276-2.5303)
No. 4
63.80 (2.5118)
63.80-63.87 (2.5119-2.5145)
No. 5
63.40 (1.4961)
63.40-63.47 (2.4961-2.4988)
No.6
63.00 (2.4803)
63.00-63.07 (2.4804-2.4830)
-
63.15 (2.4862)
No. 7
62.60 (2.4646)
62.60-62.67 (2.4646-2.4673)
-
62.75 (2.4704)
No. 1
65.00 (2.5591)
64.95-64.97 (2.5571-2.5578)
64.85 (2.5531)
No.2
64.60 (2.5433)
64.55-64.57 (2.5413-2.5421)
64.45 (2.5374)
No. 3
64.20 (2.5276)
64.15-64.17 (2.5256-2.5263)
..�.. -0
·.;
.!:
"'
-�..
Ill
Replace cylinder liner
64.35 (2.5334)
-
-
-
63.95 (2.5177) 63.55 (2.5017)
64,05 (2.5217)
Replace bearing
3-12-4 Nominal dimensions
Assembly standard or clearance
Repair limit
Service limit
No.4
63.80 (2.5118)
63.75-64.77 (2.5099-2.5500)
-
63.65 (2.5059)
No. 5
63.40 (2.4961)
63.35-63.37 (2.4941-2.5342)
-
....,
No. 6
63.00 (2.4803)
62.95-62.97 (2.4784-2.4791)
-
62.85 (2.4744)
.,E
No. 7
62.60 (2.4646)
62.55-62.57 (2.4626-2.4633)
-
62.45 (2.4587)
Clearance
-
0.03-0.12 (0.0012-0.0047)
0.30 (0.0118)
-
Replace camshaft and/or bearing
Camshaft end play
-
0.10-0.23 (0.0040-0.0090)
0.30 (0.0118)
-
Replace cam thrust bearing
..;., .,
E 'ii
"C "iii
......, "'
.,E (J
CJ
Item
Intake
7.85 (0.3091)
-
-
7.05 (0.2775)
CJ
Exhaust
7.85 (0.3091)
-
-
7.05 (0.2775)
-
-
0.10 (0.0039)
-
-
0.30 (0.0118)
.,E
Runout
.."
"' :i J:.
"' C
..
;
Idle gear to camshaft gear Idle gear to injection pump drive gear
-
0.14-0.32 (0.0055-0.0125)
-
0.35 (0.0138)
Idle gear shaft outside diameter
55.0 (2.165)
54.94-54.97 (2.1630-2.1641)
-
-
Idle gear bushing inside diameter
55.0 (2.165)
55.00-55.03 (2.1654-2.'l 665)
-
-
-
0.03-0.09 (0.0012-0.0035)
0.20 (0.0079)
-
Clearance
(1.733)
44.0
44.009-44.034 (1.7326-1.7336)
-
Breadth of idler gear
43.9 (1.729)
43.894-43.960 (1.7282-1.7307)
-
-
0.049-0.140 (0.0019-0.0055)
0.30 (0.0118)
51.4 (2.024)
51.22-51.25 (2.0165-2.0177)
-
.,
Gear to gear case clearance
-
0.033-0.100 (0.0013-0.0039)
0.13 (0.0051)
0
Depth of gear case
-
38.040-38.067 (1.4977-1.4987)
-
-
Width of gear
-
37.975-38.000 (1.4951-1.4960)
-
-
End play
-
0.040-0.092 (0.0016-0.0036)
0.15 (0.0059)
-
-
0.15-0.28 (0.0060-0.0110)
0.40 (0.0157)
-
End play Gear outside diameter
Q.
E ::s
0.08-0.23 (0.0032-0.0090)
Length of idle gear shaft
'c
....
CJ
Q.
0
Gear backlash
Repair or replace
Replace gear
Replace shaft Replace shaft
Replace idler gear bushing
-
..
Case bushing inside diameter
-
18.034-18.061 (0.7100-0.7110)
-
-
c
Shaft outside diameter
-
17 .976-17 .994 (0.8078-0. 7084)
-
-
"'., .::
Replace camshaft
Crankshaft gear to idle gear
Camshaft gear to oil pump drive gear
..
¡i=e
63.25 (2.4902)
..
:!:
Corrective method
Replace gear and/ or case
Replace gear and/ or case
Replace gear ass'y
Replace bushing
3-12-5 Nominal dimensions
Assembly standard or clearance
Repair limit
Service limit
Corrective method
-
0.040-0.090 (0.0016-0.0035)
0.15 (0.0059)
-
Replace bushing
Gear inside diameter
-
18.122-18.147 (0.7135-0.7144)
-
-
Shaft outside diameter
-
18.064-18.082 (0.7112-0.7119)
-
-
Clearance
-
0.040-0.083 (0.0016-0.0032)
0.15 (0.0059)
-
Deflection between crank shaft pulley to generator pulley
-
15-22 (33.1-48.51
-
-
Compression pressure kg/cm 2 (lb/sq.in)
-
28-30 (399-426) at 200 rpm
26 (370)
-
Differences between cylinders kg/cm 2 (lb/sq.in)
-
Within ±3 (±43)
-
-
Flatness of flange face
-
0.1 (0.004)
-
0.5 (0.02)
Item
.,
> � ·;: Cl ""
E
::, Cl.
0
�
�.,
.,, ., .?! 0
..,
-.; .0
>
C
0 'Bl .,
.,� ::,�
ECl. i�
8 C. .,.:,:.0 co�
., C
-e .., -c ,,,_ ::, 0 C c,:,
fO :it:
.t::. C
X c,:,
WE
Clearance
Replace bushing
Apply force 10 kg (22 lb)
Engine overhaul
Repair or replace Flatness of flange face
-
0.1 (0.004)
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
-
0.5 (0.02)
3-12-6 HINO EP100 HINO EP100T ENGINE BOLTS TIGHTENING TORQUE lb.ft
kg•cm
Size
Tightening position
P1.75
650-900
47-65
1,000-1,300
73-94
Mounting bracket fitting bolts (Front)
M12
Flywheel housing fitting bolts
M14
P2.0
Main bearing cap bolts
M16
P2.0
Oil pump safety valve
M30
P1.5
800-900
58-65
M14
80-86
•
2,700-2,900
P2.0
1,100-1,200
M10
P1.5
450-500
Connecting rod cap bolts
M15
P1.5
Cooling jet nozzle fitting bolts
M12
P1.5
Oil pump assembly fitting bolts
@
•
2,200-2,400 200-250
•
196-209
33-36
@
•
160-173 15-18
Oil strainer fitting bolts
MS
P1.25
200-250
15-18
Oil filter regulator valve
M22
P1.5
300-400
22-28
Oil filter safety valve
M22
P1.5
250-350
19-25
Oil filter center bolt
M16
P2.0
400-500
29-36
Oil filter assembly fitting bolts
M10
P1.5
350-400
26-28
Oil cooler element fitting nuts
MS
P1.25
150-250
11-18
M20
P1.5
200-300
15-21
Oil cooler plug
M36
P1.5
350-450
25-32
Oil cooler various plug
MS
P1.25
190-260
14-18
Oil cooler fitting bolts
MS
P1.25
M17
P2.0
M10
P1.5
MS
P1.25
Cylinder head bolts Camshaft thrust plate fitting bolts
•
•
• • •
130-180
10-13
3,300-3,500
•
239-253
• • •
14-18
650-750 190-280 190-260
47-54 14-18
Injection pump drive shaft fitting bolts
MS
P1.25
Idle gear shaft fitting bolts
M14
P2.0
Camshaft drive gear fitting bolt
M22
P1.5
Injection pump drive gear fitting nut
M24
P1.5
2,000-2,200
145-159
Timing gear plate fitting bolts
MS
P1.25
190-260
14-18
Oil pan fitting bolts
MS
P1.25
190-270
14-19
1,800-2,000 2,000-2,200
131-144 145-159
Flywheel fitting bolts
M16
P1.5
Coolant pump vane fitting nut
M10
P1.5
1,150-1,250
83-90
Coolant pump cover fitting bolts
MB
P1.25
180-230
14-16
Coolant pump assembly fitting bolts
M10
P1.5
350-500
26-36
Nozzle holder fitting nuts
MS
P1.25
Rocker arm support bolts
M12
P1.75
Rocker shaft fitting bolts at both end
MS
P1.25
190-260
14-18
Rocker arm adjust screw nuts
M10
P1.0
400-500
29-36
Rocker arm cover fitting bolts
MS
P1.25
190-260
14-18
Tappet chamber cover
MS
P1.25
190-260
14-18
Injection pump bracket fitting bolts
M10
P1.5
450-500
33-36
Injection pump mounting bolts
MS
P1.25
380-500
28-36
Injection pump through bolt at coupling
M10
P1.5
600-650
44-47
Intake manifold
MS
P1.25
190-270
14-19
Thermostat case cover
MS
P1.25
190-270
14-19
Air intake heater fitting nuts
M22
P1.5
230-330
17-23
Fuel filter center bolt
M16
P2.0
400-450
29-32
Fuel filter bleeder plug
MS
P1.25
50-100
3.7-7.2
End nipples of injection pump
M14
P1.5
300-400
22-28
@
•
2,600-2,900
130-190 1,100-1,200
@
•
189-209
10-13 80-86
3-12-7 Size
Tightening position Holding clip of injection pipe
MB
P1.25
kg·cm
lb.ft
50-100
3.7-7.2
Starter fitting nuts
M14
P2.0
1,100-1,500
80-108
Exhaust manifold
MlO
Pl.5
450-500
33-36
• ---1,���'t
Crankshaft pulley fitting nut
M22
Pl.5
Coolant pump pulley nut
M18
P1.5
Turbocharger fitting nuts
M10
P1.5
450-500
33-36
Intake pipe (Turbo. t intake manifold)
M10
P1.5
350-500
25-36
200-250
15-18
250-300
18-21
250-300
18-21
Joint bolts of fuel pipe Joint bolts of fuel pipe Joint bo Its of fuel pipe
M10
P1.0
M10
Pl.5
M12
P1.5
M12
Pl.75
M14
P1.5
M14
P2.0
• �O='t;860" ,., •1 ·- 1' • ,.. " (800-2,400
131-173
Joint bolts of fuel pipe
M16 P1.5
300-350
22-25
Flare nut (for the pipe of 6.35 mm dia.)
M12
P1.0
200-220
14.5-15.9
Flare nut (for the pipe of 10 mm dia.)
M16
P1.5
400-500
29-36
Flare nut (for the pipe of 12 mm dia.)
M20
P1.5
650-700
47-50
Generator supporting bolt & fitting nut
M14
P1.5
1,300-1,400
94-101
Cooling fan fitting bolts
M14
P1.5
350-500
26-36
Engine mounting fitting nuts (Front & Rear)
M16
P1.5
1,400-1, 600
102-115
NOTE: 1. • mark means that it is needed to apply a light coat of clean engine oil to the thread of bolt. 2. @ mark means that it is needed to apply a light coat of clean engine oil to the thread of bolts or nuts and further .more to tighten the nuts or bolts to the specified torque and loosen each one, and then tighten its to the specified torque again in the sequence order.
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
(K.P.)
FUEL INJECTION PUMP
IP-1 IP-100E-01
CHAPTER IP HINO EP100 FUEL INJECTION PUMP HINO EP100T FUEL INJECTION PUMP DESCRIPTION ....................................... IP- 2 TROUBLESHOOTING ................................. IP- 3 SPECIAL TOOLS ..................................... IP- 6 INJECTION PUMP .................................... IP- 8 FEED PUMP ......................................... IP-17 ADJUSTMENT ....................................... IP-19
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
FUEL INJECTION PUMP
IP-2
DESCRIPTION
10 11 12 13 14
tr��:!_�,�.�
JIIL---+--- 15 16 17 18 19
8 9 HINO EP100 HINO EP100T FUEL INJECTION PUMP 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Nut Washer 0-ring Deflector Snap ring 0-ring Camshaft Bearing Cover Delivery valve holder
SM4-342
11. 12. 13. 14. 15. 16. 17. 18. 19.
Delivery valve gasket Adjusting shim Delivery valve Flange sleeve Plunger barrel Plunger Control rack Control sleeve Tappet
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FUEL INJECTION PUMP
IP-3
TROUBLESHOOTING Symptom
Possible cause
Remedy /Prevention
Engine does not start -----"""T""--1 Fuel not reaching injection pump • Fuel lines clogged or damaged . . . . . . . . . . . .
Clean or replace fuel lines.
• Fuel filter clogged . . . . . . . . . . . . . . . . . . . .
Clean or replace the filter element.
• Air in fuel caused by improper . . . . . . . . . . . connections of fuel I ine between fuel tank and feed pump
Repair connections.
• Filter incorporated in inlet side of feed pump clogged
Remove foreign material.
• Faulty feed pump check valve . . . . . . . . . . . .
Repair or replace it.
• Feed pump piston spring broken . . . . . . . . . .
Replace it.
• Feed pump push rod or tappet sticking . . . . . .
Repair or replace it.
Fuel reaching injection pump • Faulty connection of accelerator wire to pump adjusting lever.
Repair connection.
• Control rack faulty or sticking
Repair it.
• Damaged camshaft bearing . . . . . . . . . . . . . .
Repair it.
• Plunger worn or sticking
Correct or replace it.
. . . . . . . . . . . . . . .
• Faulty connection of engine . . . . . . . . . . . . . stop wire to pump stop lever.
Repair it.
Nozzle faulty • Fuel leakage caused by loosened nozzle holder.
Inspect and tighten it.
• Low opening pressure of nozzle . . . . . . . . . . .
Adjust it.
• Nozzle pressure spring broken . . . . . . . . . . . .
Replace it.
• Nozzle needle sticking to nozzle body
Correct or replace it.
. . . . . .
Pump out of timing • Improperly retarded injection timing
Correct injection timing.
• Incorrect timing caused by improper Installation of pump.
Check engine timing and correct it.
• Woodruff key for pump camshaft cut off.
Replace it.
• Improper pre-stroke adjustment
Correct it to obtain specified injection timing.
IP-4
Symptom
FUEL INJECTION PUMP
Possible cause
Remedy /Prevention
Excessive smoke---------- Black smoke • Excessive fuel delivery caused by ......... . incorrect adjustment of fuel load stopper screw.
Adjust fuel delivery on test stand.
• Excessively advanced injection timing.
Correct it.
• Large spread in fuel delivery
Adjust it.
• Bad nozzle fuel spray characteristics . . . . . . . .
Check and correct them.
White smoke • Improperly retarded injection timing.
Advance injection timing.
• Water in fuel
Check and clean fuel lines.
Low idle speed--------�- Improper adjustment of idle button . . . . . . . . irregular Bad fuel spray characteristic of nozzles.
Correct it.
Incorrect injection timing. . . . . . . . . . . . . . .
Correct it.
Incorrect initial tension setting of idling spring or the spring broken.
Adjust or replace it.
Control rack not smoothly move . . . . . . . . . .
Disassemble pump and repair it.
Large spread in fuel delivery . .. . . . . . . . . . .
Adjust it.
Plunger worn . . . . . . . . . . . . . . . .. ... . . .
Replace it.
Governor linkage not smoothly move.
Correct it.
Defective feed pump . . . . . . . . . . . .. . . . . .
Disassemble and repair it.
Engine always runs------�- Accelerator cable sticking . . . . . . . . . . . . . . . at hig speed Governor linkage sticking. . . . . . . . . . . . . . . Control rack sticking . . . . . . . . . . . . . . . . . . Engine starts and stops-----� - Fuel lines clogged ................... . [ Air in fuel caused by damaged ........... fuel lines or improper connection of fuel lines.
Check and repair them.
Check and correct it. Disassemble and repair the governor. Check and correct it. Clean or replace fuel lines. Repair fuel lines or replace fuel lines and gaskets.
FUEL INJECTION PUMP
Symptom
Possible cause
IP-5
Remedy /Prevention
Engine has low power -----,----1 Pump out of timing • Excessive advanced timing, . . . . . . . . . . . . . . resulting in loud knocking.
Check and correct it.
• Excessively retarded timing resulting in black smoke.
Check and correct it.
• Defective injection pump overflow. . . . . . . . . valve.
Repair or replace it.
• Feed pressure too low
Repair the feed pump.
• lnproper accelerator cable adjustment . . . . . .
Adjust it.
Nozzle faulty • Fuel leakage from nozzle holder
Check and repair nozzle holder.
• Bad nozzle spray characteristic . . . . . . . . . . .
Repair or replace it.
• Loosened adjusting screw in nozzle . . . . . . . . holder, resulting in low opening pressure.
Adjust it.
• Nozzle pressure spring broken . . . . . . . . . . . .
Replace it.
Pump faulty • Fuel leakage from delivery valve holder.
Retighten the delivery valve holder if it is loosened or replace O-ring if the O-ring is defective.
• Defective seat of delivery valve assembly.
Repair or replace it.
• Delivery valve spring broken
Replace the spring.
• Plunger worn . . . . . . . . . . . . . . . . . . . . . . .
Replace it.
• Large spread in fuel delivery . . . . . . . . . . . . .
Adjust it.
• Wear of tappet roller . . . . . . . . . . . . . . . . . .
Replace the roller.
• Camshaft bearing worn or broken
Replace it.
• Improper adjustment of governor fuel load stopper screw.
Adjust it.
Bad fuel nozzle spray pattern after-dribble.
Check and correct it.
High nozzle opening pressure
Adjust the opening pressure.
Incorrect fuel deliveries to some nozzles.
Readjust the fuel deliveries.
FUEL INJECTION PUMP
IP-6
SPECIAL TOOL Prior to starting a fuel injection pump overhaul, it is necessary to have these special tools. BEARING REMOVER
MEASURING DEVICE
MEASURING PLATE
09500-1160
09500-1310
09511-1300
SOCKET WRENCH
WRENCH
BRACKET
� 09511-1340
09511-1350
09511-1380
OUTER RACE PULLER
EXTRACTOR
MOUNTING DEVICE
09511-1800
09511-1700
CLAMP PLATE
EXTRACTOR
0-RING INSERT
09511-1830
09511-1850
� 09511-1820
FUEL INJECTION PUMP
TAPPET HOLDER
09511-2040
IP-7
FUEL INJECTION PUMP
IP-8
HINO EP100 INJECTION PUMP PARTS HINO EP100T INJECTION PUMP PARTS
P-TYPE PUMP
i-------� ' I
T = 1, 100-1,200 (80-86)
I
2
I
3 4 5 6
T = 200-300 (15-21)
7
20
T = 120-150 (9-10)
21
�1T�•,.:�1.soo1�-1os1 14
I
SM4-341
for equipped with industrial engine.
T = Tightening torque kg-cm (lb.ft)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Plunger block assembly 0-ring Delivery valve spring Gasket Delivery valve Plunger barrel Plunger Shim Collar 0-ring
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Deflector Snap ring 0-ring Coupling Sleeve Oil seal Bearing cover Shim 0-ring Taper roller bearing
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Cam shaft Control sleeve Upper plunger spring seat Plunger spring Lower plunger spring seat Tappet Center bearing Taper roller bearing Bearing holder Shim
FUEL INJECTION PUMP
IP-9
IMPORTANT POINT (S) - DIASSEMBL Y WARNING
0 Breaking of the lead seals or crimp caps by anyone other than HINO or pump manufacture authorized service stations to make these adjustment will void the warranty. 0 If fuel pump or governor difficulties are suspected, consult only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injec tion pump lead seals and crimp caps can be reinstalled as required. 0 Measure and record the fuel delivery characteristics of the pump before disassembling it. 0 Keep the parts for each cylinder in separate groups and in an orderly arrangement. Parts to be replaced and parts to be used again must be kept separately.
REMOVE THE TIMER ASSEMBLY. Refer to "TIMER AND COUPLING". REMOVE THE GOVERNOR. Refer to "GOVERNOR".
REMOVE THE CAMSHAFT FROM PUMP BODY. 1. 2.
Remove the screw plug. Turn the camshaft and when the tappet reaches top dead center, insert the tappet holder into the screw plug hole.
Special tool: Tappet holder (09511-2040)
3. 4.
Remove the cover setting bolt. Using a special tools, takeout the bearing cover.
Special tools: Bracket (09511-1380) Eextractor (09511-1710)
FUEL INJECTION PUMP
IP-10
5.
Remove the center bearing bolt and pull out the camshaft with the center bearing .
SM 4- 3 49 SM4-348 ._______ _ -=-..:...:..., '-------=- _:_;_-=. _:.::.J
REMOVE THE TAPPET ASSEMBLY. 1. 2.
Set up the mounting device on bottom of the pump housing. Operate the lever to push up the tappet and pull out tappet holder.
Special tools: Mounting device (09511-1800)
::-i; n '-�� ---
, _ ,---.... - r ,J
�;:),_ �� ()
REMOVE THE SPRING SEAT WITH PLUNGER. r:.i.
(\
3.
Using small pincers, pull out lower spring seat together with plunger.
NOTE: Put the plunger in order in a tray containing clean diesel fuel.
SM4-351
REMOVE THE CONTROL SLEEVE UPPER SPRING SEAT. NOTE: To do this, it is essential to line up the sleeve ball with the groove in the pump housing; otherwise the control sleeve will not come out.
REMOVE THE PLUNGER BLOCK ASSEMBLY. Fasten extractor to the delivery valve holder, and withdraw plunger block assembly.
Special tool: Extractor (09511-1830) NOTE: Put the plunger block assembly and adjusting shims in a tray containing clean diesel fuel.
SM4-353
FUEL INJECTION PUMP
IP-11
REMOVE THE CONTROL RACK 1.
Use the wrench, remove the screw bush.
Special tool: Wrench (09511-1350) 2.
Remove the pin from the control rack and pull out the control rack.
DISASSEMBLY THE PLUNGER BLOCK ASSEMBLY. 1.
Remove the delivery valve holder fit the clamp plate in vise and place the plunger block assembly on it.
Special tool: Clamp plate (09511-1820)
REMOVE THE TAPER BEARING FROM THE CAMSHAFT. 1.
Remove the taper bearing from the drive end of the camshaft.
Special tool: Bearing remover (09500-1160)
2.
Use the guide to remove the bearing at the governor side.
SM4-125
--------=
r---.._---;---___ t:J
OUTER RACE / PU LLER
REMOVE THE OUTER RACE FROM THE BEARING COVER. Use the outer race puller, to tap out the outer race in the bearing cover.
Special tool: Outer race puller (09511-1700)
FUEL INJECTION PUMP
IP-12
IMPORTANT POINT (S) - ASSEMBLY WARNING 0 Wash all parts with clean diesel fuel before installing them, and any defective or damaged parts must be replaced. 0 Do not allow dust or other foreign matter to enter the pump during assembly. 0 Apply grease to O-rings and oil seals before installing them. 0 Assemble the parts in correct order and to correct tighten ing torques, assembled dimensions etc. 0 Assembly takes place in the reverse order of disassembly. ASSEMBLING THE PLUNGER BLOCK 1.
Before install the plunger ba rrel should be inspect the plunger barrel and plungers for wear, scratches, or discoloration.
2.
Tilt the plunger to about 60 . Pull the plunger out approxi mately 10 to 15 mm (0.39-0.59 in) and release it to see if it slides down smoothly from its own weight.
3.
Assemble the plunger barrel into the flange sleeve.
°
SM4-257
NOTE: Be sure that the knock pin of the flange sleeve is fitted into the guide groove on the plunger barrel.
SM4-357
4.
Install the delivery valve, delivery valve gasket, delivery spring and delivery valve holder on the flange sleeve in this order.
NOTE: Before install the delivery valves, inspect the delivery valves for scratches on the valve seat or the piston sections.
SM4-258
FUEL INJECTION PUMP 5.
IP-13
Tighten the delivery valve holder.
NOTE: O-ring should first be assembled in the delivery valve holder. In doing this, be sure that O-ring is coated with grease to prevent it from being damaged.
SM4-356
6. COLLAR
Install the collar, O-ring, deflector, ring and O-ring.
NOTE: The deflector should not be installed upside down with the hole near to its lower edge.
0-RING
PLUNGER BARREL
SM4-358
7.
Install the small O-ring in the housing by with the inserter.
Special tool: O-Ring inserter (09611-1850)
SM4-359
INSTALL THE PLUNGER BLOCK ASSEMBLY TO THE PUMP BODY. 1.
Tighten the delivery valve holder using a socket wrench and a torque wrench.
Special tool: Socket wrench (09511-1340) NOTE: Tightening should be made in three steps in the order of 1,200 ➔ 0 ➔ 1,200 ➔ 0 ➔ 1,200 kg-cm (87) lb.ft (87) (87) SM4-360
Hino Engine Parts email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 website: www.HeavyEquipmentRestorationParts.com
IP-14
FUEL INJECTION PUMP INSTALL THE CONTROL RACK AND THE CONTROL SLEEVE. Assemble the control sleeve, inserting it until the ball on the sleeve is parfectly fitted in the notch of the control rod.
NOTE: Make sure that the ball of the control sleeve is well fitted in the groove on the control rack; otherwise the ball section of the control sleeve will be bent when the next associated parts are assembled.
INSTALL THE UPPER SPRINC. SEAT, THE PLUNGER SPRING AND.THE PLUNGER. Insert the plunger in the barrel. Make sure that the aligning mark on the plunger vane is pointing toward the front of the pump housing. Install the lower spring seat on the plunger.
NOTE: Do not interchange plungers with barrels.
INSTALL THE TAPPET. Using the mounting device to press in the tappet and hold it in with the tappet holder.
Special tool: Mounting device (09511-1800) Tappet holder (09511-2040)
INSTALL THE CAMSHAFT. Place the center bearing on the camshaft and insert the cam shaft into the pump housing.
MEASURE THE PROTRUDING LENGTH OF THE CAMSHAFT. 1.
Measure the distance from the surface of the end of the pump housing to the surface of the end of the measuring plate (where the tapered section of the cam-shaft starts).
Special tool: Measuring plate (09511-1300) Standard length: 13.3-14.3 mm (0.524-0.563 in)
FUEL INJECTION PUMP 2.
IP-15
If the specification is not met, use appropriate shim plates at the governor end of camshaft until the specification is met.
GOVERNOR HOUSING
(GOVERNOR END)
SM4-365
Ml:ASURE THE CAMSHAFT END PLAY. 1.
Attach the special tool onto the camshaft drive end and measure the thrust clearance of the camshaft with a dial gauge.
Special tool: Camshaft end play gauge (09500-1310) Standard end play: 0.02-0.06 mm (0.0008-0.0023 in)
2.
If the specification is not met, use appropriate shim plates at the drive end of camshaft until the specification is met.
BEARING COVER SHIM (DRIVE END)
SM4-367
MEASURE THE SLIDING RESISTANCE OF THE CONTROL RACK. After the pump body has been assembled, attach a spring scale to the control rack and check that the control rack slides smoothly through its entire stroke. Assembly standard: Less than 130 g (4.59 oz)
INSTALL THE TIMER ASSEMBLY. Refer to "TIMER".
INSTALL THE GOVERNOR. Refer to "GOVERNOR".
FUEL INJECTION PUMP
IP-16
INSPECTION AND REPAIR Inspection Item Tappet wear.
Standard
Limit 0.2mm (0.008 in)
Remedy
Inspection Procedure
Replace, tappet assembly. TAPPET ROLLER ROLLER BUSHING
! - ROLLER Pl N
SM4-129
Tappet surface wear.
Camshaft wear
0.2 mm (0.008 in)
Replace, tappet.
Replace, cam shaft.
KEY GROOVES
OIL SEAL CONTACT SURFACE SM4-131
Roller and center bearing wear, any other damage.
Replace, if necessary.
Visual check
FUEL INJECTION PUMP
IP-17
FEED PUMP FP/KE-TYPE
20-----1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Feed pump housing Push rod Oil seal Piston Spring Gasket Plug Joint bolt Filter Gasket
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Pin Retainer ring Roller Tappet Sliding block Check valve Spring Gasket Plug Priming pump
IMPORTANT POINT (S) - DISASSEMBLY REMOVE THE PRIMING PUMP AND CHECK VALVES. 1.
Unscrew the priming pump and remove the spring and inlet check valve.
2.
Remove the outlet check valve and spring.
IP-18
FUEL INJECTION PUMP REMOVE THE TAPPET Remove the snap ring and pull out the tappet.
G REMOVE THE FILTER FROM INLET PIPE JOINT. Clean the filter with clean diesel fuel.
IMPORTANT POINT (S) - ASSEMBLY INSTALL THE TAPPET. INSTALL THE SNAPRING.
SM4-290
INSTALL THE PISTON. Insert the piton and spring in the ·housing and screw on the chamber plug with a new gasket.
SM4-291
INSTALL THE PRIMING PUMP AND CHECK VALVES.
FUEL INJECTION PUMP
IP-19
ADJUSTMENT
PREPARATION 1.
Mount the injection pump correctly on the pump tester.
2.
Attach a rack measuring device to the control rack and set to
3.
Install calibration nozzles and lines of the following specifica tions. Nozzle Nozzle holder assembly: 105780-8140 Opening pressure: 175 kg/cm (2,489 lb.ft)
a)
''O''.
b)
Line Outside diameter: 8.0 mm (0.3150 in) 3.0 mm (0.1181 in) Inner diameter: Length: 600 mm (23.6 in)
4. a) b)
Calibration oil Calibration oil: SAE J967C ° ° Oil temperature: 40-45 C (104-113 F)
SM4-370
ADJUSTING THE PRE-STROKE OF N0.1 PLUNGER.
HOLDER
1.
SPRING GASKET
2.
DELIVERY VALVE
3.
Remove the 1st cylinder delivery valve holder, spring delivery valve and gasket. Install the plunger stroke measuring gauge to the flange sleeve by turning it as far as it will go. Bring the tappet of the first cylinder to its bottom dead center, and set the dial indial indicator zero.
SM4-371
OVERFLOW PIPE HIGH PRESSURE
0
SM4-372
4. a) b) c)
Measure the pre-stroke Set the control rack at full-load position. Loosen the overflow screw of each nozzle holder. Operate the high-pressure pump of the pump tester and let fuel run out of the overflow line.
FUEL INJECTION PUMP
IP-20
d)
Move the angle dial to set the first cylinder of the pump to bottom dead center and adjust the pre-stroke gauge to zero.
e)
Turn the camshaft clockwise with the angle dial and read the dial gauge when the fuel stops running out of the over flow line. This reading is the pre-stroke value of the pump.
SM4-373
OVERFLOW PIPE
Pre-stroke: 2.94-3.30 mm (0.1158-0.1299 in)
PLUNGER BARREL SM4-374
f)
If the pre-stroke value is not within specification, adjust by changing the adjusting shim. The shims can be replaced by pulling up the plunger block slightly.
ADJUST THE INJECTION INTERVAL.
1.
Using the No.1 cylinder injection starting point as a base, inspect and adjust the injection interval in the order of injec tion.
Injection interval: Injection order:
2.
6-cylinder ° ° 59 45' -60 15' 1-4-2-6-3-5
If the injection intervals are not within specification, adjust by using the same procedure as for pre-stroke adjustment.
FUEL INJECTION PUMP 3.
IP-21
Set the No.1 cylinder at the injection starting point, and check that the marks on the timerr or coupling and the marks on the pump body are aligned. If the timing marks are not aligned, make a new mark on the timer or coupling and erase the old mark.
MEASURING AND ADJUSTING THE INJECTION VOLUME. 1.
Measure the injection volume for each control rack position and pump speed.
Injection volume: Refer to "CALIBRATION chart."
SM4-378
2.
SM4-379
To adjust the injection volume, loose the flare nut of injection pipe and the lock nut of the plunger block assembly and turn to left or right the plunger block assembly.
GV-1
GOVERNOR
GV-06E-01
CHAPTER GV HINO EP100 HINO EP100T INJECTION PUMP GOVERNOR (MODEL: RSV) DESCRIPTION •.....•...•....•....................... GV-2 GOVERNOR ...•....•................................ GV-3 SPECIAL TOOL .......•..•...•.••.....•.............•. GV-4
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GV-2
GOVERNOR
DESCRIPTION [MODEL: RSV]
1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Governor spring Control rod Knuckle Swivel lever Maximum speed stopper bolt Camshaft Control lever Stop lever Supporting lever Flyweight
11. 12. 13. 14. 15. 16. 17. 18. 19.
12
Sleeve Link Start spring Guide lever Tension lever Idle sub spring Full load stopper bolt Idle spring Floating lever
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GOVERNOR
GV-3
GOVERNOR
18
8
---.. � ' 11
��@-13 f -14
23
�)
-
. �I
14. 15_ 16. 17. 18. 19. 20. 21. 22_ 23_ 24. 25. 26.
2s26
�rP!?
2 4 2 2 ��" , I
29 Governor housing Stopper bolt Woodruff key Flyweight Sleeve Bearing Shim Guide lever assy Link Start spring Supporting lever Tension lever Full load stopper
i7 28 )I
r�l�"�
J '@'� -{}
:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
15
Idle spring Lock nut Governor cover Swivel lever Governor spring Gasket Pin Plug Control lever Woodruff key Coller OHseal Bush
30
27. 28. 29. 30. 31. 32. 33. 34, 35. 36. 37.
O-ring Snap ring Stop lever Cap Idle stopper bolt Idle sub spring Nut Cap nut Closing cover O-ring Cap nut
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GV-4
GOVERNOR
SPECIAL TOOL Prior to starting an injection pump governor overhaul, it is necessary to have these special tools. FLYWEIGHT EXTRACTOR
ROUND NUT WRENCH
09511-1900
IMPORTANT POINT (S) - DISASSEMBLY WARNING 0 Breaking of the lead seals or crimp caps by anyother other than HINO or pump manufacture authorized service stations to make these adjustment will void the warranty. 0 If fuel pump or governor difficulties are suspected, consult only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injec tion pump lead seals and crimp caps can be rainstalled as required. DISASSEMBLY THE GOVERNOR COVER FROM PUMP BODY. 1.
Disconnect the shackle from the control rack.
NOTE: When remove the governor cover fitting bolt, hold the governor cover.
2.
Disconnect the return spring.
GOVERNOR
GV-5
REMOVE THE FLYWEIGHT ROUND NUT. NOTE: Use the holding spanner to keep the camshaft from rotat足 ing. Special Tools: Round Nut Wrench (09511-1500)
SM4-384
REMOVE THE FLYWEIGHT, USING THE FLYWEIGHT EX足 TRACTOR. Special Tool:
Flyweight Extractor (09511-1900)
IMPORTANT POINT (S) - Assebmly WARNING 0 Wash all parts with clean diesel fuel before installing them, and any defective or damaged parts must be replaced. 0 Do not allow dust or other foreign matter to enter the pump during assembly. 0 Apply grease to O-rings and oil seals before installing them. 0 Assemble the parts in correct order and to correct tighten足 ing torque, assembled dimensions etc. 0 Assembly takes place in the reverse order of disassembly. INSTALL THE ADJUSTING LEVER Measure the thrust clearance of the adjusting lever.
ADJUSTING LEVER
Thrust Clearance: 0.05-0.20 mm (0.002-0.0078 in)
CHECK THE GOVERNOR LINKAGE FOR SMOOTH OPERA足 TION. Hook under the guide lever, and pull upwards, using a spring balance.
SM4-302
GOVERNOR
GV-6
INSTALL THE FLYWEIGHT TO PUMP CAMSHAFT. Using a special tools, tighten the round nut.
Special Tools: Round Nut Wrench (09511-1500)
SM4-384
INSTALL THE GOVERNOR HOUSING TO.PUI\/IP BODY. 1. 2.
Connect the shackle to control rack. Connect the return spring.
ADJUSTMENT OF THE GOVERNOR [MODEL; RSV] 1.
PREPARATION 1. 2. 3. 4.
2.
MAXIMUM SPEED STOPPER BOLT SWIVEL LEVER ADJUST SCREW
STOP LEVER
STEPS IN GOVERNOR ADJUSTMENT. Perform governor testing and adjustment in the following sequence (For values of N. and R Refer to "CALIBRATION chart"): 1. 2. 3.
IDLING SCREW FULL LOAD STOPPER BOLT IDRING SUB SETTING SCREW SM4-386
Connect the rack measuring device to the control rack and set to "O". Gonnect the fuel line. Refill the camshaft chamber with engine oil. Install the angle gauge on the adjusting lever.
Adjustment of maximum speed control. Adjustment of speed droop. Adjustment of idling speed control.
GOVERNOR 1.
GV-7
Adjustment of maximum speed control NOTE: The control lever should be full load position. a) Adjust the full load stopi:;er bolt. At a pum·p speed of Na rpm, adjust the rack position to Ra mm with the full load stopper bolt.
z 0
!:::
(/) 0 a.
Ra 1----..J"'T'----,
� u <!
a:
O .____,.N_a --PUMP SPEED (rpm)
FULL LOAD STOPPER BOLT
SM4-386
r\
z i= a.
0
z 0
b) Adjust the maximum speed stopper bolt. At a pump speed of Nb rpm, adjust the rack position to Rb mm with maximum speed stopper bolt.
Rb
I
NOTE: The control rack should start to be pulled.
\
Nb PUMP SPEED (rpm)
2.
Adjust of speed droop. At a pump speed of Ne rpm, adjust rack position to Re mm with swivel lever adjusting screw.
3.
Adjusting of idling speed control a) At a pump speed of Na rpm, adjust the rack position to Rd mm with idling screw.
Rb
(/) 0 a. l<'. (.)
a: 0
-----=--...,_ Nb
SWIVEL LEVER ADJUST SCREW Ne
PUMP SPEED (rpm)
SM4-387
NOTE: The control lever angle, refer to CALIBURATION chart. ......=..-IDLING SUB SETTING SCREW
b) At a pump speed of Ne rpm, adjust the rack position to Re mm with idling sub setting screw.
· SM4-386
GOVERNOR EXTERNAL LEAD SEALS AND CRIMP CAPS. NOTE: All adjusting devices on the fuel injection pump governor, are wired and lead sealed as a protection for the customer. This is to prevent unauthorized readjustment which may cause engine malfunction and/or engine failure. Periodical ly check to insure that these seals are not broken as this will void the warranty.
SM4-388
C-16E-01 CALIBRATION INJECTION PUMP SPECIFI CATION
Engine model Injection pump part number Injection pump type
EP1 OOT Use for generator set 22020-1951 NP-PE6P120
Governor type
RSV
Timer type Feed pump type Test nozzle type Test nozzle opening pressure
Not equipped NP/K-P
f-
105780-8140 175 kg/cm' (2,489 psi)
f-
TEST CONDITION
Inner diameter Length Type Oil temperature
Calibration oil Fuel feerl pressurP.
INJECTION TIMING
INJECTION VOLUME
8.4 (0.33) 5,7 (0.22)
Idling speed
MAXIMUM SPEED STOPPER BOLT
Injection volume cc (cu.in)
Max. variation limit cc (cu.in)
500
56.1-58,1 (3.423-3,544) 3,25-6,25 (0,199-0,381)
2 (0.122)
lndling sub spring set
Nb: Approx 890
Rb: should be start to pulled control rack
Maximum speed stopper bolt
Ne: 895-905
Re: 8.2 (0.323)
Swivel lever adjusting screw
Nd: 930-940
Nd: 5.5-6.0 (0.217-0.236)
Idling sub spring set
Idle
Re: 5.7 (0.224)
Idling screw
Ne: 360
/Rack limiter
E
V.P 1 900 rpm set
Swivel lever adjusting screw
Rd: 5.5-6.0 (0.217-0.236)
□
1
CONTROL LEVER ANGLE
SWIVEL LEVER ADJUST SCA EW
Re: 8.2 (0.323)
Nd: 780-790
Governor characteristic diaphragm
Measuring strokes
ADJUSTING POSITION
Ne: 745-755
NOTE: Recommended setting of swivel adjusting screw: 8 clicks from bottom end.
°
500
,2
<.:)
60 ± 15' 3.4 - 3.5 mm (0.134 - 0.134 - 0.138 in) Pump speed (rpm) 900 360
§
°
Injection interval Pre-stroke
Maximum speed stopper bolt.
ii
z
Rotation Injection order
Control lever
,E
0
1.5 - 1.8 kg/cm' (21.33 - 25.59 psi) Clockwise viewed from drive side 1-4-2-6-3-5
Rack position mm (in)
Full load
Ra:
B.4
STOP �+-+-- 750 rpm set
GOVERNOR ADJUSTMENT
� �
\ tor 750 ,pm ,..-set Rd: 5.5 6.0 Re: 5.7
I\_
� ;:!_g ., ., 0
0
... 4 ±5 ° ° 2 ... 32 ±3 ° ° 3 ... 16 ±5 4 ... , , Lever angle "V.P" means. Vertical position
rt,5'
Ab
Ac , 8.2
0
STOP LEVER
/Ab
\�
0,
IDLING
FULL LOAD STOPPER BOLT
Adjusting position
Rb: should be start to pulled control rack
0
Maximum speed
Control rack position mm (in) Ra: 8.4 (0.331 I
:li Nb: Approx. -690 E
a:
40 -45 C (104 - 113 F) 1.6 ko/cm 2 (22.8 r,i)
Overflow valve opening pressure
Pump speed (rpm)
z :a
SAE J967C °
Adjusting lever position
Na: 410-430
8.0 mm (0.31 in) 3.0 mm (0.12 in) 600 mm (23.6 in)
Outer diameter Injection pipe
Adjusting item
2 2
\
for 900 rpm set
\_
/ "'o "'0,
11
/"'0
g cl;
0,
"'0
"' � �
"'"'
0 o,
"'
0, M "'0,
.0
• 'C
.0
z
z z
0
z z
J, 6 • 'C
Pump speed (rpm) -
IK.P.I
21-0BESF-01E
GENERATOR
GENERADOR GENERATRICE
SYMBOL MARKS SIMBOLOS SYMBOLES ............................................ 21- 1 A GLOSSARY OF TECHNICAL TERMS GLOSARIO DE TERMINOS TECNICOS LEXIQUE DES TERMES TECHNIQUES ....................... 21- 2 DATA & SPECIFICATION â&#x2013;¡ATOS Y ESPECIFICACIONES DATA & CARACTERISTIQUES ............................. 21- 3 DESCRIPTION DESCRIPCION DESCRIPTION
21- 4
OVERHAUL REPARACION GENERAL REVISION ............................................. 21- 5 TROUBLESHOOTING LOCALIZACION DE AVERIAS RECHERCHE DES CAUSES D'ENNUI ET REMEDE .............. 21-20 REPAIR SPECIFICATIONS ESPECIFICACIONES DE REPARACION CARACTERISTIQUES DE REPARATION ...................... 21-21
21-1-
SYMBOL MARKS
The following symbols have been adapted for simplicity and for easy comprehension. SIMBOLOS Se han adoptado los siguientes si'mbolos para simplidad y facil comprensi6n. SYMBOLES Les symboles suivants ont ete adoptes afin de simplifier et de faciliter la comprehension
la\tl l}�I El El
ASSEMBLY
ARMADO ASSEMBLAGE
DISASSEMBLY
DESARMADO DESASSEMBLAGE
INSTALLATION
INSTALACION MISE EN PLACE
REMOVAL
REMOCION DEPOSE
INSPECTION
�
Im
INSPECCION CONTROLE
MEASUREMENT MEDICION Ml:SURE
El
8 Iii
B IT]
TIGHTENING
APRIETE SERRAGE
CLEAN
LIMPIEZA NETTOYAGE
IMPORTANT
IMPORTANTE IMPORTANT
ADJUSTMENT AJUSTE REGLAGE
LUBRICATION
LUBRICACION GRAISSAGE
21-2 A GLOSSARY OF TECHNICAL TERMS GLASARIO DE TERMINOS TECNICOS LEXIOUE DES TERMS TECHNIQUES
ENGLISH
1. About
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Ammeter And At Bad Good Capacity Insulation resistance In Limit Less than More than Resistance Service limit Standard Tightening torque Voltage meter
ESPANOL
1. Alrededor de
2. Amperimetro 3. y 4. A
5. Malo
6. 7. 8. 9.
10. 11. 12. 13. 14. 15. 16. 17.
Bueno Capacidad Resistencia de aislamiento Pul. Lfmite Menos de Mas de Resistencia Lfmite de servicio Estandard Par de apriete I ndicadora de tenci6n
FRANCAIS
1. 2. 3. 4. 5. 6. 7.
8. 9.
10. 11. 12. 13. 14. 15. 16. 17.
Environ Amperem6tre ET A Mauvais Bon Capacitl� Resistance d'isole111ent Pouce Lirnite I nferieur(e) a Depasse Resistance Lirnite d'utilisation Nol mal (e) Couple de serrage Compteur de tension
21-3
GENERATOR DATA AND SPECIFICATIONS GENERATOR Type . . . . . ... . . . . . . . . . . . . . . . . . . . Output power . . . . . . . . . . . . . . ... . . . . Normal voltage . . . . . . . . . . . . . . . . . . . . . Charging rotation and voltage . . . . . . . . ... Direction of rotation ................. Allowable max. speed . . . . ... . . . . . . . . . . Power and rotating speed ..............
Alternator 24 V, 20A 24V 900 r.p.m., 27V Right (From the pulley side) 7,200 r.p.m. 28V, 20A, at 5,000 r.p.m.
21-4 DESCRIPTION
2
3
\
I
I
5
\
SM21-073
GENERATOR 1. 2. 3. 4.
Brush I.C. Regulator Stator Rotor
5.
Pulley
Fig. 21-1
21-5
OVERHAUL
1824E 1-NO. 20
3
;1ÂŤ ______ 7 I
I
I I
I
20
7
I 221
'21 1
t_ ______ ..J
DETAIL "A"
10
15--
1. Rotor 2. Stator 3. Bearing retainer
4. Rear bearing 5. 6. 7. 8.
9. 10.
11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Felt cover Felt Front bracket Collar Fan Pulley Front bearing Terminal insulation Heat sink with rectifier Condenser Connector O-ring Rear bracket Regulator Cover Brush holder Brush Brush spring
Fig. 21-2
21-6
El Fig. 21-3
ALTERNATOR Dismounting
1. Disconnect the battery 8 terminal.
21-0218
L. o;,connect the B and E mm;n,1. ,....,
Fig. 21-4
W04-046
Remove the alternator set bolts and alternator assembly.
Fig. 21-5
W04-046
21-7 DISASSEMBLY
1. Disassemble the regulator and brush. 1). Remove the brush cover.
Fig. 21-6
21-0250
El Fig. 21-7
21-0251
El Fig. 21-8
2) Remove the regulator.
3) Remove the brush holder set screws.
21-0252
Disassemble the rotor. 1) Remove the through bolts.
Fig. 21-9
21-0253
21-8
13 Fig. 21-10
21-0254
13 Fig_ 21-11
4) Remove the rotor by using a press.
21-0256
13 Fig. 21-13
3) Remove the pulley, fan and collar.
21-0255
13 Fig. 21-12
2) Remove the front bracket assembly.
21-0257
5) Remove the bearing retainer.
21-9
El Fig. 21-14
21-0258
El Fig.21-15
6) Remove the front bearing_
7) Remove the rear bearing.
27-0259
Remove the stator assembly_ 1) Unsolder the regulator lead wires.
Fig. 21-16
21-0260
2) Remove the stator coil assembly.
Fig. 21-17
21-0233
21-10 3) Remove the heat sink assembly.
Fig. 21-18
21-0261
INSPECTION
1. Brush 1) Measure the brush length.
Fig. 21-19
21-0234
Standard 16 mm
Limit 7mm
2) Confirm that the brush is movable freely with the brush holder.
Fig. 21-20
21-0235
Rotor 1) Check the conduction of the rotor coil.
Fig. 21-21
21-0262
Standard About 12.5.1'1
Limit Less than 11.Q
21-11 2) Check the insulation between the slip ring and the core.
Fig. 21-22
21-0263
Standard Limit More than 1 Mn Less than 0.5 Mn
3) Measure the outside diameter of the slip ring.
Fig. 21-23 Standard 34.5 mm
21-0264
Limit 33.5 mm
Stator 1) Check the conduction. (U.V.W. terminal)
Fig. 21-24
Resistance
SM21-037
N-U N-V N-W
About0.4 n
21-12 2) Check the insulation.
SM21-038
Fig. 21-25 Standard More than 1 M.\1
Limit Less than 0.5 M.\1
Heat sink 1) Inspect the each positive side rectifier condition. (1) Connect the circuit tester (±) lead to the rec tifier holder and the 0 lead to the rectifier terminal.
B
A
1). I nspeccione la condici6n del rectificador de cada lado positive. ( 1) Conecte el conductor C±) del pro bador de cir cuito al portarrectificador y el conductor 0 at terminal del rectificador.
SM21-013A
Fig. 21-26 A: Good
B: Bad
1) Verifier que chacun des redressurs cote positif est en bonne condition. ( 1) Connecter le conducteur C±) du controleur de circuit au porte-redresseurs et le conducteur 0 a la borne de redresseur. (2)
B
C±) lead to the rectifier terminal and to the rectifier holder.
0 lead
(2) El conductor 0 con el terminal del rectifica dor y el conductor 0 con el portarrectifi cador.
a
(2) Connecter le conducteur E) la borne de redresseur et le conducteur au porte-redres seurs.
0
SM21-013B
Fig. 21-27 A: Good
A
B: Bad
2) Inspect the each negative side rectifier condition. (1) Connect the circuit tester E) lead to the rectifier terminal and the 0 lead to the recti fier holder.
B
2) I nspeccione la condici6n del rectificador de cada la«!Jo negative ( 1) Conecte el conductor E) del probador de circuito con el terminal del rectificador y el conductor 0 con el portarrectificador.
Fig. 21-28
SM21-012A
2) Verifir!r q11l1 chilc11n des redresseurs cf1tr'.! negatif est en bonnc condition. ( 1) Connecter le conducteu1· E) cJ11 controleur de cirC t it la borne dl, redrnsscur r!t le conduct r.ur 0 au porte-rec.lresseurs.
a
21-13 (2)
B
A
(±) lead to the rectifier holder and 0 lead to the rectifier terminal.
(2) El conductor (±) con el portarrectificador, y el conductor 0 con el terminal de rectificador. (2) Connecter le conducteur (±) au porte-redres seurs et le conducteur 0 a la borne de redres seur.
SM21-012B
Fig. 21-29 A: Good
B : Bad
5. I.C. regulator 1) Check the resistance between each terminal.
5. Regulador I.C. 1) Revise la resistencia entre cada terminal. 5. Regulateur a circuit integral 1) Verifier la resistance entre les bornes.
C
L
SM21-035
Fig. 21-30
RESISTANCE BETWEEN EACH TERMINAL Tester
Resistance
Tester
Resistance
+ Lead
- Lead
n.
+ Lead
- Lead
n.
R
L
About 10
L
R
00
R
F
About 10
F
R
00
R
C
00
C
R
00
R
E
About 1.5 K
E
R
00
L
F
About 10
F
L
About2 K
L
C
About 90
C
L
00
L
E
About 100
E
L
About 1.5 K
F
C
About 10
C
F
00
F
E
About 180
E
F
00
C
E
About 40
E
C
00
21-14 Condenser 1) Inspect the condenser function. (1) Connect the test leads. (2) Reverse the polarity of the test leads. 2) Measure the condenser capacity. (Condenser tester)
21-0242
Fig. 21-31
I Capacity
About 0.5 ÂľF
Connector 1) Check the resistance between each terminal.
4
SM21-074
Fig. 21-32 1, 2. 3. 4.
R Lead L Lead N Lead Support
RESISTANCE BETWEEN EACH TERMINAL Tester
Resistance
+ Lead
- Lead
n
R
L
400 - 500
L
Support
00
Support
L
9 -12
21-15
ZQ
ASSEMBLY 1. Install the stator assembly. 1) Install the heat sink assembly.
NOTE: Be careful with the each positon of two heat sink. Install the (-) pole heat sink, which has printed circuit, lower.
21-0233
Fig. 21-33
2) Install the O-ring into the rear bracket .
• .
'"
I:·"· , .
Fig. 21-34
.•,•"-. "'" ,...,.,,,,.. ,.·
..
,�
21-0265
E)
3) Install the stator. Solder the lead wires of the stator to the each terminal of the heat sink as shown in the figure .
....
Fig. 21-35
21-0260
Installation of the rotor. 1) Install the felt, bearing and the bearing retainer into the front bracket.
Fig. 21-36
21-0270
21-16
El Fig. 21-37
21-0266
El Fig.21-38 I Tightening torque
Tightening torque
3) Install the fan and pulley.
21-0267 980-1,300 kgâ&#x20AC;˘cm (71-94 lb.ft)
El Fig. 21-39
2) Install the rotor into the front bracket.
4) Install the through bolts.
21-0268 60-90 kgâ&#x20AC;˘cm (4-6.5 lb.ft)
3. Installation of the regulator and the brush holder assembly. 1) Install the brushes into the holder. And then solder the lead wires to the support. NOTE: In installing the brusties, solder the wires so that brush projection should be 16 mm. NOTE: Suit the concave face .of the brush to the convex face of the slip ring..
Fig. 21-40
21-0270
21-17
El 21-0252
Fig. 21-41 Tightening torque
19-25 kgâ&#x20AC;˘cm (1.4-1.8 lb.ft)
El
3) Install the I.C. regulator.
21-0251
Fig. 21-42 Tightening torque J
2) Install the brush holder.
19-25 kgâ&#x20AC;˘cm (1.4-1.8 lb.ft)
CHARGING SYSTEM CIRCUIT - Precautions -
.. . .... _ _J
Fig. 21-43 1. Alternator 2. IC Regulator 3. Field coil
SM21-010B 4. Starter switch 5. Char11e warning lamp 6. Battery
1. Note the battery polarity carefully so as not to make reverse connections. If the connections are reversed, the diodes will short the circuit and allow large current to flow through and damage the diodes 'and IC regulator as well as burn up the wiring harness. 2. Use care not to make wrong connections of terminals. 3. When charging the battery with a quick charge. Disconnect the battery terminals . 4. Do not perform tests with high voltage insulation resistance tester. 5. When in operation, never disconnect the battery.
21-18 INSPECTION 1. Measure the resistance between each terminal after assembling. (1.5V circuit tester, x 1)
Fig. 21-44
21-0269
Tester
Resistance
· Tester
Resistance
tn)
+ Lead
- Lead
R
00
N
E
7-10
B
N
7-10
N
B
00
R
L
400-500
E
R
00
R
E
00
E
L
00
L
E
00
E
N
00
+ Lead
- Lead
B
'
(nl
�r
Inspect the alternator performance. 1) Turn on switch SW 1 and off SW2 to increase the rotation of the alternator slowly.
2. lnspeccione el funcionamiento del alternador.
1) Posicionar en "ON" el interruptor SW I y en "OFF" SW2 y aumentar de a poco la rotaci6n del alternador.
2. l11specter la µerformance cJe l'alternateur. 1) Augmenter lenternent la rotation de l'alternateur, l'interruptem SW 1 etant mis sur la position ON et SW 2 sur la µosition OFF. Fig. 21-45
SM21-014A
1. Ampere-meter 2. Volt-meter 3. Load
2) When voltage reaches 28V, turn on swigch SW2 regulate load resistance. Increase the rotation of the rotor keeping voltage at 28V. 2) Cuando el voltaje llega a 28V, posicionar en "ON" el interruptor SW 2 para regular la restencia de carga. Aumente la rotaci6n del rotor mante niendo el voltaje a 28V.
a
2) Lorsquc la tension arrive 28V, 111ettrn SW 2 sur la position ON. Auq111cntcr la rot;,tion du rotor tout r;n rnai11tcnant la tension 28V par reglc1ge rle la rt'!sistancc) c!n charqr).
a
Fig. 21-46 Less t_han 5,000 rpm
SM21-014B
Standard 28V, 20A
21-19 3
ďż˝
Inspect the IC regulator performance. Turn on switch SW 1 and off SW 2 to increase the rotation of rotor to 5,000 rpm.
3. lnspeccione el funcionamiento del regulador de IC
Posicionar el interruptor SW 1 en "ON", SW2 en OFF y aumentar la rotaci6n del alternador a 5000 ppm.
3. lnspecter la performance du regulateur a C.I. Porter la rotation du rotor a 5_000 tr/mn. SW1 etant missur la position ON et SW 2 sur la position OFF. Fig. 21-47
I s.ooo rpm
=-\
SM21-014A
Standard 28.SV - 29.5V
MOUNTING 1. Adjust the V-belt tension and tighten the set bolt.
1. Adjuste la tension de la correa en V y apriete el perno de fijaci6n. 1. Regler la tension de la courroie trapezo¡i dale et serrer le boulon de blocage. Fig. 21-48
W04-058
El Fig. 21-49
2. Connect the battery 0 terminal.
2. Conecte el terminal de bateriia. 2. Connecter la bcirne de batterie.
21-081
PRECAUTIONS ON THE VEHICLE 1 _ Note the battery polarity carefully so as not to make reverse connections_ If the connections are reversed, the diodes will short the circuit and allow large current to flow through and damage the diodes and IC regulator as well as burn up the wiring harness. 2. Do not disconnect the alternator terminals when in operation_ 3. When charging the battery with a quick charge disconnect the battery terminals. 4. Do not inspect with a megger tester. 5. When in operation, never disconnect the battery_
21-20 TROUBLESHOOTING Fuse is blown out Poor operation of meter When charging current is not conducted
Poor connecting or wiring of each terminals Breaking of short-circuit of coil and wiring inside the alter nator Poor diode Trouble of regulator
Poor wiring Belt is loosened Charging is insufficient
Poor regulating voltage of regulator Trouble of alternator (Short-circuit of coil, poor diode) Poor battery Note: Charging current will be reduced when the battery's charging is almost completed.
When charging current is excessive
Poor alternator or regulator (Short-circuit of wiring, coil, transistor) Regulating voltage of regulator is too high
21-21 REPAIR SPECIFICATIONS Item
Standard
Brush length mm
20
Outside diameter of slip ring mm
32.5
Resistance of coil (nl
Stator
0.91
Rotor
9.0
Service limit
5.5 32.1
-
TIGHTENING TORQUE Item
kg·cm
lb.ft
980 - 1,300
71 -94
60-90
4-6.5
M5 x 0.8
19 -25
1.3 -1.8
M6x1
33-45
2.4-3.3
Pulley lock nut Through bolt Others
IK.P.i.
22-0lESF-02
STARTER
ARRANCADOR DEMARREUR SYMBOL MARKS SIMBOLOS SYMBOLES .........•..........•..........•...•...•.... 22- 1 A GLOSSARY OF TECHNICAL TERMS
GLOSARIO DE TERMINOS TECHNIQUES
LEXIQUES DES TERM ES TECHNIQUES ....•............•..•... 22- 2
DATA & SPECIFICATION
□ ATOS Y ESPECIFICACIONES
DATA & CARACTERISTIQUES .•.......••......•...•.....•... 22- 3 DESCRIPTION
DESCRIPCION
DESCRIPTION ................................•.•.•..••. 22- 4 OVERHAUL
REPARACION GENERAL
REVISION ..........•....•.•.••..•..••........•........ 22- 5 REPAIR SPECIFICATIONS ESPECl FICACIONES DE REPARACION CARACTERISTIQUES DE REPARATION ....................•...22-27
22-1 SYMBOL MARKS The following symbols have been adapted for simplicity and for easy comprehension.
SIMBOLOS Se han adoptado los siguientes simbolos para simplidad y facil comprensi6n.
SYMBOLES
Les symboles suivants ont ete adoptes afin de simplifier et de faciliter la comprehension.
l"'1i..l 1
l� �I
a
E3
ASSEMBLY ARMADO MONTAGE
DISASSEMBLY
DESARMADO DE MONTAGE
l!B
E]
INSTALACION MISE EN PLACE
REMOVAL
REMOCION DEPOSE
INSPECCION CONT.ROLE
MEASUREMENT
MEDICION MESURE
CLEAN
LIMPIEZA NETTOYAGE
IMPORTANT
INSTALLATION
INSPECTION �
El
TIGHTENING
APRIETE SERRAGE
�
IMPORT ANTE IMPORTANT
[BJ
ADJUSTMENT
[I]
LUBRICATION
AJUSTE REGLAGE
LUBRICACION GRAISSAGE
22-2 A GLOSSARY OF TECHNICAL TERMS GLOSARIO DE TERMINOS TECNICQS LEXIOUE DES TERMES TECHNIQUES
ENGLISH
ESPANOL
FRANCAIS
1. 2. 3. 4. 5. 6. 7. 8.
1. 2. 3. 4. 5.
1. Lb. 2. Pouce 3. lnferieur 4. Superieur 5. Limite de reparation 6. Li mite d'utilisation 7. Standard (normal) 8. Couple de serrage
Ft.lb In Less than More than Repair limit Service limit Standard Tightening torque
lb.pie Puig. Menos de .. Mas de .. Li mite de reparaci6n 6. Li mite de servicio 7. Estandard 8. Par de apriete
a a
22-3
STARTER (24V, 6.0 KW) ARRANCADOR (24V, 6.0 KW) DEMARREUR (24V, 6.0 KW) DATA & SPECIFICATIONS Model ................................. Mechanism . . . . .. . . . . . . . .. . . . . .. . . . ... . . Output ................................ Number of teeth of pinion . . . . . . . . . . . . . . . . . . . Module ................................
â&#x2013;¡ ATOS
28100-1472A (0350 602 003) Pinion shift type 24V, 6.0 KW 11 3.5
Y ESPECIFICACIONES
Modelo ................................ Mecanismo . . . .. . . . . . . . . . . . . . . . . . . . . . . . . Salida ................................. Numero de dientes del pin6n . . . . . . . . . . . . . . . . . Modulo ................................
28100-1472A (0350 602 003) Tipo cambio de pin6n 24V, 6.0 KW 11 3,5
DATA & CARACTERISTIOUES Modele ................................ Mecanisme Puissance Nombre des dents de pignon . . . . . . . . .... . . . . . . Module . .. . . ................
28100-1472A ( 0350 602 003) Type a pignon d'entrainement 24V,6.0 KW 11 3,5
22-4 DESCRIPTION DESCRIPCION DESCRIPTION C80-190EA
2
1
A'
STARTER
1. Brush
2. 3.
Magnetic switch Pinion shift lever 4. Clutch and pinion 5. Pinion stopper 6. Commutator 7. Field coil 8. Armature 9. Reduction gear 10. A-A' section
Fig. 22-1
ARRANCADOR 1.
2. 3. 4. 5.
6. 7. 8. 9.
10.
Escobilla Conj unto de interrupter magnetico Palanca de cambio Embrague y pifi6n Tope del pii'i6n Colector Bobina de campo lnducido Engranaje de recci6n Secci6n A-A'
DEMARREUR 1. 2. 3. 4. 5.
6. 7.
8.
9. 10.
Balai Contacteur magnetique d'engagement Levier d"enclenchement Pignon et accouplement Butee de pignon Collecteur Enroulement de champs Endu it Engrenages de reduction Coupe A-A'
22-5
OVERHAUL REPARACION GENERAL REVISION 1846T 1-NO. 22
�� i 23 22
��·-
31
24
STARTER
1. Magnetic switch assembly 2. Contactor point assembly 3. Contactor with terminal cover assembly
4. Terminal assembly 5. Shim 6.
7. 8.
9. 10. 11. 12. 13. 14. 15. 16.
17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
Pinion shift lever Lever set bolt Moving core Through bolt Commutator end frame assembly Brush holder assembly Brush spring Brush Band Connecting bar Field coil Armature assembly Ball bearing Gear housing Shim Drive shaft O-ring Shim Center bracket Center bearing Clutch and pinion Pinion stopper Hook Clip Pinion case Front bearing
Fig. 22-2
ARRANCADOR
DEMARREUR
1. Conjunto de interrupter magnetico 2. Conjunto de punto de contactor 3. Contactor con conjunto de cubierta de terminal 4. Conjunto de terminal 5. Lamina 6. Palanca de cambio de pii'l6n 7. Tornillo de fijaci6ri de la palanca 8. Nucleo m6vil 9. Perno pasante 10. Conjunto de bastidor final del colector 11. Conjunto de portaescobilla 12. Resorte de la escobilla 13. Escobilla 14. Banda 15. Barra de conexi6n 16. Bobina de campo 17. Cojunto de inducido 18. Cojinete de bolas 19. Caja de engranaje 20. Lamina 21. Eje impulsor 22. AnilloO 23. Lamina 24. Mensula central 25. Cojinete central 26. Embrague y piii6n 27. Tope del piii6n 28. Gancho
1. Ensemble contacteur magnetic que d'engagement 2. Ensemble contacteur en point 3. Contacteur avec couvercle de borne 4. Ensemble borne 5. Rondelle d'epaisseur 6. Levier d'enclenchement 7. Bou Ion de fixation du lever 8. Noyau mobile 9. Bou Ion travers 10. Ensemble couvercle de collecteur 11. Ensemble porte-balai 12. Ressort de balai 13. Balai 14. Bride 15. Barre de connexion 16. Enroulement de champ 17. Ensemble induit 18. Palier bille 19. Carter d 'engrenages 20. Rondelle d'epaisseur 21. Arbre de commande 22. Aneau 0 23. Rondelle d'epaisseur 24. Ensemble cercle de jante 25. Palier intermediaire 26. Pignon et accouplement 27. Butee de pignon 28. Crochet 29. Bride 30. Carter de pignon 31. Palier avant
29.
Abrazadera
30. Caja del pi i'l6n 31. Cojinete delantero
a
a
22-6
E3
STARTER Dismounting
1. Disconnect the battery terminal.
ARRANCADOR Desmontaje
1. Desconecte el terminal de la baterf a.
DEMARREUR De montage
1. Debrancher la borne de batterie.
Fig. 22-3
21-081
E3 Fig. 22-4
3. Remove the starter set bolt .
3. Remueva el perno de sujeci6n del arrancador. 3. Deposer la vis de fixation du demarreur.
22-060
E3 Fig. 22-6
2. Desconecte el cable conectado a los terminales B y C del arrancador. 2. Deposer le cable qui est connecte a la borne B et C du demarreur.
22-059
E3 .-t..
Fig. 22-5
2. Disconnect the cable which are connected to B and C terminal of the starter.
22-061
4. Dismount the starter assembly.
4. Desmonte el conjunto de arrancador. 4. Deposer !'ensemble demarreur.
22-7 Disassembly
1. Disconnect the connecting¡ bar.
Desarmado 1. Desconecte la barra de conexi6n. Desassemblage 1. Deposer la barre de connexion.
Fig. 22-7
22-062
2. Remove the magnetic switch set bolts.
2. Remueva los pernos de sujeci6n del interruptor magnetico. 2. Deposer les vis de fixation du contacteur magneti que.
Fig. 22-8
22-063
3. Remove the magnetic switch assembly.
3. Remueva el conjunto de interruptor magnetico. 3_ Deposer !'ensemble contacteur magnetique.
Fig. 22-9
22-064
4. Remove the moving core.
4. Remueva el nucleo m6vil. 4. Deposer le noyau mobile.
Fig. 22-10
22-065
El
22-8
.....
5. Remueva el perno pasante. 5. Deposer les boulons a travers.
22-066
Fig.22-11
El Fig. 22-12
6. Remove the pinion case.
6. Remueva la caja del pin6n. 6. Deposer le carter de pignon.
22-067
El
7. Remove the center bracket with the pinion clutch assembly.
7. Remueva la mensula central con conijunto de em braque de pinion. 7. Deposer le support central ainsi que !'ensemble embrayage de pignon comme un ensemble.
22-126
Fig. 22-13
El Fig. 22-14
5. Remove the through bolt.
22-125(8)
22-069
8. Remove the clip.
8. Remue va el abrasadera. 8. Deposer du bride:
22-9
El Fig. 22-15
22-075
10. Remueva la lamina. 10. Deposer la rondelle d'epaisseur.
11. Remove the pinion shift lever set bolt. 11. Remue va el perno de. sujecion de la palanca de . cambio de pinion.
11. Deposer la vis de fixation du levier d'enclenchement.
22-121
El Fig. 22-18
10. Remove the shim.
22-0119
El Fig. 22-17
9. Separe el embraque de pinion y el eje impulsor. 9. Separer i !embrayage de pignon et l'arbre d'entra1ne ment.
22-123
El Fig. 22-16
9. Separate the pinion clutch and the drive shaft.
22-076
12. Remove the band. 12. Remueva la banda.
12. Deposer la bride.
22-10
El Fig. 22-19
14. Remove the brush.
14. Remueva la escobilla. 14. Deposer le balai.
22-078
El Fig. 22-21
13. Remueva el tornillo de ajuste de la escobilla. 13. Deposer la vis de fixation de balai.
22-077
El Fig. 22-20
13. Remove the brush set screw.
15. Remove the through bolt.
15. Remueva el perno pasante. 15. Deposer le bou Ion a travers.
22-079
16. Remove the gear housing together with the armature.
16. Remueva la caja de engranaje junta con el inducido. 16. Deposer le carter d'engrenage avec l'induit.
Fig. 22-22
22-080
22-11
1��1 Fig. 22-23
17. Remueva el inducido de la caja de engranaje. 17. Deposer l'induit du carter d'engrenage.
22-081
E3 Fig. 22-24
17. Remove the armature from the gear housing.
18. Remove the commutator end frame.
18. Remueva el bastidor final del colector. 18. Deposer le couvercle de collecteur.
22-082
Inspection & repair
1. Armature 1) Shortcircuit test. (1) Place the armature on the armature tester. (2) Operate the tester and place the iron piece on the armature. * If the iron piece is not vibrated, the armature is good.
Fig. 22"-25
22-083
lnspeccion y reparacion 1. lnducido 1) Prueba de cortocircuito. ( 1) Coloque el inducido sobre el probador de in ducido. (2) Opere el probador y coloque una pieza de hierro sobre el inducido. * Si la pieza de hierro no vibra, significa que el inducido esta en buenas condiciones. Controle & reparation 1. lnduit 1) Essai de court-circuit ( 1) Placer l'induit sur I 'appareil d'essai d'induit. (2) Fonctionner l'appareil et placer une piece de fer mince sur l'induit. * Si la piece de fer mince n'est pas vibree, l'induit est bon.
22-12 2) Check the insulation.
2) Revise el aislarniento. 2) Verifier I 'isolement.
22-084
Fig. 22-26 Standard
More tha111MD
3) Measure the wave of commutator.
3) Mida la onda del colector. 3) Mesurer I 'usure du collecteur.
Fig. 22-27
22-085 Less than 0.05 mm (0.0020 in) 0.1 mm (0.0039 in)
4) Measure the outside diameter of the commutator.
4) Mida el diarnetro exterior del colector. 4) Mesurer le diametre exterieu¡r du collecteur.
Fig. 22-28
22-086
Standard
40 mm ( 1.575 in)
Service limit
38 mm (1.496 in)
22-13 5) Measure the depth of under cut.
5) Mida la profundidad del rebaje. 5) Mesurer la profondeur du mica.
Fig. 22-29
1. Quantity of mica 2. Segment 3. Mica Standard Repair limit
1. Cantidad de mica 2. Segment 3. Mica
1. Ouantite du mica 2. Segment 3. Mica
0.5~0.Bmm (0.0197~0.0315 in} 0.2 mm (0.0079 in}
· ·�
2. Field coil 1) Check the conduction between the series coil and the yoke. * Should be conducted.
2. Bobina de campo 1) Revise la conducci6n entre la bobina en serie y el yugo. * Debe haber conducci6n. 2. Enroulement de champ 1) Verifier la conduction entre l'enroulement de champ et la culasse de demarreur. * 11 faut elre conductible. Fig. 22-30
22-087
EJ Fig. 22-31
22-088
2) Check the insulation. (1) Remove the coil earthing screw at 2 points.
2) Revise el aislamiento. ( 1) Remueva el tornillo de puesta a tierra de la bobina en 2 puntos. 2) Verifier l'isolement ( 1) Deposer les vis de masse d'enroulement a 2 points.
22-14
E3 Fig. 22-32
(2) Apart the end of coil from the yoke. (2) Separe el extrema de la bobina del yugo.
(2) Separer l'extremite d'enroulement de la culasse.
22-089
(3) Check the insulation.
(3) Revise el aislamiento. (3) Verifier l'isolement.
22-090
Fig. 22-33 Standard
More than 1 MD.
3. Drive shaft 1) Measure the d.rive shaft for bend.
3. 1) 3. 1)
22-091
Fig. 22-34 Repair limit Service limit
Eje impulsor Mida el eje impulsor por siesta combado. Arbre de commande Verifier la torsion de l'arbre de commande.
0.05 mm (0.0020 in) 0.10 mm (0.0039 in)
2) Inspect the spline and internal gear for wear and damage.
2) I nspeccione la estri a y el engranaje interno en cuanto a dafios y desgaste. 2) Verifier l'usure et la deterioration de la cannelure et l'engrenage interieur.
Fig. 22-35
22-092
22-15
l!tl Fig. 22-36 Standard Service limit
22-093 19 mm (0.748 in) 19.2 mm (0.756 in)
Fig. 22-37 Standard Service limit
4. Bushing 1) Measure the inside diameter of the bushings. (1) Front bushing 4. Buje 1) Mida el diametro interior de los bujes. ( 1) Buje delantero. 4. Bague 1) Mesurer '1e diametre interieur des bague ( 1) Bague avant.
(2) (2)
Center bushing. Buje central.
(2)
Bague central.
22-094 28 mm (1.102 in) 28.2 mm (1.110 in)
5. Brush holder 1) Check the insulation between the brush holder and the bracket. 5. Portaescobilla 1) Revise el aislamiento entre el portaescobilla y la mensula. 5. Porte-balai 1) Verifier I 'isolement entre le porte-balai et le cou vercle.
Fig. 22-38 I Standard
22-095 More than 1MS1
2) Check the tension of the brush spring. 2) Revise la tension del resorte de la escobilla. 2) Verifier la tension du ressort de palai.
Fig. 22-39 Standard Service limit
22-096 1.4 kg (3 lb) 1.0 kg (2 lb)
22-16 3) Measure the brush length.
3) Mida la longitud de la escobilla. 3) Mesurer la longueur de balai.
Fig. 2240 Standard Service limit
22-097
20 mm (0.787 in) 14 mm (0.551 in)
6. Magnetic switch 1) Check the conduction between the C terminal and the body. * Should be conducted.
6. I nterruptor magnetico 1) Revise la conducci6n entre el terminal Cy el cuerpo. * Debe haber conducci6n 6. Contacteur magnetique d'engagement 1) Verifier la conduction entre la borne C et le corps. * 11 taut etre conductible. Fig. 22-41
22-098
2) Check the conduction between the C terminal and the coil terminal. * Should be conducted
2) Revise la conducci6n entre el terminal Cy el terminal de bobina. * Debe haber conducci6n. 2) Verifier la conduction entre la borne C et la borne d'enroulement. * 11 taut etre conductible. i\..
\¡¡
Fig. 22-42
22-099
7. Pinion and clutch 1) Check the pinion teeth for damage.
7. Pifi6n y embrague 1) Revise los dientes del pifi6n en cuanto a dafios. 7. Pignon et accouplement 1) Verifier la deterioration des dents de pignon.
Fig. 22-43
22-100
22-17 2) Fix the shaft and rotate the pinion to check the clutch. * If it turns both side or does not turn at all, replace it with new one.
2) Fije el eje y gire el pifi6n a fin de revisar el embrague. * Si gira a ambos lados o no gira para nada, reemplace par uno nuevo. 2) Fixer l'arbre et tourner le pignon afin de verifier l'accouplement. * Si l'accouplement se tourne toutes les deux cotes ou ne se tourne pas du tout, remplacer-le avec un neuf. Fig. 22-44
22-101
OJ
Assembly NOTE:
When assembly the starter motor, apply grease at the following points. Be sure to use the proper kind of grease at each point.
Armada NOTA:
Al remontar el motor del arrancador, aplique grasa en los puntos siguientes. Asgurese de utilizar la clase adecuada de grasa en cada punto.
Remontage N.B.: Fig. 22-45
2
Bushing (Front)
1
Buje {Delantero)
Bushing (Pinion gear)
2
Buje (Pinon satelite) Buje (Centro) y laminilla de ajuste Engranaje de reducci6n Cojinete de bolas (Centro) Cojinete de bolas (Tracero) Embrague Eje
3
Bushing (Center) & shim
3
4
Reduction gear & shim
4
5
Bearing (Center)
5
6
Bearing (Rear)
6
7
Clutch
7
8
Shaft
9
Pinion shift lever
8
Lubrication position 1
3
2 4 7
5 6
8 9
9
Palanca del eje pin6n
Characteristic of recommended lubricants
Lors du remontage du demarreur, appliquer de la graisse aux points suivants. S'assurer d'utiliser la graisse appropriee a chaque point.
Bague (Avant) 2
3
4 5 6 7
8 9
Bague (Pignon d'attaque) Bague (Central) a cale Pignon de d'emultiplication et cale Roulement (Central) Roulement (Arriere) Em bray age Arbre Levier de l'arbre de pignon
BRAND
Lithium and sope based bearing grease
Pyronoc·2 (Nihon Sekiyu) Multemp SRL (Kyodo Yushi)
Lithium and sope based bearing grease (containing malybdenum disulfide) High film strength grease
Multemp MS2 (Kyodo Yushi)
Urea based high temperature grease ° ° ° ° Operation temp. -20 C 250 C (-4 F-482 F)
Multemp SRL (Kyodo Yushi)
~
22-18 Posici6n de lubricaci6n
3
1
4
7
5
8
6
Position de graissage 1
3
4 7 8 9
5
Caracteristicas de los lubricantes recomendades
6
9
Marca
Grasa de cojinete a base de litio
Pyronoc-2 (Nihon Sekiyu) Multemp SRL (Kyodo Yushi)
Grasa de cojinete a base de litio (con bisulfito de molibdeno) Pel icula de grasa altamente resistente
Multemp MS2 (Kyodo Yushi)
Pel icula de grasa altamente resistente ° ° ° ° Operation temp. -20 C - 250 C (-4 F - 482 F)
Multemp SRL (Kyodo Yushi)
Caracteristiques des lubrifiants recommandes
Marque
Graisse pour roulement savan
a la base du lithium et du a
Pyronoc-2 (Nihon Sekiyu) Multemp SRL (Kyodo Yushi)
Graisse pour roulement la base du lithium et du savon (comprenant la diusulfate de molybdene) Graisse a haute resistance de filme
Multemp MS2 (Kyodo Yushi)
Temperature de fonctionnement de la graisse pour roulement haute temperature la base de l'uree ° ° ° ° -20 C- 250 C(-4 F- 482 F)
Mui temp SR L ( Kyodo Yushi)
a
a
22-19 Assembling of the motor 1. Install the end frame to the yoke.
Armado del motor 1. I nstale el bastidor final al yugo. Remontage du moteur 1. Remettre le couvercle a la culasse.
Fig. 22-46
22-082
El Fig. 22-47
2. Install the armature into the gear housing.
2. I nstale el inducido en la caja de engranaje. 2. Remettre l'induit dans le carter d'engrenage.
22-102
3. Install the armature into the yoke.
3. lnstale el inducido en la horquilla. 3. Remettre l'induit dans la culasse.
Fig. 22-48
22-103
El Fig. 22-49
22-0145
Tightening torque 1140~160 kg.cm(10.2 ~ 11.Sft.lb}I
4. Tighten the through bolt.
4. Apriete el perno pasante. 4. Resserrer le boulon a travers.
22-20
El Fig. 22-50
6. Install the band.
6. lnstale la banda. 6. Remettre la bride.
22-076
El Fig. 22-52
5. lnstale la escobilla. 5. Remettre la balai.
22-078
El Fig. 22-51
5. Install the brush.
7. Install the pinion shift lever.
7. I nstale la palanca de cambio de pifi6n. 7. Remettre le levier d'enclenchement.
22-121
El
8. Installation of the drive shaft. Install the shim into the drive shaft.
8. lnstalaci6n del eje impulsor lnstale la lamina en el eje impulsor. 8. Remontage de I 'arbre de commande Remettre la rondelle d'epaisseur a l'arbre de com mande.
Fig. 22-53
22-105
22-21
Fig. 22-54
Fig. 22-55
Fig. 22-56
El
9. Install the drive shaft. 9. lnstale el eje impulsor. 9. Remettre l'arbre de commande.
El
10. Install the shim. 10. lnstale la lamina. 10. Remettre la rondelle d'epaisseur.
El
11. Install the center bracket. 11. lnstale la mensula central. 11. Remettre le cercle de jante.
22-074
22-073
22-106
12. Pretighten the through bolt and mesure the thrust gap, move the drive shaft in and out. 12. Preajuste el perno pasante y mida la holgura de
empuje moviendo el eje de transmisi6n hacia dentro y hacia fuera. 12. Measurer le jeu de butee en depalacant l'arbre d'entra1nement vers l'interiour et vers l'exteriour.
Fig. 22-57 Standard
22-0118 0.1~0.3 mm (0.0039~0.0118 in)
22-22
El Fig. 22-58
Fig. 22-59
Fig. 22�0
13. lnstale el conjunto de embrague de pii'i6n. 13. Remettre I 'ensemble p ignon a accouplement.
22-070
El
14. Install the pinion stopper. 14. lnstale el tope del pifi6n. 14. Remettre la butee de pignon.
El
15. Install the hook and clip.
22-108
15. I nstale el 15. Remettre le circlip.
22-109
El Fig. 22�1
13. Install the pinion clutch assembly.
22-067
16. Install the pinion case.
16. I nstale la caja del pii'i6n. 16. Remettre le carter de pignon.
Fig. 22-62
I
Tightening torque \ 140~160 kg.cm (10.2~11.5 ft.lb)
Fig. 22-63
Fig. 22-64
Fig. 22-65
Tightening torque
22-23
El
17. Tighten the through bolt. 17. Apriete el perno pasante. 17. Resserrer le boulon a travers.
El
18. Install the moving core. 18. lnstale el nucleo m6vil. 18. Remettre le noyau mobile.
El
19. Install the magnetic switch assembly. 19. lnstale el conjunto de interruptor magnetico. 19. Remettre I 'ensemble contacteur magnetique d'engage ment.
El
20. Tighten the set bolt. 20. Apriete el perno de sujeci6n. 20. Resserrer la vis de fixation.
I
22-065
22-064
22-0147
60~90 kg.cm (4.4~6.5 ft.lb)
22-24
El Fig. 22-66
I
Tightening torque
I
21. Install the connecting bar.
21. Instate la barra de conexi6n. 21. Remettre la barre de connexion.
22-0144 165~225 kg¡cm (14~17 ft.lb)
Inspection
1. Measurement of the timing gap.
1) Arrange the circuit as shown in Fig. 22-68. 2) Turn on the switches S1 and S2. 3) Open S2 alone when the pinion pops out.
lnspeccion
1. Medici6n del huelgo de sincronizaci6n 1) Disponga el circuito de la rnanera indicada en la Fig. 22-68. 2) Gire los interruptores S1 y S2. 3) Abra solarnente S2 cuando aparezca el pifi6n.
Cont role
Fig. 22-67
1. 1) 2) 3)
Mesure de la course du pignon Arranger le circuit comrne le montre la Fig. 22-68. Ouvrir l'interrupteur S1 et S2. N'ouvrir que S2 quand le pignon sort.
4) With above condition, push the end of pinion back to measure the gap.
4) En la condici6n de arriba, presione el extremo del pifi6n hacia atras para medir el huelgo. 4) A la condition ci-dessus, repousser l'extremite du pignon afin de mesurer le jeu.
Fig. 22-68 Standard
22-113 0.5~1.5 mm (0.0197~0.0591 in)
22-25 2. Adjustment of the timing gap. The timing gap can be adjusted by increasing or decreasing the number of the shim which is installed between the magnetic switch and the center bracket. 2. Ajuste del huelgo de sincronizaci6n. El huelgo de sincronizaci6n puede ajustarse aumen tando o disminuyendo el numero de laminas in staladas entre el interuptor magnetico y la mensula central.
Fig. 22-69
2. Reglage de la course du pignon Le reglage peut etre accompli en augmentant ou diminuant le nombre des rondelles d'epaisseur qui sont mises entre le contacteur magne.tique et le cercle de jante.
22-114
El
Mounting 1. Mount the starter assembly.
Montaje
1. Monte el conj unto de arrancador.
Installation
1. Installer !'ensemble demarreur.
Fig. 22-70
22-061
El Fig. 22-71 I Tightening torque I
2. Apriete los pernos de sujeci6n. 2. Resserrer les vis de fixation.
22-060 650~870 kg.cm (47~62 ft.lb)
El Fig. 22-72
2. Tighten the set bolts.
22-059
3. Connect the cables.
3. Conecte los cables. 3. Connecter les cables.
22-26
El Fig. 22-73
21-081
4. Connect the battery terminal.
4. Conecte el terminal de la bateri a. 4. Connecter la borne de batterie.
22-27 REPAIR SPECIFICATIONS SERVICE STANDARD
Unit: mm (in)
Item Bushing inside diameter
Commutator
Nominal size
Service limit
Measure
Front
19 (0.748)
19.2 (0.756)
Replacement
Center
28 (1.102 )
28.2 (1.110)
Replacement
Outside diameter
40 (1.575 )
38
Wave Under cut
Brush length Tension of brush spring Bend Drive shaft
Repair limit
Thrust play
Insulating resistance
(1.496 )
Replacement
Less than 0.05 (0.0020)
More than 0.1 (0.0039)
Repair
0.5 ~ 0.8 (0.0197 ~ 0.0315)
Less than 0.2 (0.0079)
Repair
20 (0.787)
14 (0.0551)
Replacement
1.4 kg (3 lb)
1.0 kg (2 lb)
Replacement
0.05 (0.0020)
More than 0.1 (0.0039)
Replacement
0.1 ~ 0.3 (0.0039 ~ 0.0118)
Adjustment
More than 1 MS°2
Less than 0.5MS°2
Replacement
TIGHTENING TORQUE Item
kg.cm
lb.ft
M terminal
165 ~ 225
12 ~ 16
Through bolt
140 ~ 160
10.2~11.5
60 ~ 90
4.4 ~ 6.5
650 ~ 870
47 ~ 62
Magnetic switch set bolt Starter set bolt
22-28 ESPECIFICACIONES, DE REPARACION NORMAS DE SERVICIO
Unidad: mm (pull Tamafio nominal
Item Diametro interior del buje
Colector
Li mite de servicio
Li mite de reparaci6n
Contramedida
Delantero
19 (0,748)
19,2 (0,756)
Ree mplace
Centro
28 (1,102 )
28 ,2 (1 , 110)
Reemplace
Diametro exterior
40 (1,575 )
38
Menos de O,05 (0,0020)
Onda
0,5 (0,0197
Rebaje
~ 0,8 ~ 0,0315)
(1,496)
Reemplace
Mas de 0,1 (0,0039)
Reparaci6n
Menos de 0,2 (0,0079)
Reparaci6n
Longitud de la escobilla
20 (0,787)
14 (0,551)
Reemplace
Tension del resorte de la escobilla
1,4 kg (3 lb)
1 ,0 kg (2 lb)
Reemplace
0,05 (0,0020)
Mas de 0,1 (0,004)
Reemplace
Eje impulsor
Camba Juego de empuje
0,1 (0,0039
Resistencia de aislamiento
~ 0,3 ~ 0,0118)
Ajuste
Mas de 1Mil
Reemplace
Menos de 0,5Mil
PARES DE APRIETE Item
kg.cm
lb.pie
~ 16
10.2
Perno de sujeci6n del interrupter magnetico
~ 225 140 ~ 160 60 ~ 90
4,4
~
Perno de sujeci6n del arrancador
650
~ 870
47
~ 62
Terminal M Perno pasante
165
12
~ 11.5 6,5
22-29 CARACTERISTIOUES DE REPARATION NORME D'UTILISATION Designation Diametre interieur du bajue
Collecteur
Unite: mm Dimension nominale
Remede
19
19,2
Remplacement
Central
28
28,2
Remplacement
Diametre exterieur
40
38
Rem placement
Profondeur du mica
Mains du 0,05
Plus de 0,1
Reparation
o,5a0,8
Mains du 0,2
Reparation
Longueur de balai Tension de ressort de balai Torsion Jeu de cannelure
20
14
Remplacement
1.4 kg
1,0 kg
Remplacement
0,05
Plus du 0, 1
Remplacement
0,1
a o,3
Reglage
Plus du 1MS1
Resistance d'isolement
Mains du 0,5MS1
COUPLE DE SER RAGE Designation Borne M Bou I on
Limite d'utilisation
Avant
Usu re
Arbre de commande
Li mite de reparation
a travers
Vis de fixation du contacteur magnetique d'engagement Vis de fixation du demarreur
kg.cm 165 a 225
a 150 60 a 90
140
550
a 870
Rem placement
22-30 0350 602 003 0
>
w
X
I-
E
>
z
....J
<1:
�
e-
lLQ
oIa: :J
W....J
mo
2>
E y
Cl
_,,
w :J
0 II-
1:J o_ 1:J 0 o_
aa:
w
::iw z a: z
24
6
12
6
20
5
10
5
16
4
8
4
12
3
6
3
8
2
4
2
4
0
2
0
CHARACTERISTIC CURVE
I'---r--..E I
p
V
" ' J '""
"' I I
\
" "L/I/
\)
I
1
0 0
v-......
/
V 200
/
..........____
400
l
"
v /
/
7
............
I/
\ I/
)"
"-. -.\
�
600
/
1/T
800
" '-....
--
--
\ I'--\ \ \
r--...\
1000
'
1200
1400
CURRENT I (A) SM-22-015
Fig. 22-74
Combination of 0350 602 003
STARTER SWITCH
TO ALTERNATOR (N) TERMINAL BATTERY SWITCH
C BLOCK RELAY
e BATTERY SM-22-014
Fig. 22-75
22-31 0350 602 003 <!
i
�
!E
w
..I
w 0
w .., <!
en
wo 0-
3
0 (.) a:
= "·
Cl
0
>
wo �> :) w z a:
a: <! a..
w
z
f-
24
6
12
20
5
10
16
4
8
4
12
3
6
3
8
2
4
0
4
GUAVA CARACTERISTICA
I
(/J 0..
6
I'---,-..._E �
I
\/
7'
7
7
2
0
0
V 0
V
I'I'-..
I
\
2
7
,I
"J\
,,v)
"/
/
\ V
.._I'--
I/
/
p
/
I"-.�\
"'
V
r------......
400
200
r----.� 600
V
V
........
V
/
VT
800
�
�
\ 1"----I'-...' \
r----r--. \ 1000
1200
1400
CORRIENTE (A) Fig. 22-76
SM-22-015
Combinacion de 0350 602 003
BOTON DEL· ARRANCADOR
HACIA EL TERMINAL DEL ALTERNADOR
CONMUTADOR DE LA BATERIA
/
C BLOQUE DEL RELE MOTOR DELARRANCADOR
EB B ATERIA SM-22-014
Fig. 22-77
22-32 0350 602 003 2:
C:
0
co <l'. z
Q z w w
w l a: 0
E -----
w z a:
Cf)
w
E
0
y
a:
w .J (l_ ::J 0 u
z
I-
w
2
w u z <l'. Cf) Cf)
(l_
24
6
12
20
5
10
16
4
8
12
3
6
3
8
2
4
2
4
COURBE DE CARACTERISTIOUE
::J (l_
6
" IV
I"-.. ......._E
�
-
J
0
-.,
"�I "'
I 0
V
.I
V
/
'---..
/.....
I/
'V
)
/
V
r--,.... .._
400
600
800
V
V
VT
\
�
�
200
/
""'\
.Iv
\)
2
0
r---...
I
4
' 0
"
p
�\
i
\ 1"----r--.... \
'
-r---r--._\ 1000
1400
1200
COURANT IA) SM-22-015
Fig. 22-78
Combinasion du 0350 602 003
CLE DE CONTACT
VERS LA BORNE DE L'ALTERNATEUR INTERRUPTEUR DE BATTERIE
B
e
C RELAIS EN BLOC DEMARREUR
e BATTER IE SM-22-014
FilJ. 22-79
TURBOCHARGER
TC-1 TC-SE-01
CHAPTER TC HINO EP100T TURBOCHARGER DATA AND SPECIFICATIONS .......................... TC-2 DESCRIPTION ....................................... TC-2 TROUBLESHOOTING ................................. TC-3 OVERHAUL CRITERIA ............................... TC-4 SPECIAL TOOL ...................................... TC-5 TURBOCHARGER .................................... TC-6
TC-2
TURBOCHARGER
DATA AND SPECIFICATIONS Type ................................. External dimensions {Length x Width x Height) ...... Turbine type . . . . . . . . . . . . . . ..... . . . . . . . . . Blower type . . . . . . . . . ... . .. . . . . . . . . . . . . . . Lubricating mettiod ... . . ... . . . . . .. . . .. . . . . Bearing type .... . . . . • . . . . .. . .......... . . Maximum allowable continuous revolution . . . . . . . . Direction of rotation .......•............... Maximum allowable continuous inlet ............ termperature
RHC 7 229 mm x 215 mm x 215 mm Radial flow type Centrifugal type External lubrication type Full floating type 132.000 rpm Counterclockwise as seen from the turbine side ° 730 C
DESCRIPTION 1
1881J 1-No. 20
J
9
5 �������--,.?d_ 13 14 15
7
18
8
1.
2. 3. 4. 5. 6.
Oil inlet Air outlet Bearing case Heat protector Turbine case Turbine rotor
7. 8. 9. 10. 11.
12.
Gas outlet Gas inlet Blower case Blower impeller Air inlet Seal ring on blower side
13.
14. 15. 16.
17. 18.
Turbine rotor assembly Seal plate Thrust spacer Journal bearing Oil outlet Journal bearing
TC-3
TURBOCHARGER
TROUBLESHOOTING Possible cause
Symptom
Remedy /Prevention
Dense black smoke, ------.--- Insufficient air intake
• Air cleaner is choked with dust, ............ Disassemble and clean or replace the air cleaner element. causing greater intake air resistance. • Air inlet is choked . . ... . .... . . . ... . ... Repair. • Air is leaking from intake menifold . ... . .... Repair. Turbocharger does not rotate smoothly.
• Engine oil impurities deposited on rotor, resulting in heavy rotation or sticking.
Overhaul and clean turbocharger and/or change engine oil.
Bearing sticking
• Insufficient lubrication or blockalge . .... . ... Check lubricating oil system, of lubricating oil lines. and/or repair.
• Abnormal wear or damage of seal ring caused by wear of journal bearing, due to insufficient lubrication.
Repair.
• Temperature of lubricating oil too high ....... Check cooling system.
• Unbalanced rotating parts ............... Change rotating parts.
• Incomplete warming-up, failure ............ Operate vehicle properly. to idle before stopping engine, or jack rabbit starts. 1-----1
Loose or damaged turbine rotor or blower impeller.
• Over-rotation . .......... . .... . . .. .. . . Check and adjust the engine.
• Temperature of exhaust gas too high ........ Check and adjust the engine.
• Foreign matter present ..... . ... . . ... . . . Remove foreign material. Inspect the air cleaner and air intake manifold. Repair if necessary.
• Worn thrust bearing . . . .. . . . . . . . ..... .. Overhaul and repair.
• Incomplete assembly . . ... . .. . . ... . ... .. Reassembly.
High volume exhaust-----.- --Exhaust gas leaking before turbocharger, ....... like noise. L therefore insufficient revolution.
Check and repair connections.
Deformed or blocked exhaust gas lines ........ . Repair. therefore insufficient revolution.
White smoke---------.--Choking defects, or deformation of ............ Repair and replace the lines. oil return lines so that oil leaks around blower or turbine sides. L
Seal ring may be broken or worn due . . . . ..... . Replace the thrust washer. to abnormal wear of thrust washer.
TC-4
TURBOCHARGER
Possible cause
Symptom
Remedy /Prevention
Loss of power-------""T --Gas leakage from exhaust system ............ . Repair. �
Air leakage from air manifold .............. . Repair.
Clogged air cleaner element ............... . Clean or replace.
Turbocharger dirty or damaged ............. . Repair or replace.
Poor response of------...--Carbon accumulation on the turbine .......... Change engine oil, clean side seal ring and heavy rotation. turbocharger turbocharger. L
Poor combustion ...................... . Check fuel system and improve combustion.
High pitched noise-------.-----1 Noise and vibration • So called "surging" Surging sometimes occurs when the gas passage at the nozzle of the turbine housing is choked or when compressed air does not flow in proper responses to acceleration.
Overhaul and clean turbocharger.
• Loosen rotating parts . .. . . .. . . . . . . . . . . . Replace. Vibration
• Joints loose between turbocharger .......... Check the mounting and repair. and intake, exhaust manifold or oil lines. • Damaged bearing, loose rotating parts, . . . . ... Repair. imbalanced rotating parts, etc.
OVERHAUL CRITERIA CONDITIONS WHICH DETERMINE WHEN A TURBOCHARGER OVERAHUL MAY BE NEEDED. THE ENGINE LACKS POWER OR ENGINE EXHAUST EMITS BLACK SMOKE. BOOST PRESSURE IS BELOW THE NORMAL VALUE.
Inspect the turbocharger boost pressure according to the following procedures.
NOTE: Before measurement ° o Coolant temperature should approximately 80 C. o Air cleaner element should be clean. WARNING
When making a pressure test, be sure that personnel are adequate ly protected against any stream of pressurized air that might be released by a leak or the rupture of a hose.
. TC-5
TURBOCHARGER 1.
Remove the blind plug on the intake pipe and install the hose and pressure gauge (special tools).
Special Tools: Pressure Gauge (09444-1250) Hose ( 17108-1040)
Do Boost pressure hose
2.
Disengage the clutch and run the engine at maximum rpm.
3.
Read boost pressure. It the boost pressure is below the normal value, turbocharger overhaul is needed.
SM51-001
Boost Pressure: Less than 0.16 kg/cm 2 OTHER FACTORS
SM51-016
1.
Noisy of excessive vibration of the turbocharger.
2.
Excessive engine oil consumption.
3.
Gas leakage at the turbine end or blower end.
4.
Oil leakage from the turbocharger.
SPECIAL TOOL Prior to starting an turbocharger overhaul, it is necessary to have these special tools.
ATTACHMENT FOR MEASURING TURBINE SHAFT RADIAL PLAY
BOOST PRESSURE GAUGE
BOOST PRESSURE GAUGE HOSE
09444-1230
09444-1250
17108-1040
TURBOCHARGER
TC-6
TURBOCHARGER 1881J 1-No. 20
16 T = Tightening torque: kg-cm (lb.ft)
1.
2.
3. 4.
5.
6.
Retainer ring Oil thrower Seal ring Seal plate Lock plate Blower case
7.
8.
9.
10. 11. 12.
Journal bearing Thrust spacer Thrust bearing Blower impeller Lock nut Turbine case
13. 14. 15. 16.
Turbine rotor assembly Heat protector Bearing case Plate
IMPORTANT POINT (S) - BEFORE DISASSEMBLY 1.
Rotate the blower impeller by hand to see if it turns smoothly. If it does not turn smoothly, clean and inspect the bearing and turbine rotor.
2.
Check the turbine rotor for axial play (A). If the axial play is greater than the service limit, replace the thrust bearing and/or thrust spacer.
SM51-002A
Axial Play: 0.06 - 0.09 mm (0.0023 - 0.0035 in) Service Limit: 0.11 mm (0.0043 in)
SM51-002
TURBOCHARGER 3.
TC-7
Check the turbine rotor for radial play using a special tool. If the radial play is greater than the service limit; replace the bearings and/or turbine rotor.
Special Tool: 09444-1230 Radial Play: 0.11 - 0.18 mm (0.004 - 0.007 ii'!) Service Limit: 0.215 mm (0.0085 in)
SM51-002A
IMPORTANT POINT (S) - DISASSEMBLY REMOVE THE BLOWER CASING. NOTE: o Make matching marks on the blower case and bearing case to aid alignment during reassembly. o If the blower casing cannot easily be removed by hand, tap it carefully all around using a plastic hammer and carefully remove it. o Be careful not to damage the blower impeller.
REMOVE THE BLOWER IMPELLER. 1.
Remove the blower impeller fitting nut.
NOTE: Turn the lock nut clockwise to loosen the nut (left-hand threads). 2.
Remove the blower impeller by hand.
SM51-018
REMOVE THE TURBINE CASING. NOTE: o Make matching marks on the turbine case and bearing case to aid alignment during reassembly. o Because the bolts on the turbine side are exposed to high temperature, if they have seized, do no apply an unreasonable force to remove them because they may break. Spray a lubricant onto them, then wait for about 15 minutes and loosen them. o Be careful not to damage the turbine blades. o If the turbine casing cannot easily be removed by hand, tap it carefully all round using a plastic hammer and carefully remove it. REMOVE THE TURBINE ROTOR WITH HEATER PROTECTOR. REMOVE THE BEARINGS. 1.
Remove the holding plate.
NOTE: Mark one side of the holding plate so that it can be replaced in the proper direction during assembly.
SM51-020
TURBOCHARGER
TC-8
2.
Remove the seal plate. Pull out the seal plate using the attachment and a sliding hammer.
3.
Remove the oil thrower from the seal plate.
4.
Remove the thrust bearing and thrust spacer. Loosen the bolt, then remove the thrust bushing using a 10 dia. copper rod.
NOTE: When removing the thrust bearing and thrust spacer, be careful not to damage the thrust bearing hole in the bearing case.
5.
Remove the retainer rings of each bearing.
NOTE: When removing the retainer ring, be careful not to damage the front face of the hole in the bearing case. 6.
Remove the bearings.
REMOVE THE SEAL RINGS. NOTE: When removing the seal ring, be very careful not to damage the groove of the seal ring.
SM51-025
IMPORTANT POINT (S) -ASSEMBLY CLEAN ALL PARTS. 1.
Before cleaning, the disassembled parts should be visually inspected to check for burning, abrasion, carbon deposits, gas and oil leakage.
2.
Thoroughly clean all the parts with diesel fuel, using a soft brush, and dry with compressed air.
NOTE: o Never use a caustic cleaning solution, as it may attack aluminum. o Never use a wire brush.
TURBOCHARGER
TC-9
ASSEMBLE THE JOURNAL BEARINGS.
OIL INLET 0
1.
Install the first retainer ring in the bearing casing.
NOTE: o Bevelled edge of the retainer ring should be towards the bearing. o Make sure that the retainer ring is securely fitted in the groove. o Install the retainer ring with the gap facing as shown in the drawing. 2.
Install the bearing in the bearing case.
NOTE: Apply clean engine oil. 3.
Install the other retainer ring.
NOTE: The only nearest turbine side of the retainer ring should be installed according to the figure on the left.
OIL OUTLET
4.
OIL INLET
Repeat step 1) through 4) to install the second bearing.
�VIEWFROM TURBINE ROTOR � SM51-026
ASSEMBLE THE THRUST BEARING;
2
1.
Install the thrust spacer on the turbine shaft.
NOTE: Lubricate thrust spacer surface. 2.
Coat the thrust bearing with clean engine oil and install the thrust bearing.
NOTE: Always use new screws and lock washers.
SM51-027
SEALRIN
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BEAR ING CASE
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ASSEMBLE THE TURBINE ROTOR. 1.
Install a new seal ring in the seal ring groove of the turbine shaft.
2.
Install the holding plate.
3.
Position the heat protector on the bearing case.
4.
Coat the journals of the turbine rotor with clean engine oil and install the turbine rotor in the bearing case.
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HOLDING PLATE
HEAT PROTECTOR
TURBINE SHAFT
SEAL RING GAP SM51-029
NOTE: o The gap in the seal ring of the turbine shaft must face towards the oil inlet. o Insert the seal ring concentric with the turbine shaft. If it is inserted with unreasonable force, it may be damaged. o When inserting the turbine shaft, be very careful not to damage the journal bearing.
TURBOCHARGER
TC-10
INSTALL THE SEAL PLATE. 1.
Insert two new seal rings on the oil thrower.
2.
Install the oil thrower in the seal plate.
NOTE: The openings of seal rings should be positioned as shown.
SM51-024
SM51-005A
3.
Install the seal plate in the bearing case.
NOTE: o The oil return hole should face the oil outlet side. Apply silicone R.T.V. sealer to the flanged surface of the seal plate. o Take care that the silicone sealer does not protrude from the flange. 4.
Tighten the four screws with lock washers.
NOTE: Always use new screws and washers. SM51-030
FIT THE BLOWER IMPELLER ON THE TURBINE ROTOR AND TIGHTEN THE LOCK NUT. NOTE: Remember that this nut has left-hand threads.
SM51-031
INSTALL THE TURBINE CASE TO THE BEARING CASE, BEING SURE TO ALIGN THE MATCHING MARKS. NOTE: Always use new lock plates. ASSEMBLE THE BLOWER CASE. 1.
SM51-032
Install the blower case to the bearing case referring to the matching marks.
NOTE: Coat the flange face of the blower case with silicone R.T.V. sealant. 2.
Tighten the six fitting bolts.
ASSEMBLY TEST 1.
Rotate the blower impeller by hand to see if it turns smoothly. Refer to page TC-6.
2.
Check the turbine rotor for axial play (A). Refer to page TC-6.
3.
Check the turbine rotor for radial play using a special tool. Refer to page TC-7.
TC-11
TURBOCHARGER INSPECTION AND REPAIR
Unit: mm (in) Inspection Item
Standard
Limit
Remedy
Turbine Shaft Diameter
12.28 (0.4835)
Replace
Turbine Shaft Bend
0.011 (0.0004)
Replace
Seal Ring Groove Width of Turbine Shaft
1.63 (0.0642)
Replace shaft assembly.
A:
Replace
Bearing Case Inside Diameter
18.55 (0.7303)
Inspection Procedure
B:
17.11 (0.6736) Journal Bearing Inside Diameter
Journal Bearing Outside Diameter
Thrust Spacer Height
12.36 (0.4866)
Replace
16.98 (0.6685)
Replace
4.68 (0.1843)
Replace
SM51-007
Seal Ring Groove Width
G1:
of Oil Thrower
1.75 (0.0689) G2: 1.52 (0.0598)
Replace
G1
G2
SM51-006A
TURBOCHARGER
TC-12
INSPECTION AND REPAIR Unit: mm (in)
Inspection Item Thrust Bearing Thickness
Standard
Limit
4.48 (0.1764)
Remedy
Inspection Procedure
Replace
SM51-038
Sealing Bore of Seal Plate
H1:
Replace
16.05 (0.6319) H2: 14.05 (0.5531)
H1
H2
SM51-006B
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