Hino K13C T K13CT Engine Workshop Manual free download by engineparts2

HIND

NDEX: ENGINE GROUP

GENERAL INTRODUCTION

HINO K13C T WORKSHOP MANUAL

ENGINE TURBOCHARGER INJECTION PUMP INJECTION PUMP GOVERNOR GENERATOR STARTER

I I

INJECTION PUMP CALIBRATION

ELECTRICAL EQUIPMENT

FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino IndusÂ trial Engine. Applicable models: K13C-T and K13D-T engine When making any repairs on your engine, be careful not to be injured through improper procedures. As for maintenance items, refer to the Operation Hand Book. All information and specifications in this manual are based upon the latest product information available at the time of printing. Hino Motors reserves the right to make changes at any time without prior notice.

Hino Motors. Ltd.

Gl-1

GENERAL INTRODUCTION Hino K13C Hino K13D

GI-V259E-01

CHAPTER GI GENERAL INTRODUCTION GENERAL PRECAUTION ........................................................... GI- 2 HOW TO USE THIS WORKSHOP MANUAL ............................. GI- 2 IDENTIFICATION INFORMATION ............................................. GI- 4 SPECIFICATIONS ...................................................................... GI- 5 SPECIFIED TORQUE FOR STANDARD BOLTS ........................ Gl-11 PROCEDURE FOR INSTALLING JOINTS AND GASKETS OF ENGINE PIPE ....................................................... Gl-12 RECOMMENDED LUBRICANTS FOR ALL HINO ENGINE ....... Gl-14

GENERAL INTRODUCTION

Gl-2

GENERAL PRECAUTION Some recommended and standard maintenance services for your engine are included in this section. When performing maintenance on your engine, be careful not to get injured by using improper work proce dures. Improper or incomplete work can cause a malfunction of the engine, which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your Hino dealer.

WARNING

When working on your engine, observe the following general precautions to prevent personal injury and/or property damage, in addition to the particular NOTES or WARNINGS in each chapter. o

Always wear safety glasses or goggles to protect your eyes.

Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the en gine.

Bind long hair securely behind the head.

Always stop the engine and turn off the starter switch, unless the operation requires the engine running. Removing the key from the switch is recommended.

To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator, muffler, exhaust pipe and tail pipe.

Do not smoke while working on the engine, since engine fuel and gas from battery are flammable.

Take utmost care when working on the battery. It contains corrosive sulfuric acid.

Large electric current flows through the battery cable and starter cable. Be careful not to cause a short, which can result in personal injury and/or property damage.

Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide.

Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belt when the engine is running.

Be careful not to leave any tool in the engine compartment. Tools may be hit by moving parts and can cause personal injury.

HOW TO USE THIS WORKSHOP MANUAL

SLIDING HAMMER � DESCRIPT ION

This workshop manual is designed as a guide for servicing the engine. An INDEX is provided on the first page of each chap ter. TROUBLESHOOTING is dealt with in each chapter. When beginning op erations, refer to the TROUBLE SHOOTING section for a guide to appropriate diag noses. SPECIAL TOOLS are dealt with in each chapter. When ordering a special tool, confirm the part num ber with the applicable parts catalog.

09420-1442 ◄ ... ----PART NUMBER SMI-J001

Gl-3

GENERAL INTRODUCTION REPAIR PROCEDURES

Repair procedures when self-explanatory, such as simple installation and removal of parts, have been omitted. Illustrations, such as the one below, have been provided to make such simple procedures clear. Only essential procedures requiring specific direc tions have been dealt with explicitly.

EXAMPLE:

TIMING GEAR AND CAMSHAFT

OVERHAUL

T = 18.64-25.49 {190-260, 1 4- 1 8}

T = 107.88- 1 27.48 { 1 , 1 00-1,300, 80-94}

� � 2 - ' \ \

•-<t-\

�. (:��/�

'<)'{..��. ,\,-.;_:'¼ L G-� r /3 ';:_/ 'CV �/ 'J

(.�,.

«�w�

·��-� 1 c;{�\)v\]5-' 12 7� &<-

�� -s.-.

�

/�

0 /

� 'l'K"¾� � \.tf<jW,·

G,''\� J

�11

.....__,.,., '-' '\. �� J-�10 � ,,,::J.,<_ '\_ ,-,/ 9 8 ,._✓, _. ; 0 '\

.<'"?'� �<

T = 107.88-127.48 {1,100-1,300, 80-94} 1. 2. 3. 4.

Thrust bearing Camshaft gear Oil pump drive gear Idler gear Bushing

6. 7. 8. 9. 10.

T = 1 8.64-25.49 {190-260, 1 4-18} T = Tightening torque: N-m {kgf-cm, lbf-ft}

SMl-091

Idler gear thrust plate Straight pin Idler gear shaft Crankshaft gear Injection pump drive gear

11. 12. 13. 14.

Idler gear thrust plate Camshaft Front end plate gasket Front end plate

In some cases, illustrations may be of parts which dif fer in some nonessential way from the parts found on your particular engine. In such cases, the principle or procedure being illustrated applies regardless of such nonessential differences.

GENERAL INTRODUCTION

Gl-4

IDENTIFICATION INFORMATION ENGINE SERIAL NUMBERS

K13C, K13D

Please quote these numbers when ordering spare parts or reporting technical matter to receive prompt service attention. The engine serial number is engraved on the engine cylinder block.

SM1-087

Gl-5

GENERAL INTRODUCTION

HINO K13C T ENGINE SPECIFICATIONS DIESEL ENGINE FOR INDUSTRIAL USE

K13C-T

HINO

12.882 liters, 4-cycle 6-cyl., water-cooled turbocharged

e PERFORMANCE (STD. specs.) GENERAL USE (SAE J1349 Gross)

GENERATOR USE (SAE J1349 Gross) Stand-by Power

Output,

Max. torque

Prime Power

Min. fuel

Output at

Intermittent rating Continuous rating N•m(lbfoft)

consumption

1,500 r/min

1,800 r/min

1,500 r/min

1,800 r/min

kW(HP) at r/min

g/kWh(lb/HPh) kW(HP)

kW(HP)

237 {317} at 2,000·

213 {286} at 2,000 1,265 {933} at 1,200 222 {0.364}

245 {333}

196 {262}

226 {303}

at r/min.

212 {288}

e ENGINE DESCRIPTION (STD. specs.) Ambient conditions: Intake air temperature Barometric pressure Water Vapor pressure

SAE ° 25 C 100 kPa 1.0 kPa

e ENGINE DESCRIPTION 1. Type 2. Combustion chamber 3. Cylinder Bore x Stroke 4. Piston displacement 5. Compression ratio 6. Direction of rotation 7. Dimensions (L x W x HJ 8. Dry weight

Diesel, 4-cycle, 6cyl., in-line, overhead valve, water-cooled Turbocharged Direct injection type 135 x 150 mm {5.31 x 5.91 in.} 12.882 liters {786.0 cu. in.} 17. 6 Counterclockwise viewed from flywheel Approx. 1,586 x 858x 1,178mm {62.4x 33.8 x 4 6.4 in.} Approx. 1,050 kg {2,315 lb}

e FEATURES 1. Cylinder block 2. Cylinder head 3. Crankshaft 4. Piston and rings

5. Camshaft 6. Valves

Mono block cast iron with replaceable wet liner In two blocks, each one for three cylinders, 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

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

GENERAL INTRODUCTION

Gl-6

e STANDARD EQUIPMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Flywheel housing Flywheel Fuel injection pump type Governor Fuel injection nozzle type Fuel filter Water separator Cooling system Lubricating system Oil filter Intake manifold Exhaust manifold with flange plate Generator

14. Starter 15. Safety relay 16. Connectors of electrical equipments

HINO own (SAE No. 1 type) HINO own (SAE 14 in. type) BOSCH "P" type Mechanical, 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 rear Upward exhaust Alternator with integral regulator 24V, 20A 24V, 7 kW

e 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 sender 15. Oil pressure gauge 16. Intake heater 17. Intake heater relay 18. Intake heater indicator 19. Tachometer with hour-meter 20. Tachometer cable 21. Muffler 22. Air cleaner 23. Air cleaner cap 24. Radiator with cooling fan shroud

Gl-7

GENERAL INTRODUCTION Hino K13C Hino K13D

SM1-131

SM1-132

NOTE

1) These specifications are subject to change without notice. 2) These specifications are for export models. 3) All specifications of the products are with normal manufacturing allowances and tolerances. 4) The performance and drawings are for standard specifications.

Hine Motors.Ltd.

GENERAL INTRODUCTION

Gl-8

HINO K13D T ENGINE SPECIFICATIONS DIESEL ENGINE FOR INDUSTRIAL USE

K13D-T

HINO

13.267 liters, 4-cycle 6-cyl., water-cooled turbocharged

e PERFORMANCE (STD. specs.) GENERAL USE (SAE J1349 Gross)

GENERATOR USE (SAE J1349 Gross) Stand-by Power

Output,

Max. torque

Output at

1,500 r/min

1,800 r/min

1,500 r/min

1,800 r/min

kW(HP)

210 {285}

171 {230}

193 {259}

Intermittent rating Continuous rating N•m(lbf-ft)

consumption

kW(HP) at r/min

g/kWh(lb/HPh) kW(HP)

199 {266} at 2,000·

179 {240} at 2,000 1,098 {810} at 1,200 218 {0.358}

at r/min.

Prime Power

Min. fuel

186 {253}

e ENGINE DESCRIPTION (STD. specs.) Ambient conditions: Intake air temperature Barometric pressure Water Vapor pressure

SAE ° 25 C 100 kPa 1.0 kPa

e ENGINE DESCRIPTION 1. Type 2. Combustion chamber 3. Cylinder Bore x Stroke 4. Piston displacement 5. Compression ratio 6. Direction of rotation 7. Dimensions (L x W x H) 8. Dry weight

e FEATURES 1. 2. 3. 4.

Cylinder block Cylinder head Crankshaft Piston and rings

5. Camshaft 6. Valves

Diesel, 4-cycle, 6cyl., in-line, overhead valve, water-cooled Turbocharged Direct injection type 137 x 150 mm {5.39 x 5.91 in.} 13.267 liters {809.6 cu. in.} 16.5 Counterclockwise viewed from flywheel Approx. 1,544 x 885 x 1,187 mm {60.8x 34.8 x 46.7 in.} Approx. 1,050 kg {2,315 lb}

GENERAL INTRODUCTION

e STANDARD EQUIPMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. Starter 15. Safety relay 16. Connectors of electrical equipments

Gl-9

GENERAL INTRODUCTION

Gl-10 Hino K13C Hino K13D

SM1-133

SM1-134

NOTE

Hine Motors.Ltd.

GENERAL INTRODUCTION Hino K13C Hino K13D

Gl-11

SPECIFIED TORQUE FOR STANDARD BOLTS

1. FLANGE BOLT Class

ï¿½ M8X1.25

Unit: N-m {kgf-cm, lbf-ft}

(SJ

28.5 {290, 21.0}

36 {370, 26.8}

M10X1.25

60 {610, 44.1}

74.5 {760, 55.0}

M10X1.5

55 {560, 40.5}

68.5 {700, 50.6}

M12X 1.25

108 {1,100, 79.6}

136 {1,390, 100.5}

M12X 1.75

97 {990, 71.6}

125 {1,280, 92.6}

M14 X1.5

171.5 {1,750, 126.6}

216 {2,210, 159.8}

M14X2

154 {1,570, 113.6}

199 {2,030, 146.8}

2. BOLT WITH WASHER Class

Unit: N-m {kgf-cm, lbf-ft} 4T

No Mark

M6X1

6 {60, 4.3}

10 {100, 7.2}

13 {130, 9.4}

M8X1.25

14 {140, 10.1}

25 {250, 18.1}

31 {320, 23.1}

M10X1.25

29 {300, 21.7}

51 {520, 37.6}

64 {650, 47.O}

M10X1.5

26 {270, 19.5}

47 {480, 34.7}

59 {600, 43.4}

M12X1.25

54 {550, 39.8}

93 {950, 68.7}

118 {1,200, 86.8}

M12X1.75

49 {500, 36.2}

83 {850, 61.5}

108 {1,100, 79.6}

M14 X1.5

83 {850, 61.5}

147 {1,500, 108.5}

186 {1,900, 137.4}

M14X2

74 {750, 54.2}

132 {1,350, 97.6}

172 {1,750, 126.6}

Representation

DiameterX Pitch

GENERAL INTRODUCTION

Gl-12 Hino K13C Hino K13D

PROCEDURE FOR INSTALLING JOINTS AND GASKETS OF ENGINE PIPE

1. Gasket seal type (aluminum + rubber, asbestos or copper). Tightening torque chart

Location of gasket seal

GASKET

SMI-J017

Clamping screw size (Diameter) mm {in.}

Tightening torque N-m {kgf-cm, lbf-ft}

8{0.315}

13{130,9}

10{0.394}

20{200,14}

12 {0.472}

25 {250,18}

14{0.551}

25 {250,18}

16 {0.630}

29{300, 22}

18{0.709}

39{400,29}

20{0.787}

*39 {400,29}

24{0.945}

69{700, 51}

28{1.102}

127 {1,300, 94}

SMI-J019

2. Metal seal type (Flare connector type).

Location of metal seal CONNECTOR

FLARE NUT

SMI-J020

LOCK WASHER

SMI-J022

Tightening torque chart

Clamping screw size (Diameter) mm {in.}

Tightening torque N-m {kgf-cm, lbf-ft}

12{0.472}

20{200, 14}

14{0.551}

31{320,23}

16 {0.630}

39{400,29}

18{0.709}

59{600,43}

20{0.787}

64{650,47}

GENERAL INTRODUCTION

Gl-13

Hino K13C Hino K13D

3. Metal seal type (Nipple connector type)

Location of metal seal GASKET

NUT

ďż˝ FLARE cdNNECTOR CONNECTOR SMI-J023 NOTE:

FLďż˝NECTOR CONNECTOR SMI-J024

Tightening torque chart

Clamping screw size (Diameter) mm {in.}

Tightening torque N-m {kgf-cm, lbf-ft}

10{0.394}

11{110,8}

20{0.787}

20{200, 14}

o Before installing the joints, ensure that there is no dirt or burrs adhering to the various seat faces (pipe joints, gaskets, etc.) o Because the pipes can move relatively freely during installation and the seat faces are liable to tilt, first temporarily tighten the pipes, then tighten them to the specified torque and ensure that there is no leakage from them. o When tightening two pipes together, be very careful that they do not rotate together. o After installing the pipes, apply the correct pressure to each pipe joint and ensure that there is no leakage. o Ensure that the various tightening torques conform to the above table. * If a soft washer #4840 FR-N (aluminum + rubber and carbon press fit part) is loosened or removed subsequent to being installed, be sure and replace it with a new one. There is no need to replace it, however, for normal retightening.

..."""

C')

HIND

LUBRICANTS

POSITIONS

RECOMMENDED LUBRICANTS FOR ALL HINO ENGINE

ATMOSPHERIC TEMP. Above 32" C (90" Fl

ENGINE OIL

(AP.I. CDJ Previous Classification (AP.I. OS) IMIL-L-2104CJ (Mll·l·45199B)

Vanellus C-3 40

(Mll-G-109248)

Coolant Pump Bearing

RPM DELO 300 Oil

SAE 40

RPM DELO 400 Oil SAE 30, or 15W/40

Castrol or Deusol CRD 40 Turbomax Castrol or Deusol

RX Super 40. 15W/40

ESSO Essolube D-3 40. XD-3 40 Essolube D-3 30, XD-3 30

Vanellus C-3 20W

RPM DELO 400 Oil SAE 'l0/20W, 15W/40 RPM DELO 300 Oil SAE 20/20W

Castrol or Deusol CRD 20W/20 Castrol or Deusol RX Super 20W/20 15W/40

Vanellus M 40

RPM DELO 200 Oil SAE 40 RPM DELO 100 Oil SAE 40

32" -o• C (90" ~32" F)

Vanellus M 30

o· --12· (32" ~10'F)

Gulf Super Duty

Motor Oil 40, 15W-40

TOTAL Rubia S 40

Myrina Oil 30,

TOTAL

Aimura X Oil 40 Rimura CT 40

20W-40, 15W-40 Rimura X Oil 30, 10W-30 Rimura CT 30

TOTAL Rubia TM 15W40

Myrina Oil 20, 20W-40, 15W-40 Rimura X Oil 20 Rimura CT 20

TOTAL Rubia S 20 TOTAL Rubia TM 15W40

Castrol or Deusol CRX 40 Castrol or Deusol RX Super 40. 15W/40

Essolube HDX 40, HDX Plus 40

Gulflube Mater Oil XHD 40, 1 SW-40

Mobil Delvac 1240 Mobil Delvac 1140

Rotella TX40, 20W-50 Rotella SX Oil 40, 20W-40

TOTAL Rubia H 40

RPM DELO 200 Oil SAE 30 RPM DELO 100 Oil SAE 30

Castrol or Deusol CRX 30 Castrol or Deusol RX Super 30, 15W/40

Essolube HDX 30, HDX Plus 30

Gulflube Mater Oil XHD 30, 15W•40

Mobil Delvac 1230 Mobil Delvac 1130

Rotella TX30, 20W-50 Rotella sx Oil 30, 20W-40

TOTAL Rubia H 30

Vanellus M 20W

RPM DELO 200 Oil SAE 20/20W RPM DELO 100 O il SAE 20/20W

Castrol or Deusol CRX 20W/20 Castrol or Deusol RX Super 20W/20, 15W/40

Essolube HDX 20, HDX Plus 20W-20

Gulflube Motor Oil XHD 20, 1 SW-40

Mobil Delvac 1220 Mobi l Delvac 1120

Rotella TX20, 20W-50 RoteI la SX OiI 20/20W, 20W-40

TOTAL Rubia H 20

Energrease L-2

Marfak Multipurpose 2 or Marfak All Purpose 2

Castrol LM Grease

Esso Multipurpose Grease

Gulflex Poly

Mobilgrease MP, 77, MS

Retinax A Alvania Grease R2

TOTAL MULTIS 2

Above 32'C (90' Fl

Energrease LT2

RPM Grease SRI 2

INJECTION PUMP TIMER GREASE

Injection Pump Timer

Energrease L-2

Marfak Multipurpose 2 or Marfak All Purpose 2

Castrol LM Grease

Esso Multipurpose Grease

Engine, Radiator

Anti Frost

AF Engine Coolant

Castrol Anti-Freeze Castrol Long Life Coolant

Esso Anti-Freeze Coolant

(Mll-A-53009)

Myrina Oil 40, 20W-40, 15W-40

Mobil Delvac 1310 Mobil Delvac Super 15W•40

Generator Bearing Starter Bearing

ANTI FREEZE

TOTAL

Gulf Super Duty Motor Oil 20, 15W-40

GENERATOR & STARTER BEARING GREASE

(MIL·G-109248)

Mobil Delvac 1340 Mobil Delvac Super 15W-40

SHELL

Essolube D-3 20W, XD·3 15W•40

o• ~·12 C (32" ~10'F)

SAE 30

MOBIL

Mobil Delvac 1330 Mobil Delvac Super 15W-40

Gulf Super Duty

g�� ii �.utch, a i Pinion Shift Lever & Reduction Gear

STARTER GREASE

GULF

Motor Oil 30, 15W-40

Vanellus C-3 30

ENGINE OIL

COOLANT PUMP BEARING GREASE

RPM DELO 400 Oil

SAE 40, Or 15W/40

CASTROL

Castrol or Deusol CAD 30 Castrol or Deusol AX Super 30, 15W/40

tA.P.I. CCI Previous Classification (AP.I. DMJ (Mll·l-46152) (MIL-L-2104B)

CALTEX

RPM DELO 300 Oil

32• -o· (90" -32' Fi

Cylinder Block Injection Pump Ai r Cleaner

S.A.E. NO.

HINO MOTORS LTD.

TOKYO, JAPAN

Molytex Grease EP2

NOTE: Lubricants were amended according to new classification by AP I (American Petroleum Institute)

Rubia S 30

TOTAL Rubia TM 15W40

C')

l'TI 2 l'TI :r::,, r-

= z =

C C, C: :::! C 2

Mobi lgrease 29

Aero Shell Grease 17

Mobilgrease 28

Aero Shell Grease 7

Gulflex Poly

Mobilgrease MP, 77, MS

Retinax A Alvania Grease R2

TOTAL Mullis EP 1

Cruise Master Antifreeze And Summer Coolant

Mobil Parmazone

Shellzone (U.S.A.) Glycoshell Plus (Europian Countries) Shellsafe Anti-Freeze P281 Coolguard

TOTAL ANTIGEL

'82 •12 •200

ENGINE

EN-1

EN-Y271E-01

Hino K13C Hino K13D

CHAPTER EN ENGINE Models K13C-T AND K13D-T DATA AND SPECIFICATION ................................................. TROUBLESHOOTING ........................................................... ENGINE OVERHAUL CRITERIA ........................................... ENGINE MOVING PARTS .................................................... CYLINDER HEAD .......................................................... CRANKSHAFT PULLEY ................................................ FLYWHEEL AND FLYWHEEL HOUSING ..................... TIMING GEAR AND CAMSHAFT ................................ INJECTION PUMP DRIVE ............................................ PISTON, CRANKSHAFT, CYLINDER BLOCK AND OIL PAN................................................................ LIQUID GASKET AND APPLICATION POINTS ........... LUBRICATING SYSTEM ....................................................... OIL PUMP ..................................................................... OIL COOLER AND OIL FILTER .................................... FUEL SYSTEM ...................................................................... INJECTION NOZZLE .................................................... FUEL INJECTION PUMP .............................................. COOLING SYSTEM............................................................... COOLANT PUMP .......................................................... THERMOSTAT .............................................................. RADIATOR .................................................................... COOLING FAN .............................................................. AIR INTAKE AND EXHAUST SYSTEM ................................ ELECTRICAL PARTS ............................................................. GENERATOR................................................................. STARTER....................................................................... ENGINE TUNE-UP ................................................................ ENGINE TUNE-UP ON TEST BENCH ..........................

EN - 3 EN - 7 EN - 12 EN - 14 EN - 16 EN - 31 EN - 33 EN - 36 EN - 42 EN - 44 EN - 61 EN - 62 EN - 66 EN - 69 EN - 71 EN - 73 EN - 76 EN - 78 EN - 79 EN - 82 EN - 83 EN - 84 EN - 87 EN - 90 EN - 90 EN - 91 EN - 92 EN - 97

DSY103A TSY102A OCY103A MPY103A LSY103A FSY103A CSY103A FDY103A IEY103A CPY103A TUY103A

ENGINE Hino K13C Hino K13D

EN-3

DATA AND SPECIFICATION

Model

HINO K13CTB-NSZA, K13CTB-HAJA, K13CTJ-NSAC, K13CTB-EWAA K13CUC-EWBA, K13CUC-EVBA

Type

Diesel 4 cycle, vertical, 6 cylinder, in-line overhead valve, water-cooled, direct injection.

Aspiration

Turbocharged

Bore and stroke

135 x 150 mm {5.31 x 5.91 in.}

Piston displacement

12.882 L {786.1 cu.in.}

Compression ratio

16.5: 1 (K13CTB-NSZA/HAJA/EWAA/EVBA) 17.6: 1 (K13CTJ-NSAC, K13CUC-EWBA)

Firing order

1-4-2-6-3-5 (The cylinder numbers are counted in order from the timing gear side.)

Direction of rotation

Counterclockwise viewed from flywheel

Compression pressure

2.85-3.04 MPa {29-31 kgf/cm2, 413-440 lbf/in2.} at 200 r/min.

Idling revolution

700 - 750 r/min.

Dry weight

Approximately 1,050 kg {2,315 lb} (K13TB-NSZA/HAJA/EWAA, K13CTJNSAC, K13CUC-EWBA) Approximately 1,040 kg {2,293 lb} (K13CUC-EVBA)

Valve seat angle

Valve face angle Valve timing (flywheel travel)

Valve clearance (when cold)

Intake

30°

Exhaust

45°

Intake

30°

Exhaust

45°

Intake opens

14° before top dead center

Intake closes

42° after bottom dead center

Exhaust opens

48° before bottom dead center

Exhaust closes

16 ° after top dead center

Intake

0.40 mm {0.0157 in.}

Exhaust

0.50 mm {0.0197 in.}

Engine oil pump Type Drive Engine oil cooler

Full forced pressure feed by gear pump By gear Multi-plate type, water cooled

Injection nozzle Type Valve opening pressure Coolant pump Type Drive Thermostat Type

Multi-hole nozzle type 21.57 MPa {220 kgf/cm2, 3,128 lbf/in2.}

Forced circulation by volute pump By gear Wax type, bottom bypass system

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-4

ENGINE

Hino K13C Hino K13D

14 째 before top dead center for No.1 cylinder of the compression stroke (K13CTJ-NSAC. K13CUC-EVBA)

Injection timing (flywheel travel)

18째 before top dead center for No.1 cylinder of the compression stroke (K13CTB-EWAA, K13CUC-EWBA) 19째 before top dead center for No.1 cylinder of the compression stroke (K13CTB-NSZA) 21째 before top dead center for No.1 cylinder of the compression stroke (K13CTB-HAJA)

Injection pump No.

22020-3641 (K13CTB-NSZA/HAJA). 22020-4931 (K13CTJ-NSAC) 22020-5240 (K13CTB-EWAA), 22020-5320 (K13CUC-EWBA/EVBA)

Engine oil volume (L)

L: 16 H: 20 TOTAL: 27 (K13CTB-NSZA/HAJA, K13CTJ-NSAC) L: 20 H: 40 TOTAL: 45 (K13CTB-EWAA. K13CUC-EWBA/EVBA)

ENGINE

EN-5

Hino K13C Hino K13D

Model

HINO K13DTA-NSAA, K13DTB-EUAA, K13DTB-EWBB, K13DTB-EWBA, K13DTB-EVBA

Type

Diesel 4 cycle, vertical, 6 cylinder, in-line overhead valve, water-cooled, direct injection.

Aspiration

Turbocharged

Bore and stroke

137 x 150 mm {5.39 x 5.91 in.}

Piston displacement

13.267 L {809.6 cu.in.}

Compression ratio

16.5: 1

Firing order

1-4-2-6-3-5 (The cylinder numbers are counted in order from the timing gear side.)

Direction of rotation

Counterclockwise viewed from flywheel

Compression pressure

2.8-3.0 MPa {29-31 kgf/cm2, 412-440 lbf/in. 2} at 200 r/min.

Idling revolution

700 - 750 r/min. Approximately 1,050 kg {2,315 lb} (K13DTA-NSAA) Approximately 1,065 kg {2,348 lb} (K13DTB-EUAA, K13DTB-EWBB/EWBA) Approximately 1,067 kg {2,352 lb} (K13DTB-EVBA)

Dry weight

Valve seat angle

Valve face angle Valve timing (flywheel travel)

Valve clearance (when cold)

Intake

30°

Exhaust

45°

Intake

30°

Exhaust

45°

Intake opens

14 ° before top dead center

Intake closes

42° after bottom dead center

Exhaust opens

48° before bottom dead center

Exhaust closes

16° after top dead center

Intake

0.40 mm {0.0157 in.}

Exhaust

0.40 mm {0.0157 in.}

Engine oil pump Type Drive Engine oil cooler

Full forced pressure feed by gear pump By gear Multi-plate type, water cooled

Injection nozzle Type Valve opening pressure Coolant pump Type Drive Thermostat Type

Multi-hole nozzle type 19.6 MPa {200 kgf/cm2, 2,844 lbf/in.21

Forced circulation by volute pump By gear Wax type, bottom bypass system

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-6

ENGINE

Hino K13C Hino K13D

Injection timing (flywheel travel)

16° before top dead center for No.1 cylinder of the compression stroke (K13DTA-NSAA, K13DTB-EUAA, K13DTB-EWBA/EVBAI 18 ° before top dead center for No.1 cylinder of the compression stroke (K13DTB-EWBB)

Injection pump No.

22020-4920 (K13DTA-NSAA), 22020-5450 (K13DTB-EUAA, K13DTB-EVBA), 22020-5800 (K13DTB-EWBB), 22020-5480 (K13DTB-EWBA)

Engine oil volume (LI

L: L: L: L:

20 16 20 16

H: 40 TOTAL: 47 H: 20 TOTAL: 25 H: 40 TOTAL: 45 H: 20 TOTAL: 27

(K13DTA-NSAA), (K13DTB-EUAA), (K13DTB-EWBB/EWBA) (K13DTB-EVBA)

EN-7

ENGINE Hino K13C Hino K13D

TROUBLESHOOTING Symptom

Possible cause

Remedy/Prevention

Engine overheating _ _ _ _ ___, Coolant • Insufficient coolant ........................................... Add coolant. • Defective thermostat ........................................ Replace the thermostat. • Overflow of coolant due to leakage of ............ Repair. exhaust into cooling system • Coolant leakage from cylinder head gasket ... Replace gasket . • Defective coolant pump ................................... Repair or replace. Radiator • Clogged with rust and scale ............................. Clean radiator. • Clogged with iron oxide due to leakage ......... Clean coolant passage and of exhaust into cooling system correct exhaust leakage. • Clogged radiator core due to mud .................. Clean radiator. or other debris • Defective radiator cap pressure valve ............. Replace radiator cap. Abnormal combustion • Incorrect injection timing ................................. Adjust injection timing . • Reduced injection pressure .............................. Adjust injection pressure. • Poor fuel ............................................................ Use good quality fuel. • Poor nozzle spray .............................................. Adjust or replace nozzle. • Unsatisfactory automatic timer advance angle . Repair or replace timer. Other problems • Defective or deteriorated engine oil ................ Change engine oil. • Unsatisfactory operation of oil pump ............. Replace or repair. • Insufficient oil .................................................... Add oil.

Excessive oil consumption--�-, Pistons, cylinder liners, and piston rings • Wear of piston ring and cylinder liner ............. Replace piston rings and cylinder liner. • Worn, sticking or broken piston rings ............. Replace piston rings and cylinder liner. • Insufficient tension on piston rings ................. Replace piston rings and cylinder liner. • Unsatisfactory break-in of piston rings ........... Replace piston rings and cylinder liner. • Unsuitable oil (viscosity too low) .................... Change oil as required and replace piston rings and cylin der liners. • Incorrectly fitted piston rings ........................... Replace piston rings. (upside down) • Gaps of piston rings in line with each other ... Reassemble piston rings .

EN-8

ENGINE

Hino K13C Hino K13D

Symptom

Possible cause

Remedy/Prevention

Excessive oil consumption--�-1 Valve and valve guides • Worn valve steam ............................................. Replace valve and valve guide. • Worn valve guide .............................................. Replace valve guide. • Incorrectly fitted valve stem seal ..................... Replace the stem seal. • Excessive lubricant on rocker arm .................. Check clearance of rocker arm and shaft. Excess oil feed • Defective oil level gauge .................................. Replace oil level gauge. • Oil level too high ............................................... Drain excess oil. Other problems • Overcooled engine (low temperature wear) ... Warm up engine. Check cool ing system. • Oil leakage from miscellaneous parts ............. Repair. Piston seizure----------,----, Operation • Abrupt stoppage of engine .............................. Operate engine properly. • Insufficient oil .................................................... Add oil. • Dirty oil .............................................................. Change oil. • Poor quality oil .................................................. Replace with proper engine oil. • High oil temperature ......................................... Repair. • Low oil pressure ................................................ Repair. • Defective oil pump ............................................ Repair oil pump. • Reduced performance due to worn oil ........... Replace oil pump. pump • Suction strainer sucking air ............................. Add oil and/or repair strainer. Abnormal combustion ..................................... See Symptom: "Engine over heating". Coolant ............................................................. See Symptom: "Engine over heating". Lack of power-------�-1 Injection pump .................................................. Refer to CHAPTER IP, FUEL INJECTION PUMP. Intake • Clogged air cleaner ........................................... Clean element or replace element. Overheating ..................................................... See Symptom: "Engine over heating".

EN-9

ENGINE Hino K13C Hino K13D Symptom

Possible cause

Remedy/Prevention

Lack of power-------�-1 Fuel and nozzle • Poor nozzle spray .............................................. Adjust or replace injection nozzle. • Clogged nozzle with carbon ............................. Clean nozzle. • Wear or seizure of nozzle ................................. Replace nozzle. • Air in fuel system .............................................. Repair and bleed air from fuel system. • Clogged fuel filter ............................................. Replace element. • Use of poor fuel ................................................ Use good quality fuel. Abnormal combustion ...................................... See Symptom: "Engine over heating". Piston, cylinder liners, and piston rings ......... See Symptom: "Engine over heating". Other problems • Breakage of turbine or blower ......................... Refer to CHAPTER TU, TURBOCHAGER. Difficult starting engine _____, Electrical system • Discharged battery ............................................ Charge battery. • Defective wiring in starter circuit..................... Repair wiring of starter. • Loose or open-circuit battery cable ................. nghten battery terminal connections or replace battery cable. • Breakdown of starter ........................................ Replace starter. • Break of intake air heater ................................. Replace. (If so equipped) Injection pump .................................................. Refer to CHAPTER IP, FUEL INJECTION PUMP. Air cleaner • Clogged element ............................................... Clean the element or replace the element. Fuel system • No fuel in tank ................................................... Supply fuel and bleed air from fuel system. • Clogged fuel line ............................................... Clean fuel line. • Air sucked into fuel system through ............... Tighten fuel line connections. fuel line connections • Clogged fuel filter ............................................. Replace element. • Loose connection in high-pressure line .......... Tighten sleeve nut of high pressure line. • Water in fuel ...................................................... Drain and clean fuel system.

EN-10

ENGINE

Hino K13C Hino K13D

Symptom

Possible cause

Remedy/Prevention

Difficulty starting engine---..-j Nozzles • Seized nozzle ..................................................... Replace nozzle. • Broken or fatigued nozzle spring ..................... Replace spring. Oil system • Oil viscosity too high ........................................ Use proper viscosity oil, or install an oil immersion heater and warm up oil. Other problems • Seized piston ..................................................... Replace piston, piston rings, and liner. • Seized bearing ................................................... Replace bearing and/or crank shaft. • Reduced compression pressure ...................... Overhaul engine. • Ring gear damaged or worn ............................ Replace the ring gear and/or starter pinion. • Improperly adjusted or broken ........................ Adjust or replace the accelerator cable accelerator cable. Rough idling-------�---< Injection pump .................................................. Refer to CHAPTER IP, FUEL INJECTION PUMP. Nozzles • Uneven injection pressure ............................... Adjust. • Poor nozzle spray .............................................. Adjust or replace nozzle. • Carbon deposit on nozzle tip ........................... Remove carbon. • Seized needle valve .......................................... Replace nozzle. Engine proper • Improper valve clearance ................................. Adjust valve clearance. • Improper contact of valve seal ........................ Replace or repair valve and valve seat. • Idling speed too low ......................................... Adjust idling speed. • Coolant temperature too low ........................... Warm up engine. • Compression pressure of cylinders ................. Overhaul engine. markedly different from one another Leakage of exhaust gas ---�--1 Cylinder head gasket • Fatigued gasket (aging) .................................... Replace gasket. • Damage .............................................................. Replace gasket. • Improper installation ........................................ Replace gasket.

EN-11

ENGINE Hino K13C Hino K13D

Symptom

Possible cause

Remedy/ Prevention

Leakage of exhaust-----.,......... Cylinder head bolts • Loose bolts ........................................................ Tighten bolt. • Elongated bolts ................................................. Replace bolt. • Improper tightening torque or ......................... Tighten properly. tightening sequence Cylinder block • Cracking ............................................................. Replace cylinder block. • Surface distortion ............................................. Repair or replace. • Fretting of cylinder liner insertion ................... Replace cylinder liner or portion (insufficient projection of cylinder block. cylinder liner) Cylinder head • Cracking ............................................................. Replace cylinder head. • Surface distortion ............................................. Repair or replace. Cylinder liners • Cracking ............................................................. Replace cylinder liner. • Corrosion ........................................................... Replace cylinder liner. • Insufficient projection of cylinder liner ........... Replace cylinder liner. Other problems • Incorrect injection timing ................................. Adjust injection timing.

EN-12 Hino K13C Hino K13D

ENGINE

ENGINE OVERHAUL CRITERIA

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have these special tools. COMPRESSION GAUGE ADAPTER

COMPRESSION GAUGE ADAPTER

ST-0003

ST-0246

09508-1030

09552-1030 , 09552-1060

FACTORS TO DETERMINE THE ENGINE OVERHAUL

EXAMPLE

LOW COMPRESSION PRESS URE a. a) b) c) d)

Before measurement Set the valve clearance to the correct value. Idle the engine (Water temperature at 80° C {176° F}). Charge the battery fully. Remove the air cleaner.

SM3-F0001

Measurement a) Remove the nozzle holders. b) Install the gauge adapter in the nozzle holder hole. Special Tools: Compression Gauge Adapter (09508-10301 (09552-10301 (09552-10601 c) Disconnect the engine stop link rod from engine stop lever of the injection pump and secure it to the engine stop position with tape or string. d) Connect a compression gauge to the gauge adapter. e) Drive the engine with the starter and read the compression pressure. NOTE:

Do not continuously operate the starter for more than 15 seconds at a time.

f) Measure the compression pressure for each cylinder. If the compression pressure is low, be sure to repeat the measur ing. NOTE:

Be sure not to leak through sealing face. Unit: MPa {kgf/cm', lbf/in'.}

Engine models K13C-T, K13D-T

Compression pressure Standard

Limit

2.85-3.04 {29-31, 413-440}

2.65 {27, 384}

Difference between each cylinder

Engine speed Ir/min)

Less than 0.34 {3.43, 48.77}

200

Hino K13C Hino K13D

ENGINE

EN-13

DECREASED OIL PRESSURE Check the oil pressure warning lamp when the oil and cool ant temperature is hot [about 80° C {176° F}J.

r----7 l�I I 6I I I

a. b.

OIL I I L ____ _J

c. d. SM3-F0002

If the warning lamp is lighted, check the oil level. Check oil deterioration.If oil quality is poor, replace with a suitable grade oil. Remove the oil pressure switch and install the oil pressure gauge. Measure the oil pressure at coolant temperature 80°C {176° F} or more.

Standard oil pressure: 49-490 kPa {0.5-5.0 kgf/cm2, 7.11-71.10 lbf/in.2} Service limit: Less than 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2}

S.A.E. GRADE 40

30 20W-20 15W-40

ATMOSPHERIC TEMPERATURE -10 O

90 100

°F

-23-18

32 39

°C

OTHER FACTORS a. b. C. d. e. f.

The blowby gas increases. The engine does not start easily. Engine output decreases. Fuel consumption increases. Engine make greater noise. Excessive oil consumption.

ENGINE

EN-14 Hino K13C Hino K13D

ENGINE MOVING PARTS

DESCRIPTION Model: K13C-T

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

2 5

17. 18. 19.

Fuel injection nozzle Generator Engine oil filler cap Tension pulley Turbocharger Exhaust manifold Cooling fan pulley Coolant pump Crankshaft pulley Fuel filter Fuel injection pump Intake manifold Inspection h ole Engine oil level gauge Oil pan Water separator (If so equipped) Engine oil drain plug Oil filter (Fuel flow) Oil filter (Bypass)

S6-K13-0001 A

ENGINE

EN-15

Hino K13C Hino K13D

DESCRIPTION Model: K13D-T

Fuel injection nozzle Generator Engine oil filler cap Tension pulley Turbocharger Exhaust manifold Cooling fan pulley Coolant pump Crankshaft pulley Fuel filter Fuel injection pump Intake manifold Inspection hole Engine oil level gauge Oil pan Water separators (If so equipped) Engine oil drain plug Oil filter (Fuel flow) Oil filter (Bypass)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

5 2 6

11.

12. 13. 14. 15. 16.

8 4

17. 18. 19.

LJ S6-K13-0007

ENGINE

EN-16

HINO K13C T CYLINDER HEAD PARTS OVERHAUL Model: K13C-T

{150-180, 10.5-13}

S6-K 13-003A

T:Tightening torque:N-m {kgf-cm, lfb-ft}

1. 2. 3. 4. 5. 6. 7. 8. 9.

0-ring Plate Ventilator Cylinder head cover Cylinder head cover gasket Engine hanger Cylinder head Cylinder head gasket Cylinder head bolt Diameter 16 mm {0.63 in.}

10. Cylinder head additional bolt Diameter 12 mm {0.47 in.} 11. Clip 12. Hose 13. Nozzle holder gasket 14. Nozzle holder adapter 15. Packing ring 16. Nozzle holder 17. Nozzle 18. Nozzle holder gauge 19. Baffle plate

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-17

OVERHAUL Model: K13C-T

T:39-49 {400-500, 28-36}

1 16

11 I

I -!.-'

Jlďż˝,. _)

I I I

S6-K13-0004 T = Tightening torque: N-m {kgf-cm, lbf-ft}

1. 2. 3. 4. 5. 6. 7. 8.

Cylinder head Retainer ring Plain washer Bushing Rocker arm Rocker arm support Valve stem cap Valve cotter

9. Valve spring upper seat 10. Valve spring 11. Valve spring lower seat 12. Valve 13. Valve clearance adjusting screw 14. Push rod 15. Valve lifter 16. Valve stem oil seal

17. 18. 19. 20. 21. 22. 23. 24.

Valve guide Pipe Spacer Exhaust manifold fitting nut plug Valve seat Intake manifold fitting nut Straight pin

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-18

HINO K13D T CYLINDER HEAD PARTS OVERHAUL Model: K13D-T

T: 13-18 {130-190, 10-13}

T: 265-284 {2,700-2,900, 196-209} for 0 16

�

T: 45-49 {450-500, 33-36}

14 �

3�� ---

{800-900, 58-65} for 0 12

J-----------1,

13�

10 {150-180, 10.5-13}

12 /

T: 19-26 {190-270, 14-19}

S6-K13-0005

T = Tightening torque: N-m {kgf-cm, lbf-ft}

1. 2. 3. 4. 5. 6. 7.

Cylinder head cover gasket Cylinder head cover Ventilator Flange Valve stem oil seal Cylinder head bolt Cylinder head additional bolt

8. 9. 10. 11. 12. 13. 14.

Cylinder head Cylinder head gasket Engine hanger Straight pin Intake manifold fitting bolt Spacer Exhaust manifold fitting bolt

15. 16. 17. 18. 19. 20. 21.

Nozzle holder gasket 0-ring Nozzle holder adapter Packing ring Nozzle holder Nozzle Nozzle holder gauge

ENGINE ___________

EN-19

OVERHAUL Model: K13D-T T 40-49 {400-500 29-36)

T:148-166 {1,500-1,700 109-122)

11 1

S6-K13-0006

T = Tightening torque.. N-m {kgf-cm, lbf-ft}

1. 2 3: 4_ 5. 6. 7_

Cylinder h_ead Retainer rmg Plain washer Bushing Rocker arm Roeker arm support vaI ve stem cap

8. 9 10.• 11. 12. 13. 14.

valve cotter . Valve sprmg upper seat Va1 ve spring . Valve sprmg lower seat Valve Valve clearance adjusting screw Push rod

15. 16. 17. 18. 19. 20.

Valve lifter Valve st�m oil sea I Valve guide Pipe Plug Valve seat

EN-20

Hino K13C Hino K13D

ENGINE

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have these special tools.

ADAPTER NOZZLE HOLDER ADAPTER WRENCH

CYLINDER HEAD BOLT SOCKET WRENCH

(Used with 09621-1090, 09621-1120)

ST-0295

ST-0297

09503-1010

09621-1090 (Width across flats: 22 mm {0.866 in.I) 09621-1120 (Width across flats: 24 mm {0.945 in.I)

09621-1020

VALVE SPRING PRESS

VALVE L APPING TOOL

VALVE STEM SEAL PRESS

ST-0007

ST-0298 09470-1022

09431-1010

WIRE

ST-0005 09491-1020 Dia. 12 mm {0.47 in.} 09491-1030 Dia. 9 mm {0.35 in.}

ST-0299 09472-1041 (K13C-T) 09472-1570 (K13D-TI

Hino K13C T Hino K13D T

ENGINE

EN-21

IMPORTANT POINTS - DISMOUNTING CLEAN OFF SURROUNDING AREA OF THE NOZZLES AND THE FUEL LINE CONNECTORS. NOTE: If foreign matter is allowed to enter the combustion chamber, engine trouble may result.

REMOVE THE FUEL INJECTION PIPES. Cover open ends of pipes and fuel injection pump to preÂ vent entry of dirt.

SM3-886

REMOVE THE NOZZLE HOLDER. 1.

Remove the nozzle holder gauge and nozzle holders.

NOTE: 2.

Be careful when handling the gauge so that it is not bent or broken.

Remove the nozzle holder adapter from the cylinder head using the adapter wrench, if needs.

Special Tool: Nozzle Holder Adapter Wrench (09503-1010) 3. S6-K13--0009

Cover open ends of the nozzle holder connectors to prevent of dirt. REMOVE THE CYLINDER HEAD ADDITIONAL BOLT.

NOTE:

Additional bolt is 12 mm {0.47 in} dia.

S6-K13--0010

REMOVE THE ROCKER ARM ASSEMBLY. Loosen the rocker arm support bolts and remove the rocker arm assembly. NOTE: o Attention should be paid to the fact that the rocker arms of the intake and exhaust valves are mounted different directions. o Keep the components in their disassembly order for easy reassembly. S6-K13-0011

EN-22

Hino K13C T Hino K13D T

ENGINE LOOSE THE CYLINDER HEAD BOLTS AND REMOVE THEM. Using special tools, loosen the cylinder head bolts little by little in three stages and in the numerical order as shown in the figure.

Special Tool: Socket Wrench (09621-1090, 09621-1120) Adapter (009621-1020)

SM3-K0026

LIFT THE CYLINDER HEAD FROM THE DOWELS ON THE CYLIN DER BLOCK AND PLACE IT ON WOODEN BLOCKS. CYLINDER HEAD

PRY UP AND DOWN

□ □ □

If it is difficult to lift off the cylinder head, pry with a chisel between the cylinder head and block.

NOTE: Do not damage the machined surface of the cylinder head or block when removing the cylinder head.

SM3-F0013

IMPORTANT POINT-DISASSEMBLING REMOVE THE VALVE SPRINGS. 1.

Remove the valve cotters, valve spring upper seats, and valve springs from the cylinder head.

Special Tool: Valve Spring Press (09470-1022) 2. 3.

Remove the intake and exhaust valves. Attaching tags to the valves (giving corresponding cylinder Nos.) will eliminate time required for lapping the valve seats on reassembly.

IMPORTANT POINTS-ASSEMBLY CLEAN THE CYLINDER HEAD THOROUGHLY WITH A SUITABLE SOLVENT. NOTE: Be careful not to damage the cylinder head surface.

SM3-825

IF NECESSARY, HAND-LAP THE VALVE AND VALVE SEAT. Apply lapping compound lightly to the contact surfaces of the valve and valve seat. Turn the valve using the special tool and tap the valve lightly.

Special Tool: Valve Lapping Tool (09431-1010)

SM3-364

Hino K13C T Hino K13D T

ENGINE

EN-23

IF NECESSARY, GRIND THE VALVES AND VALVE SEATS. NOTE: o Grinding of valves and valve seats should only be performed when hand-lapping does not result in proper seating. o After grinding, always recheck the valve sink.

=:,-----o---c, SM3-J507

SM3-J507A

30•

Valve face angle and valve seat angle:

u�u V

INTAKE

,·

K13C-T

'\J4s•

EXHAUST SM3-F0045

K13D-T

Valve seat (Intake)

30 -30 15'

Valve face (Intake)

29 45'-30'

Valve seat (Exhaust)

45 -45 15'

Valve face (Exhaust)

44 15'-45

30 -30 30' 29'30'-30' °

45 -45 30' °

45 30'-45

IF NECESSARY, REPLACE THE VALVE SEAT.

HAMMER-

1. VALVE SEAT

When replacing the valve seat, cut three places on the cir cumference of an unwanted valve and weld it to the valve seat . Place a brass block at the top of the valve stem and strike it with a hammer to remove the valve seat.

VALVE

Dimensions of Hino K13C K13D valve seat machining

Unit: mm {in.}

' 30

�

30°jlNTAKE

Cylinder head dimension

A EXHAUST

�c-

Valve seat dimension

45,..,7x:usT S6-K13-0013

SM3-826

Intake

Exhaust

61.000-61.019 {2.4016-2.4023}

55.000-55.019 {2.1654-2.1661}

11.2-11.3 {0.4410-0.4448}

61.085-61.100 {2.4050-2.4055}

55.085-55.100 {2.1688-2.1692}

9.80-10.0 {0.3859-0.3937}

8.80-9.00 {0.3465-0.3543}

Heat the cylinder head to about 80 °-100 ° C {176-212° F} in hot water. On the other hand, cool the valve seat with dry ice or ice water for about 15 minutes. Hold the seat with pincers and place it into the heated cylinder head.

Hino K13C T

ENGINE

EN-24 Hino K13D T

IF NECESSARY, REPLACE THE HINO K13C VALVE GUIDES. 1. 2.

(A)

Remove the valve stem oil seal. Using a brass rod and hammer, install the valve guide as shown in the figure.

Valve Guide Height (Al: 22.1-23.1 mm {0.871-0.909 in.} NOTE: Apply engine oil lightly to the valve guide outer circumÂ ference before installation. SM3-K0002 IF NECESSARY, REPLACE THE VALVE STEM OIL SEAL.

L-7

SPECIAL fl.,/TOOL

PÂˇ .

VALVE STEM OIL SEAL

After removing the valve stem oil seal, install the valve spring lower seat and valve, then apply engine oil to the oil seal lip. Strike the valve stem oil seal into the valve guide with the special tool. Special Tool: Valve Stem Seal Press (09472-1570) NOTE: o After installing of the oil seal, check for deformation or cracking of the rubber. o Do not use the special tool if its tip (surface contacting valve spring lower seat) is worn or deformed.

SPRING RUBBER

COAT OIL

S6-K 1 3-0014 INSTALL THE VALVE AND VALVE SPRING . PAINT

NOTE:

o Apply engine oil to the contact surfaces of each parts. o Make sure that the valves are installed in the correct cylinders. o Since this valve spring is evenly pitched, it can be installed either end up.

SM3-1986

Press valve spring upper seats, then install the valve cotters securely in the valve spring upper seats. Special Tool: Valve Spring Press (09470-1022) NOTE:

o When the valve spring is compressed, be careful of damage to the valve stem oil seals due to contact of the valve spring upper seats. o Strike the valve stem lightly with a hammer to assure proper fit the valve cotter.

Hino K13C T Hino K13D T

ENGINE

EN-25

ASSEMBLE THE ROCKER ARM.

Lubricate the rocker arm shaft and bushing, then assemble the rocker arms and shaft as shown in the figure.

ROCKER ARM (INTAKE) SM3-K0003 INSTALL THE CYLINDER HEAD.

Install the cylinder head gasket.

NOTE:

Always use new cylinder head gasket after cleaning the surfaces of the cylinder head, cylinder brock and head gasket free of all dirt, water and grease.

SM3-K0004

2. w 0 Cf)

er: <{ w (9 (9

ï¿½ i==

SM3-K0005

HINO K13C T TIGHTENING HINO K13D T TIGHTENING

HEAD BOLT SEQUENCE HEAD BOLT SEQUENCE

Using special tools, tighten the cylinder head bolts in three stage following the tightening order as shown.

NOTE:

o Apply engine oil to the bolt threads and under the bolt head. o No.15 is 12 mm {0.47 in.} dia. bolt and others are 16 mm {0.63 in.} dia. bolts for K13D-T, 18 mm {0.70 in.} dia. bolts for K13C-T. Special tools: Socket Wrench (09621-1090, 09621-1120) Adapter (09621-1020)

----

Tightening torque

1st step

50% of specified torque

2nd step

75% of specified torque

3rd step

100% of specified torque

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Hino K13C T

ENGINE

EN-26 Hino K13D T

INSTALL THE ROCKER ARM. 1. Install the valve stem caps. NOTE: o Make sure that both the end of the valve stem and the inside of the valve stem cap are free from dust. o Apply engine oil to the valve stem ends and put the valve stem caps on the valve stem ends. o Do not drop the valve stem cap into the engine.

S6-K 13-001 6

2. 3.

Apply engine oil to both ends of push rod and insert the push rods in correct order. Mount the rocker arm assembly on the cylinder head, make sure that the push rods interlock with the adjusting screws.

NOTE: 4.

Always loosen the lock nut and raise the adjusting screws fully to the top.

Tighten the rocker arm support fitting bolts.

SM3-427

O-RING GROOVE

INSTALL THE NOZZLE HOLDER ADAPTER. 1. 2.

Insert the new 0-ring to the nozzle holder adapter. Using a special tool, screw-in into the cylinder head until it is stopped.

Special Tool: Nozzle Holder Adapter Wrench (09503-1010) NOTE: When the adapter is removed, replace the O-ring with a new one and apply engine oil. S6-K 13-0019

- •-•--•DIRECTION OF THE ADAPTER

Loosen and adjust the adapter within 1/2 turns so the line connecting the tapped holes on the nozzle holder adapter flange meets the crankshaft at a right angle.

AXIS OF THE CRANKSHAFT

S6-K13-0020

INSTALL THE NOZZLE HOLDER. 1. �GAUGE

! :�

NOZZLE HOLDER

�-� S6-K13-0021

Insert a packing ring to the underside of the nozzle holder flange, fit a new nozzle holder gasket to the tip of the nozzle holder and insert the nozzle holder into the adapter.

NOTE:

o When mounting the nozzle holder, direct the high pressure inlet connector towards the engine front side (timing gear side). o The projection of the packing ring towards the ex haust manifold side.

Hino K13C T Hino K13D T NOZZLE HOLDER GAUGE

ENGINE 2. PACKING RING

EN-27

Place the nozzle holder gauge on the upper surface of the nozzle holder flange, align holes of the gauge, holder flange and adapter, and tighten the bolt.

NOTE: After tightening the bolt, confirm that the clearance beÂ tween the upper surface of the nozzle holder adapter and lower surface of the holder flange is 4.5-5.5 mm {0.1772-0.2165 in.}, and the nozzle holder gauge is free from deflection and bending. (The nozzle holder gauge is used for locating to the nozzle holes).

4.5-5.5 mm {0.1772-0.2165 in.l =?,1, S6-K13-0019

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-28 Hino K13C T Hino K13D T

INSPECTION AND REPAIR Standard

Inspection Item

Cylinder Head Flatness

0.05 {0.0019} or less

Limit

li i

Regrind. t _ :: _ � _ �_ o�_ -� 8_:_ __ _ _ _ - _ _ __ _ _, �

,.Service limit 0.30 {0.011 8}

Replace.

Replace, if necessary.

Cylinder Head: Cranks and Damage (Dye penetrate check)

Unit: mm {in.}

Inspection Procedure

Remedy

: �

��

�,.,-

SM3-F0050

Visual check

ill�

c:;Jo �OJ::Yb

Valve Seating Condition (Use of red lead marking compound)

Hino K13C Hino K13D

Intake

There should be good contact around entire circumference of valve head.

29 45'-30 (K13C-T)

Measure. Regrind or replace the valve and/or the valve seat.

29 30'-30 (K13D-T) Valve Face Angle t-------+-----------1 ° ° 44 15'-45 (K13C-T) Exhaust ° ° 44 30'-45 (K13D-T)

Hino K13C Hino K13D

30 -30 15' (K13C-T) °

In ake ° ° 30 -30 30' (K13D-TI t ---1 ----+------Valve Seat Angle 1-° ° 45 -45 15' (K13C-T) Exhaust ° ° 44 -45 30' (K13D-TI Adjusting Screws and Push Rods: Damage

Rocker Arm and Valve Stem Cap: Wear and Damage

�b

30·

Replace, if necessary.

Resurface or replace.

SM3--F0052

Visual check

Hand-lap with the lapping compound.

SM3--F0053

uwu V

INTAKE

Visual check

,·

"')45·

EXHAUST

SM3-F0045

SM3-1066

SM3-1103

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-29

Hino K13C Hino K13D

Unit: mm {in.} Standard

Inspection Item Upper Spring Seats and Lower Spring Seats: Wear and Damage

3.0 {0.118}

6.0 {0.236}

1.0 {0.039}

Limit (Wear of A+ wear of CJ and/or (wear of B + wear of CJ is more than 1.0 {0.039}

Remedy Replace.

Inspection Procedure Measure.

LOWER SEAT

Replace the nozzle holder gasket.

Nozzle Protrusion from Cylinder Head Surface

4.75-5.25 {0.1871-0.2066}

Intake Valve Sink

0.75-1.00 {0.0296-0.0393}

0.25 {0.0098}

Exhaust Valve Sink

0.45-0.70 {0.0178-0.0276}

-0.05 {-0.0019}

Intake Valve Stem Outside Diameter

12.0 {0.4724}

11.85 {0.4665}

Exhaust Valve Stem Outside Diameter

12.0 {0.4724}

11.80 {0.4645}

Intake Valve Guide Inside Diameter

12.0 {0.4724}

Exhaust Valve Guide Inside Diameter

12.0 {0.4724}

S6-K13-0091

Clearance between Valve Stem and Valve Guide (Intake)

0.050-0.080 {0.0020-0.0031}

r�.� �� \ 1�:�

Replace the valve Measure. and/or the valve "O" IS CYLINDER C+) HEAD SURFACE 'j "'seat.

Replace the valve guide and/or the valve seat.

Measure.

A: 10 {0.394} B: 30 {1.181} C: 67 {2.638}

0.30 {0.0118} SM3-F0042

Clearance between Valve Stem and Valve Guide (Exhaustl

0.070-0.113 {0.0028-0.0044}

0.35 {0.0137}

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-30 Hino K13C Hino K13D

Unit: mm {in.} Remedy

Standard

Limit

Rocker Arm Shaft Outside Diameter

28.0 {1.1024}

27.92 {1.0092}

Replace.

Rocker Arm BushingInside Diameter

28.0 {1.1024}

28.08 {1.1055}

Replace.

K13C-T

0.044-0.112 {0.0017-0.0044}

0.15 {0.0059}

Replace.

K13D-T

0.020-0.054 {0.008-0.0021}

Inspection Item

Clearance between Rocker Arm Shaft and Rocker Arm Bushing

Inspection Procedure Measure.

S6-K 13-0098

Valve Spring Setting Load

438 N {44.7 kgf, 99 lbf} at 57.5(2.264)

397 N {40.5 kgf, 89Ibf}

Replace.

Measure.

SM3-F0046

Valve Spring Squareness

2.0 {0.0787} or less

Replace.

Measure.

-=Push Rod Bend

0.5 {0.0196}

Replace.

"J,l

Measure. /

�'� ....._,____ SM3-292

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE Hino K13C Hino K13D

EN-31

CRANKSHAFT PULLEY

OVERHAUL

7 1. 2. 3. 4.

Collar Torsional dumper Coupling Crankshaft pulley 5. Sleeve 6. 0-ring 7. Dust slinger

�T:98-117 {1,000-1,200, 73-86}

/�

®-- 1 T:823 {8,400, 607}

SM6-K13-0023

T = Tightening torque: N-m {kgf-cm, lbf-ft}

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have these special tools. PRESS

0-RING

ST-0088 09402-1250

9851-70101

ST-0108

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-32 Hino K13C Hino K13D

IMPORTANT POINT-DISMOUNTING REMOVE THE CRANKSHAFT PULLEY. NOTE:

o Use a puller if necessary. o Do not remove the crankshaft gear unless it consid ered absolutely necessary.

IMPORTANT POINT-ASSEMBLY REPLACE THE DUST SLINGER. 1. Remove the dust slinger with lever.

SM3-1059

SPECIAL TOOL

\r�

TSLINGER

Using the special tools, install the dust slinger.

Special tools: Press (09402-1250) O-ring (9851-70101) NOTE:

To prevent wear of the side lip of the oil seal, inject about 0.5-1 cm 3 {0.03-0.061 cu•in.} of grease (lithium based) into the "U" groove of the dust slinger.

,�:�:,::24

IMPORTANT POINT-MOUNTING INSTALL THE CRANKSHAFT PULLEY. NOTE:

Apply engine oil to thread of the crankshaft.

ENGINE Hino K13C Hino K13D

EN-33

FLYWHEEL AND FLYWHEEL HOUSING

Hino K13C T Hino K13D T

OVERHAUL

T=128-137 {1,300-1,400, 94-101}

1. 2. 3. 4.

6. 7. 8.

T=o16 mm {0.630 in}: 125-135 {1,300-1,400, 94-100} T:020 mm {0.787 in}: 215-235 {2,200-2,400, 155-170}

Stay Shim Flywheel housing Inspection hole cover Oil seal retainer Oil seal Ring gear Flywheel

S6-K13-0025

T = Tightening torque: N-m {kgf-cm, lbf-ft}

SPECIAL TOOL

Prior to starting an engine overhaul, it is necessary to have this special tool.

PRESS

ST-0288 09420-1050

IMPORTANT POINTS - MOUNTING PRESS

IF NECESSARY, REPLACE THE OIL SEAL.

OIL SEAL RETAINER

1. 2.

Remove the oil seal. Insert the oil seal to the oil seal retainer, ensuring that it is flush with the end of the oil seal retainer.

NOTE:

APPLY OIL ON CIRCUMFERENCE S6-K13-0026

Ensure that the lip of the oil seal is coated with oil seal lubricating grease (lithium-based).

Special tool:

Press (09482-1050)

Hino K13C

ENGINE

EN-34 Hino K13D EXAMPLE

IF NECESSARY, REPLACE THE RING GEAR.

EXAMPLE

1. a.

Remove the ring gear. Heat the ring gear evenly to about 200 ° C {392 ° F} with a torch.

NOTE: b.

SM3-F0069

SM3-F0070

Strike the ring gear periphery lightly using a metal rod as a pad to remove the ring gear.

WARNING Never touch the ring gear or flywheel while they are hot with your bare hands. 2. a.

EXAMPLE

Install the ring gear. Heat the ring gear evenly to about 200 ° C {392 ° F} with a torch.

NOTE: b.

SM3-F0071

SM3-F0072

Be careful not to overheat the ring gear.

Insert the ring gear into the flywheel so that the chamfered side is upward.

WARNING Never touch the ring gear or flywheel while they are hot with your bare hands.

INSTALL THE FLYWHEEL.

EXAMPLE

Install the flywheel and tighten the bolts through a tighten ing order with several repetition so as to reach specified torque evenly and gradually, then slacken to tighten them securely one by one with the specified torque. WARNING The flywheel is too heavy. When installing, be careful not to drop it on your feet.

SM3-2600 TIGHTENING ORDER

"O" MARK 0 (0\ 1 ,...

CRANKSHAFT COLLAR

0� ,.}'0 0Q0 000

NOTE:

o Align the "O" mark on the flywheel and crankshaft collar knock-pin. o When tightening the bolt, apply engine oil to the threads and flywheel surface of the bolts.

SM3-J128

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Hino K13C Hino K13D

ENGINE

EN-35

IMPORTANT POINTS - ADJUSTMENT GENERATOR USE ONLY ANGULAR AND PARALLEL ALIGNMENT 1. a. b. c. d.

Check the angular (face) alignment. Attach the dial indicator stand to the flywheel. Apply the dial indicator at right angle to plane surface of flywheel housing. Pretension the gauge and set to "O". Turn the flywheel slowly and measure the angular align ment.

Repair limit: FLYWHEEL

0.20 mm {0.0078 in.}

If the parallel alignment exceeds the limit, change the straight pins. NOTE: The following straight pins are available. Eccentricity (A): 0.05 mm {0.0020 in.} 0.10 mm {0.0039 in.} 0.20 mm {0.0079 in.}

S6-K 13-0027

PUNCHED MARK (DIRECTION OF ECCENTRICITY)

S6-K 13-0029

2. a. b. c. d.

Check the parallel (bore) alignment. Attach the dial indicator stand to the flywheel. Apply the dial indicator at right angle to entering surface of flywheel housing. Pretention the gauge and set to "O". Turn the flywheel slowly and measure the parallel align ment.

Repair limit: e.

0.20 mm {0.0078 in.}

If the angular alignment exceeds the limit, install the shim between the cylinder block and flywheel housing. NOTE: The following shims are available. Thickness: 0.05 mm {0.0020 in.} 0.10 mm {0.0039 in.} 0.15 mm {0.0059 in.}

S6-M 1 0C-0076

ENGINE

EN-36 Hino K13C Hino K13D

TIMING GEAR AND CAMSHAFT

DESCRIPTION 2

OVERHAUL

4 BC

T:280-300 {2,900-3,100, 209-224}

5 6 7 8 9

S6-K 13-0030

T = Tightening torque: N-m {lbf-cm, lbf-ft} 1. Cylinder block 2. Air compressor drive gear (If so equipped) 3. Coolant pump drive gear 4. Idler gear 5. Injection pump drive gear 6. Camshaft gear 7. Crankshaft gear 8. Oil pump drive gear 9. Oil pump driven gear 10. Washer 11. Idle gear bushing 12. Straight pin 13. Idle gear shaft 14. Spacer 15. Thrust plate

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Camshaft Key O-ring Bearing holder case Taper roller bearing Drive shaft Shim Gasket Bearing retainer Oil seal sleeve Oil seal Timing gear cover Timing gear plate Oil seal Tachometer drive assy (If so equipped)

31. 32. 33. 34. 35. 36. 37. 38. 39. A. B. C.

Oil hose Elbow Oil pipe Oil filler cap Lubrication fitting Engine mounting bracket Front end plate gasket (If so equipped) Flange (If so equipped) Front end plate (If so equipped) Match mark "1" Match mark "2" Match mark "3"

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-37

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have these special tools.

GEAR PULLER ADAPTER (Used with 09420-1361)

GEAR PULLER

�

ST-0289

09420-1361

09462-1011

O-RING (For suspending the valve lifter)

PRESS

9851-20104

� �

� ST-0090

SLIDING HAMMER

ST-0108

�

( )

ST-0096

(1) 09472-1021 (2) 09472-1830

ST-0288

09482-1040

IMPORTANT POINTS- DISASSEMBLY IF NECESSARY, REMOVE THE INJECTION PUMP DRIVE GEAR. 1. 2. 3.

Remove the lock nut and lock plate. Using the special tools, remove the injection pump drive gear. Remove the woodruff key.

Special Tool: Gear Puller (09420-1361) Gear puller adapter (09462-1011)

REMOVE THE IDLE GEAR SHAFT. Using the special tool, remove the idle gear shaft.

Special Tool: Sliding Hammer (09472-1021 and 09472-1830)

EN-38

Hino K13C Hino K13D

ENGINE REMOVE THE CAMSHAFT. 1.

Using the special tool, suspend the valve lifters in the cylin der block in correct order.

Special Tool: O-ring (9851-20104) 2. Remove the thrust bearing fitting bolts and pull out the camshaft with gear. CAM SHAF SM3-1097A

NOTE: Pull the camshaft, slowly turning it to prevent the cam bearings damage. SM3-2651

IF NECESSARY, REMOVE THE CAMSHAFT GEAR. 1.

Hold the camshaft assembly with a vice through wooden plate. Remove the bolt and washer, then using the special tool, 2. remove the camshaft gear. Special Tool: Gear Puller (09420-1361)

SM3-841

PRESS

IMPORTANT POINTS - ASSEMBLY PRESS

1. Using a screwdriver, remove the oil seal. 2. Install the new oil seal. Special Tool: Press (09482-1040)

�

TIMING GEAR COVER

IF NECESSARY, REPLACE THE TIMING GEAR COVER OIL SEAL.

OIL SEAL SM3-K0008

INSTALL THE TIMING GEAR PLATE.

DOWEL PIN

Fit the 0-ring to the cylinder block water gallery and install the timing gear plate with a gasket. NOTE: Align the cylinder block and timing gear plate using dowel pin.

O-RING SM3-1070 INSTALL THE CAMSHAFT GEAR TO THE CAMSHAFT. Install the camshaft gear with thrust plate and spacer. NOTE: When installing the camshaft gear to the camshaft: o Heat the gear in hot water about 100°C {212°F}, then install the gear to the camshaft with a press. o When tightening the nut, apply engine oil to the threads and plate surface of the nut.

Hino K13C Hino K13D

ENGINE

EN-39

INSTALL THE CAMSHAFT. 1.

Using the special tool, lift up the valve lifters and suspend them above the camshaft.

Special Tool: O-ring (9851-20104) 2.

Apply engine oil to all journals of the camshaft and insert the camshaft assembly into the cylinder block.

NOTE:

Insert the camshaft, slowly turning it to prevent the bearing damage.

SM3-1097

CYLINDER BLOCK

INSTALL THE IDLE GEAR SHAFT. Install the idle gear shaft with oil hole (Al positioned oil pan side.

SM3-K0010 INSTALL THE IDLE GEAR AND INJECTION PUMP DRIVE GEAR. Be sure that the match marks of the crankshaft gear, cam shaft gear, fuel injection pump drive gear, and idle gear are aligned correctly. NOTE:

CRANKSHAFT GEAR

o Incorrect installation can results in engine damage or lowering of engine performance by causing improper injection timing. o When tightening the bolt, apply engine oil to the threads and plate surface of the bolt.

SM3-K0009 MEASURE THE GEAR BACKLASH. Measure the backlash between gears with a dial gauge. Refer to the table of INSPECTION AND REPAIR.

SM3-F0101

INSTALL OIL PUMP AND OIL STRAINER. Refer to SECTION LUBRICATING SYSTEM. INSTALL THE OIL PAN Cut the protrusion of the timing gear plate gasket and tim ing gear cover gasket from the oil pan mounting surface.

";--

TIMING GEAR COVER

S6-K13-0031

EN-40

ENGINE

Hino K13C Hino K13D

INSPECTION AND REPAIR Unit: mm {in.}

Inspection Item

Standard

Limit

Gear Teeth: Pitting and Wear

Remedy

Inspection Procedure

Replace, if necessary.

Visual check

Replace the bushing and/or shaft.

Measure.

SM3-F0095

Idle Gear Shaft Outside Diameter

48.0 {1,889}

Idle Gear Busing Inside Diameter

48.0 {1,889}

Oil Clearance between Idle Gear Shaft and Idle Gear Bushing

0.038-0.088 {0.0015-0.0034}

0.20 {0.0079}

Idle Gear End Play

0.07-0.17 {0.0028-0.0066}

0.30 {0.0118}

Replace the idle gear bushing.

0.05 {0.0019}

Replace.

Camshaft Bend

SM3-F0096

Camshaft Cam Height (Intake)

55.90 {2.2008}

55.10 {2.1693}

Camshaft Cam Height (Exhaust)

55.36 {2.1796}

54.56 {2.1480}

Replace.

ol SM3-563

Camshaft End Play

0.10-0.26 {0.0040-0.0102}

0.50 {0.0196}

Replace the thrust plate.

SM3-F0098

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-41

Hino K13C Hino K13D Unit: mm {in.}

Inspection Item Camshaft Journal Outside Diameter

Standard

Limit

Journal No. 1.

66.0 {2.5984}

65.85 {2.5925}

Measure.

65.8 {2.5906}

65.65 {2.5846}

65.6 {2.5827}

65.45 {2.5767}

65.4 {2.5748}

65.25 {2.5688}

�. �� -

65.2 {2.5669}

65.05 {2.5610}

65.0 {2.5591}

64.85 {2.5531}

64.8 {2.5512}

64.65 {2.5452}

0.03-0.12

0.30

{0.0012-0.0047}

{0.0118}

7. Oil Clearance between Camshaft Journal and Camshaft Bearing

..r:. 111 111 111

Crankshaft Gear and Idle Gear

0.09-0.22 {0.0036-0.0086}

Camshaft Gear and Injection Pump Drive Gear

0.07-0.25 {0.0028-0.0098}

Idle Gear and Camshaft Gear

0.10-0.22 {0,0040-0.0086}

Idle Gear and Coolant Pump Drive Gear

0.10-0.16 {0.0040-0.0063}

Oil Pump Drive Gear and Oil Pan Driven Gear

0,40 {0.0157}

� �

("\

SM3-F0099

Replace the shaft and/or the bearing

·�\{.: � ·>

-�f'\ ---

- rrA�-, �(JJ>--

�-1 ·,,,,__.-

/�Y

SM3-F0100

-J J

Replace the gear, if necessary.

�

0.089-0.289 {0,0035-0.1137}

Valve Lifter Guide Inside Diameter

23.0 {0.9055}

0.020-0.062 {0.0008-0.0024}

0.20 {0.0078}

Should not be worn unevenly.

\e'.'

-�

23.0 {0.9055}

Valve Lifter: Wear

Inspection Procedure

Measure.

Valve Lifter Outside Diameter

Clearance between Valve Lifter and Valve Lifter Guide

Remedy

SM3-F0101

Replace the valve lifter.

Measure.

.� D

.�

� �-

SM3-F0102

Replace, if necessary.

SM3-F0103

Visual check

SM3-949

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-42

ENGINE

Hino K13C Hino K13D

INJECTION PUMP DRIVE

OVERHAUL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 2

O-ring Bearing holder case Bearing Key Drive shaft Shim Gasket Bearing retainer Sleeve Oil seal Front end plate (If so equipped) SM3-2609

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have these special tools. PULLER

PRESS

O-RING Used with 09482-1340 09482-2050

0 ST-0187

09420-1180 for K13D-T 09420-1760 for K13C-T

ST-0184

09482-1340 for K13D-T 09482-2050 for K13C-T

ST-0258

9851-36104 for K13D-T 9644-04031 for K13C-T

IMPORTANT POINTS-ASSEMBLY IF NECESSARY, REPLACE THE FUEL INJECTION PUMP DRIVE SHAFT, OIL SEAL AND SLEEVE. 1.

Using the special tool, remove the sleeve.

Special Tools: Puller (09420-1180) for K13D-T (09420-1760) for K13C-T a. b.

DRIVE SHAFT

c. d.

SLEEVE

SM3-1991

Put the puller (1), (2) onto the sleeve. Insert the hook portion of the puller between the shaft and sleeve. Insert the puller (3). After inserting the puller, screw in the center bolt (4) then remove the sleeve.

Hino K13C Hino K13D

ENGINE

EN-43

2. Using the special tools, insert the sleeve with a new 0-ring. Special Tools: Press (09482-1340) for K13D-T (09482-2050) for K13C-T O-ring (9851-36104) for K13D-T (9644-040311 for K13C-T Insert the 0-ring (5) into the press (6). a. b. Insert the new sleeve with new 0-ring into the press and then insert them into the drive shaft. c. Tap the press (A) lightly with a hammer, until the press end contact with the drive shaft end (B), with which you can detect the sleeve position. NOTE:

o o o

O-RING

Be sure to fit an O-ring on the sleeve and also apply a liberal coating of oil to the drive shaft. When striking on the sleeve, take care that the O-ring does not get cut or torn. Once a sleeve has been removed, it cannot be reused.

SM3-1992

09482- 2050 (K13C-T) i= -� '

�(

----- ----

E E

'SI" 'SI"

28.5 mm {1.12 in.} SM3-K0011

09482-1340 (K13D-T)

28.5 mm {1.12 in.} SM3-K0012

ASSEMBLE THE INJECTION PUMP DRIVE GEAR SHAFT ASSEM BLY. Adjust the pre-load of drive shaft using a proper shim. Turning Torque: 0.39-1.17 N-m {4-12 kgf-cm, 0.29�.867 lbf,ft} NOTE:

SM3-1054

Be sure that there is no loose rattling in the axis direc tion of the drive shaft.

EN-44

Hino K13C Hino K13D

ENGINE

PISTON, CRANKSHAFT, CYLINDER BLOCK AND OIL PAN OVERHAUL

T:020: 64-74 {650-700. 47-54} (with check valve)

T:018: 39-44 {400-450, 29-32}

T:20-25 {200-250, 15-18}

T:353-372 {3.600-3.800. 261-274}*

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Oil pipe Cylinder block Plug Cylinder liner 0-ring Pin Camshaft end plate Piston cooling jet Oil jet pipe Camshaft bearing

SM3-1061 SM3-1727 SM6-K13-0032

T = Tightening torque: N-m {kgf,cm, lbf,ft} * = Apply engine oil to the threads and seat surfaces before tightening.

11. Main hole plug

12. 13. 14. 15. 16. 17. 18. 19. 20.

Piston ring Piston Piston pin Retainer ring Bushing Connecting rod bearing Connecting rod Sleeve 0-ring

21. 22. 23. 24. 25. 26. 27. 28.

Crankshaft Key Oil pump drive gear Crankshaft gear Thrust bearing Main bearing Main bearing cap Collar

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-45

Hino K13C Hino K13D

OVERHAUL

7 018: T = 39-49 {400-500, 28-36} 022: T = 52-58 {530-600, 39-43} 030: T = 98-115 {1,000-1,200, 72-86}

T = Tightening torque: N-m {kgf,cm, lbf,ft} S6-K13-0033

1. 2. 3. 4.

Cylinder block Gasket Valve push rod cover Injection pump bracket

5. 6. 7. 8.

Oil pan Soft washer Plug Oil jet pipe

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-46

ENGINE

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have these special tools.

PISTON PIN PRESS

09482-1380

PISTON RING EXPANDER

ST-0241

09442-1121 (K13C-T) 09442-1131 (K13D-T)

CYLINDER LINER PULLER

CONNECTOR BOLT

09421-1090 (K13C-T) 09421-1720 (K13D-T)

9001-24265

PISTON COOLING JET CHECK GAUGE

09444-1300 (K13D-T)

ST-0292

CRANKSHAFT REAR OIL SEAL SLEEVE PRESS

ST-0019

09480-1220 (K13C-T) 09480-1010 (K13D-T)

ST-0021

ST-0030

09470-1030 (K13C-T)

ST-0230

EVE BOLT (For removing the crankshaft front oil seal sleeve)

ST-0077

ADJUSTING BAR

09472-1620

09441-1151 (K13C-T) 09441-1011 (K13D-T)

PISTON COOLING JET CHECK GAUGE

PRESS ASSEMBLV

ST-0291 09402-1041

PISTON RING HOLDER

ST-0032

09433-1010

ST-0207

Hino K13C Hino K13D

ENGINE

: ------:o

�

--------------------

EN-47

IMPORTANT POINTS- DISASSEMBLY REMOVE THE PISTONS WITH CONNECTING RODS. 1.

Remove the carbon from the upper end of the cylinder liner with a scraper or emery paper (recommended: No.150) in a circular direction.

Pull the pistons and connecting rods assembly out through the top of the cylinder.

SM3-J154

O-MARK

K13C-T

NOTE:

o Remove the connecting rods in such a way that they does not contact the cooling jet.

o Keep the pistons and connecting rod assembly in order of cylinder number.

SM3-J243A

K13D-T

O-MARK

"\':::c=-3�=-MATCH MARK S6-K 13-0034

REMOVE THE CONNECTING ROD. 1. 2.

Remove the retainer ring installed on both ends of the piston pin, using a retainer ring pliers. Using the special tool, remove the piston pin.

Special Tool: Piston Pin Press (09482-1380)

SM3-294

REMOVE THE PISTON RINGS. Special Tool: Piston Ring Expander (09442-1121) (K13C-T) (09442-1131 l (K13D-T) NOTE: o Handle the piston rings carefully because they are made of a special casting which is easily broken. o Keep the piston rings for each cylinder in order of cylinder number.

SM3-2667

Hino K13C

EN-48 Hino K13D

ENGINE REMOVE THE CYLINDER LINERS. 1.

Before removing the cylinder liners, be sure to put match marks on the cylinder block and liner flange with a pen.

NOTE: o Do not put match marks with a punch. o After removing the cylinder liners, keep them in order of cylinder number.

Using the special tool, pull the cylinder liner towards the upper part of the cylinder block.

Special Tool: Cylinder Liner Puller (09420-1090) (K13C-T) (09420-1720) (K13D-T) NOTE: After removing the cylinder liners, keep them in order of cylinder liner.

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Hino K13C Hino K13D

ENGINE

EN-49

IMPORTANT POINTS -ASSEMBLY INSPECT THE PISTON COOLING JET POSITIONING. NOTE:

o Do not remove the piston cooling jet except when performing overhauls or when otherwise necessary. o In the event that the piston cooling jet is removed, be sure to replace it with new one.

Remove the piston cooling jet connector bolt and install the special tool.

Special Tool: Connector Bolt (9001-24265) 2.

3. 4.

Prepare a commercially available oil pump [pressure about 2 kg/cm 2 {28.44 lb/sq.in.}, flow rate about 2.5 L/min {2.64 US.qts/min}]. Prepare fresh engine oil. Connect the oil line between the oil pump outlet and the special tool.

Special Tool: Connector Bolt (9001-24265) CONNECTOR BOLT SM3-579

K13C-T

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

NOZZLE COOLING JET CHECK GAUGE CONNECTOR BOLT

OIL

SM3-923

K13D-T

Install the special tool on the cylinder block.

Special Tool: Piston Cooling Jet Gauge (09470-1030) (K13C-T) (09444-1300) (K13D-T)

CYLINDER BLOCK

LOCATING PIN

COOLING JET CHECK GAUGE

S6-K13-0035

EN-50

Hino K13C Hino K13D

ENGINE 6.

Operate the oil pump, and with pressure at about 196 kPa {2 kg/cm2, 28.44 lb/in.2}, pump fresh oil from the jet, and per form a spray test. Conditions are normal if the center of stream hits a target plate 010 mm {0.39 in.}.

WARNING Engine oil is flammable. This spray test should be done in a well ventilated room and away from any open flames or electric sparks.

ABNORMAL

NORMAL SM3-581

If the spray of the cooling jet messes the circle on the target plate, realign the nozzle with the special tool.

Special Tool: Adjusting Bar (09472-1620)

,,,,:r

�--

/r-----__

i,,i

,, ,,,, ,,,,•:

� SPECIAL TOOL S6-K13-0036

lll SPRAY PATTERN

ABNORMAL /

8. VSPRAY

l:OLINGJET

When inspecting the piston cooling jet positioning, check that the spray is dispersed as shown in "4" and not as in "1", "2", or "3" in the illustration at left.

NOTE:

4 NORMAL

If the tip of the jet is damaged so that the spray pattern is bad, replace the jet with a new one. When replacing the cooling jet, always inspect the new piston cooling jet's positioning.

SM3-J549

10.

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 with soft washer. After installing the piston, make sure that there is no inter ference between the cooling jet and the piston when the piston is at bottom dead center.

Hino K13C Hino K13D

ENGINE

EN-51

INSERT THE CYLINDER LINERS INTO THE CYLINDER BLOCK. 1. Install the O-ring to the cylinder block as shown. NOTE: o Apply the silicon rubber sealer (ThreeBond No.1211 or equivalent) to the position (Al to the cylinder lin ers. o Replace the O-rings with new ones. Upper O-ring (Bl: Light Green color Lower O-ring (Cl: Black color

O-RING a: E';; E·00 0 N8

Approx.

:::;

1 mm

i::i

{0.04 in.} C

e';; ·-

"'....e �

Less than

1mm

{0.04 in.}

SM3-1170

I l

Align the match marks on the cylinder liner and block and then insert the liner.

After inserting the cylinder liner into the cylinder block, measure the inside diameter of the liner again at the O-ring position.

Service Limit: 0.03 mm {0.001 in.}

MEASURING POINT

SM3-1093

MEASURE THE PROTRUSION OF THE CYLINDER LINER FLANGE. Using the dial gauge, measure the protrusion of the top end of the cylinder liner from the cylinder block. Standard: 0.04-0.10 mm {0.0016-0.0039 in.} (K13C-T) 0.01-0.08 mm {0.0004-0.0031 in.} (K13D-TI

S42-0172-1

Hino K13C

EN-52 Hino K13D REMOVE

ENGINE IF NECESSARY, REPLACE THE CRANKSHAFT FRONT OIL SEAL SLEEVE.

SLEEVE

Remove the oil seal sleeve using the special tool.

Special Tool: Eye Bolt (09433-1010)

SPECIAL TOOL

PRESS SM3-K0013

0-RING

REMOVE

NOTE: Do not remove the crankshaft gear unless it considered absolutely necessary. 2. Install a new sleeve. Be sure to fit a new 0-ring on the sleeve and also apply liberal coating of oil to the pulley center side. When driving on the sleeve, use a suitable press, taking care that the 0-ring does not get cut or torn. IF NECESSARY, REPLACE THE CRANKSHAFT REAR OIL SEAL SLEEVE.

SLEEVE PULLER

Remove the sleeve with suitable puller. Install a new sleeve. Be sure to fit a new 0-ring on the sleeve and also apply liberal coating of oil to the crankshaft side. When driving on the sleeve, use a press, taking care that the 0-ring does not get cut or torn.

Special Tool: Press (09402-1041)

UNDER SIZE BEARING FOR CRANKSHAFT (FOR K13D-T) NOTE:

o If the wear of the crankshaft pin or journal matches an undersize bearing 4 types 0.25 mm {0.0098 in.}, 0.50 mm {0.0197 in.}, 0.75 mm {0.0295 in.}, 1.00 mm {0.0394 in.}, replace the bearing with an undersized one . o The bearing is a set consisting of upper and lower halves, consequently, be sure to replace the bearing as a set.

Bearing size

�·��

CORRECT

1'----

WRONG----'I

SM3-J234

Outside diameter Crank pin

Journal

0.25

83.695-83.715 {3.2951-3.2958}

89.66-89.68 {3.5400-3.5307}

0.50

83.445-83.465 {3.2853-3.2860}

89.41-89.43 {3.5201-3.5208}

0.75

83.195-83.215 {3.2754-3.2761}

89.16-89.18 {3.5103-3.5110}

1.00

82.945-82.965 {3.2656-3.2663}

88.91-88.93 {3.5004-3.5011}

INSPECT THE FILLET OF THE CRANK PIN AND JOURNAL. Dimension of fillet (R): 5.0-5.5 mm {0.197-0.216 in.}

Hino K13C Hino K13D

ENGINE

EN-53

INSTALL THE CRANKSHAFT. 1.

Install the crankshaft bearings on the cylinder block and bearing cap.

NOTE:

2. 3. 4.

o Install the bearing with the oil hole on the block side and the bearing without the oil hole on the cap side. o Apply fresh engine oil to sliding surface, each bearing and surface of the crankshaft.

Insert the crankshaft thrust bearings along the groove of the cylinder block. Install the crankshaft on the cylinder block. Install the thrust bearing on the No.5 bearing cap sides.

NOTE:

Apply fresh engine oil to sliding surface, each thrust bearing and crankshaft.

SM3-1090

Install the bearing caps in order form timing gear side with the arrow point toward the timing gear side.

ARROW �

� TIMING GEAR SIDE SM3-855

Tighten the cap bolts in three stages following the tighten ing order. Tightening Order: 4-3-5-2-6-1-7 6.

Tightening torque ....J w w :I:

NOTE: SM3-972

1st stage

50% of specified torque

2nd stage

75% of specified torque

3rd stage

100% of specified torque

o Apply engine oil to the bolt threads and under the bolt head. o Make sure that the crankshaft rotates smoothly. o Inspect the crankshaft end play.

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Hino K13C

EN-54 Hino K13D

ENGINE BEFORE T APPING OUT BUSHING

REMOVE SCREW

SM3-2669

IF NECESSARY, REPLACE THE CONNECTING ROD BUSHING. Set the connecting rod in the guide. Mount the plate on the connecting rod large end and fix it in place by tightening the bolt. 3. Remove the guide screw. 4. Mount the press on the spindle and fix it in place with the screw. 5. Insert the spindle into the bush. 6. Tap out the bush by tapping the spindle with a hammer. Special Tool: Press (09480-1220) (K13C-T) (09480-10101 (K13D-TI 1. 2.

AFTER TAPPING OUT BUSHING

PRESS

BEFORE TAPPING SPINDLE OUT BUSHING NEW BUSHING LINE UP HOLES

PLATE

GUIDE

7. 8.

Set the connecting rod in the guide. Insert the spindle into the connecting rod small end, and position the connecting rod. 9. Mount the plate on the connecting rod large end and fix it in place by tightening the bolt. 10. Apply a coat of engine oil to the inner and outer surfaces of the new bush, and mount it on the spindle, lining up the bush and the connecting rod oil hole. NOTE: Make sure the bush and spindle tilt angles are the same.

SM3-K001

AFTER TAPPING OUT BUSHING

11. 12.

Mount the press and fix the spindle in place with the screw. Tapping the press with a hammer, press-fit the bush, applyÂ ing a uniform pressure around its entire circumference. NOTE: o Keep tapping the press until it contacts the guide. o Make sure the bush is uniformly press-fitted.

SM3-K0016

Inspect the bushing positioning after installation. Make sure that the oil hole of the bushing and the oil path of the connecting rod are suitably aligned allowing a 4.5 mm {0.1772 in.} diameter rod to penetrate. NOTE: Misalignment can lead to insufficient lubrication, which may result in seizure. b. Insert a new piston pin. When it is turned gently, make sure that there is no catch or rough movement.

13. a.

SM-J24

Hino K13C Hino K13D

ENGINE

EN-55

ASSEMBLE THE PISTON AND CONNECTING ROD.

0-MARK

Make sure that the 0-mark at the top of the piston and the connecting rod match marks in same directions.

NOTE: 2.

Use the new retainer rings.

Apply fresh engine oil to the piston pin then fix the piston and connecting rod by inserting the piston pin.

SM3-J243

RING UPPER FACE

INSTALL THE PISTON RINGS.

Install the piston rings in sequence oil ring, third ring, sec ond ring and top ring with the identification mark at the top of the ring facing up.

NOTE: Apply oil to the piston rings.

DISCRIMINATION MARK SM3-295

SM3-2667

Ring No. Top 2nd 3rd Oil

Special Tool: Piston Ring Expander (09442-1121) (K13C-T) (09442-1131) (K13D-T)

-a-

Description SM3-2610 SM3-2610 SM3-2610

SM3-2610

To assemble the oil ring connect the ends of the coil ex pander and then fit the coil inside the piston ring after ensuring that the gap of the piston ring is 180 ° away from the joint of the coil.

Arrange the piston rings so that their gaps are equally spaced.

GAP SM3-443

SM3-573A

EN-56

Hino K13C Hino K13D

ENGINE INSTALL THE PISTON WITH CONNECTING ROD INTO THE CYL INDER LINER. 1. 2.

SM3-J246

O-MARK

Apply engine oil to the piston, cylinder liner and connecting rod bearing surface. Using the special tool, hold the piston rings. Install the piston with connecting rod using a wooden rod.

Special Tool: Piston Ring Holder (09441-1151) (K13C-T) (09441-1011) (K13D-T) NOTE: o Be sure that the O-mark on the top of the piston is nearest the identification marks of cylinder block and liner side. o When installing the piston with connecting rod, be careful that the cooling jet, cylinder liner and crank shaft are not struck by the connecting rod. If the cooling jet is struck, adjust or replace it. o Rotate the crankshaft slowly, make sure that the pis tons do not contact with the piston cooling jets.

SM3-2670

INSTALL THE CONNECTING ROD CAP.

O-MARK

K13C-T

1. 2. 3. 4.

Apply engine oil to the cap bearing surface. Align the match marks on the connecting rod and cap. Apply engine oil to the bolt threads and cap surface of the nut. Tighten the cap bolts in three stages.

SM3-J243A

K13D-T

0-MARK

'\.;:,��-MATCH MARK S6-K13-0034

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ENGINE Hino K13C Hino K13D

EN-57

INSPECTION AND REPAIR Unit: mm {in.}

Inspection Item Cylinder Liner Inside Diameter

S tandard K13C-T

135.0 {5.315}

Limit 135.2 {5,323}

Remedy

Inspection Procedure

Measure. Replace the piston and/or the liner.

Oversize pistons 0.5 {0.0197} K13D-T 0.75{0.0295} 1. { 0.03 9 4} 1-----------'-----1f--------+-----+- _ o_ o _ _ _ _ _ _ _-l x¢_ 0-211-0,230 Clearance between Piston 137.0 {5,394}

and ey1;nde, Line,

50 {1.9685}

Piston Pin Hole Inside Diameter

50 {1.9685}

Clearance between 0.001-0.015 K13c-T {0.00004-0.00059} Piston Pin and Piston 1------+--- - - - - - _ _� Pin Hole 0.001 -0.01 2 K13D-T {0.00004 -0.00047}

Connecting Rod: Wear and Damage (Dye penetrate check)

Y �� J

fjij f

{0.0083-0.0090)

Piston Pin Out Side Diameter

Crankshaft End Play

138.2 {5.444}

0.110-0.265 {0.0044-0.0104}

49.99 {1.9681}

SM3-J543

Replace the Measure. piston, the piston pin and/or the busing.

SM3-J544

SM3-J542

0.05 {0.0019} SM3-J541

0.5 {0.0196}

Replace the thrust bearing.

Replace.

Measure.

v,..

SM3-362

. ,_:

�

�� Connecting Rod Oil Hole Clogged

Clean.

�

Visual check

SM3-J255

SM3-J242

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-58

ENGINE

Hino K13C Hino K13D Unit: mm {in.} Inspection Item

Standard

Limit 0.05 {0.0019} Per 200 {7.874}

Connecting Rod Straightness

Remedy Repair or replace.

Inspection Procedure

�r

Me•�

_,J?

:;i}l ,�,

y- \-

0.05 {0.0019} Per 200 {7.874}

Connecting Rod Twist

Repair or replace.

Measure.

SM3-J527

: � :; �

1 '':' I

] /'

Piston Pin Out Side Diameter

Clearance between Piston Pin and Con necting Rod Small End Bushing

50 {1.9685}

49.99 {1.9681}

0.025-0.043 {0.0010-0.0016}

0.10 {0.0039}

Replace the busing and/or the piston pin.

·•'t Measure.

SM3-J527A

SM3-J254 Cylinder Liner Projection

Crank Pin Outside Diameter

K13C-T

0.04-0.10 {0.0016-0.0039}

K13D-T

0.01-0.08 {0.0004-0.0031}

K13C-T

84 {3.3071}

Replace.

83.8 {3.2993} Repair limit 83.8 {3.2993} Service limit 82.8 {3.2598}

K13D-T

Clearance between Connecting Rod and Crank Pin

0.050-0.101 {0.0020-0.0039}

Main Bearing Spread

96.75-98.00 {3.8091-3.8582}

Connecting rod bearing spread

89.75-90.75 {3.5335-3.5728}

0.30 {0.0118}

Measure.

Replace the crankshaft. Regrind under size bearing. Replace the crankshaft.

SM3-J257

Replace the bearing.

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ENGINE

EN-59

Hino K13C Hino K13D Unit: mm {in.}

Inspection Item

Standard

Limit

Remedy

Crankshaft Oil Hole Clogged

Clean.

Crankshaft: Cracks and Damage (Dye penetrate check)

Replace.

Inspection Procedure Visual check

SM3-J262

Crankshaft Bend

0.05 {0.0019}

Replace. (K13C-T)

Measure.

Regrind under size. (K13D-T) SM3-J688

Piston Ring Width

Top 2nd

Measure.

3.306 {0.1302}

Replace. 3.5 {0.1378}

3.25 {0.1280}

K13C-T

5 {0.1969}

4.95 {0.1948}

K13D-T

6 {0.2362}

5.95 {0.2343}

3rd Oil Piston Ring Groove Width

Measure.

Top Replace piston.

2nd 3rd Oil Clearance between Piston Ring and Piston Ring Groove

SM3-J546

3.5 {0.1378}

3.75 {0.1476}

K13C-T

5 {0.1969}

5.05 {0.1988}

K13D-T

6 (0.2362}

6.05 {0.2382}

Top 2nd 3rd Oil

0.07--0.11 {0.0028--0.043}

0.20 {0.0078}

0.04--0.08 {0.0016--0.0031}

0.10 {0.0039}

Replace piston ring and/or piston.

SM3-J545

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-60

ENGINE

Hino K13C Hino K13D Unit: mm {in.}

Inspection Item

Standard

0. 4 0-0.52 Piston Ring Gap K13C-T _ 1_ 5_8_-0 _ .0 _ _ 20 * Insert the piston Top 1----+----"{0_.0 _ -'4}_-1 0. 4 5-0.60 ring where the K13o_T { _ .0 � 3 � .� 02 _ �17�8�-0 _ 6_ }_-1 wear of the liner 1---1----+--0 0.40-0.52 is small. K1JC-T 0 { .0158-0.0204} 2nd 1------+-��----�-+ 0. 4 5-0.60 K13D-T {0.0178-0.0236}

Limit 1.5 {0.0590}

Remedy Replace.

Measure.

SM3-J253

3rd

0.45-0.60 {0.0178-0.0236}

Oil

0.35-0.55 {0.0138-0.0216}

1.0 {0.0393}

0-0.05 {0-0.0019)

0.10 {0.0039)

Regrind.

0.15 {0.0059)

Replace.

Cylinder Block Flatness

Inspection Procedure

SM3-578

Crankshaft Journal Outside Diameter

K13C-T

90 {3.5 4 3}

Flywheel Face Alignment

Replace crankshaft.

Repair limit Regrind under 89.80 size. {3.5355} Service limit Replace 88.80 crankshaft. 3 { . 4 961}

K13D-T

Clearance between Crankshaft Journal and Main Bearing

89.80 {3.5355)

0.070-0.121 {0.0028-0.00 4 7}

0.30 {0.0118}

0.20 {0.0078)

Measure.

SM3-J257

Replace bearing.

Repair and/or replace.

SM3-J129

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-61

LIQUID GASKET AND APPLICATION POINTS The engine uses liquid gasket instead of conventional sheet gaskets. Apply liquid gasket, therefore, taking the following items into account. 1.

LIQUID GASKET APPLICATION POINTS AND COATING WIDTH Recommended liquid gasket; Three Bond TB1207C: 04132-1207 Unit: mm {in.}

Parts name

Application point

Coating width 1.5 - 2.5 {0.06 - 0.10}

(a) Push rod cover (b) Oil seal retainer (c) Coolant drain plug

SM3-2611

COATING LIQUID GASKET AND PARTS ASSEMBLY PROCEDURE 1. 2. 3. 4. 5.

Completely remove old liquid gasket from each part and the respective matching part, and wipe off oil, moisture, and dirt using a cloth. Be careful not to apply excessive or insufficient liquid gasket. Also, be sure to overlap the start and end of each coating. When assembling coated parts, be careful that there is no misalignment between matching parts. If there is any misalignment, coat the parts again. Assemble the various parts within 20 minutes after applying liquid gasket. If more than 20 minutes have passed, remove the liquid gasket and apply it again. Wait for at least 15 minutes or more after assembly the various parts before starting the engine.

REMOVING PARTS When removing each part, do not attempt to pry one portion of the flange alone but use the flange collar or clearance to pry the flange at several points alternately.

ENGINE

EN-62 Hino K13C Hino K13D

LUBRICATING SYSTEM

LUBRICATING SYSTEM DIAGRAM

II !I !!

:- 32

JUUUUl t

. ., ., Â·: . .r' . 19 23

SM3-2672

Unit: kPa {kgf/cm2, lbf/in.2}

1. 2. 3. 4.

Oil pan Oil strainer Oil pump Oil pump safety valve 785-931 {8,0-9.5, 110135}

5. Oil cooler 6. Oil cooler safety valve 363-421 {3,7-4.3, 53-61} 7. Oil filter safety valve 118-176 {1.2-1.8, 18-25} 8. Warning device for

clogging of oil filter

9. Oil filter (Full flow)

10. Oil filter (Bypass)

11. Regulator valve

363-421 {3.7-4.3, 52-61}

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Check valve for turbocharger Turbocharger Main oil hole Sub oil hole Piston cooling jet Valve lifter Camshaft cam Push rod Adjusting screw Rocker arm Rocker arm shaft Valve

24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

A. B.

Camshaft journal Crankshaft journal Crankshaft pin Connecting rod Piston Idle gear Oil pressure switch Oil pressure gauge unit Oil pressure gauge Fuel injection pump Air compressor (If so equipped) To timing gear To oil pan

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ENGINE

EN-63

Hino K13C Hino K13D

OVERHAUL for model K13CTB

T = 12.5-17.5 {130-180, 9.0-13.0)

A ®

��

T = -12.5-18.5 {130-190, 9.0-13.5)

T = 105-115 {1,100-1,200, 79-86)

T = 34-39

T = Tightening torque: N-m {kgf-cm, lbf-ft} S6-kl 3-0040

1. 2. 3. 4.

Oil pump O-ring Oil pipe Oil strainer

5. 6. 7. 8.

Oil cooler Gasket Water gallery cover Plate

9. Oil filter 10. Bracket

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-64

ENGINE

Hino K13C Hino K13D

OVERHAUL for model K13CTJ and K13CUC

T = 12.5-17.5 {130-180, 9.0-13.0} 5

�' ® '

,._,v. �V//'>.

T = 34-39 {350-400, 25-28}

{1,100-1,200, 79-86}

T = Tightening torque: N-m {kgf-cm, lbf-ft} S6-K13-0041

1. Oil pump 2. O-ring 3. Oil pipe 4. Oil strainer

5. 6. 7. 8.

Oil cooler Gasket Water gallery cover Plate

9. Oil filter 10. Bracket

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-65

ENGINE Hino K13C Hino K13D

OVERHAUL for model K13D-T

T = 13-17 {130-180, 10-13}

T = 45-49 {450-500, 32-36}

T = 108-117 {1, 100-1'200, 7 9-86}

T = 45-49 {450-500, 32-36}

T = Tightening torque. N-m {kgf-cm, lbf-ft} S6-K13-0042

1. 23. 4.

Oil pump O-ring Oil pipe Oil strainer

5· 6· 7· 8.

Oil cooler Gasket Oil filter Bracket

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-66 Hino K13C Hino K13D

OIL PUMP

OVERHAUL

T = 24.5-29.4 {250-300, 19-21} 2 3 4 5 8 8 6

S6-K13-0043

T = Tightening torque: N-m {kgf-cm, lbf,ft}

Oil pump gear Oil pump case Drive gear Oil pump cover 5. Oil pump safety valve 1. 2. 3. 4.

6. Driven gear 7. Collar 8. Pin 9. Valve 10. Shim

11. Spring 12. Spring seat 13. Retainer ring

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ENGINE Hino K13C Hino K13D

EN-67

INSPECTION AND REPAIR Unit: mm {in.}

Inspection Item

Standard

Limit

Remedy

Driven Gear Shaft Outside Diameter

26 {1.0236}

Replace.

Driven Gear Inside Diameter

26 {1.0236}

Replace.

Inspection Procedure

SM3-K0017

Clearance between Driven Gear and Shaft

0.045-0.091 {0.0018--0.0035}

0.19 {0.0074}

Replace the driven gear and/or oil pump cover.

Clearance between Drive Gear and Oil Pump Case

0.05-0.13 {0.0020-0.0051}

0.18 {0.0070}

Replace the oil pump case.

Gear End Play

0.06--0.105 {0.0024--0.0039}

0.15 {0.0059}

Replace the gear and/or the oil pump case.

Gear Teeth: Pitting or Wear

Replace, if necessary.

Visual check

SM3-845A

Oil Pump Safety Valve: Wear and Damage

Replace, if necessary.

Visual check

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ENGINE

EN-68 Hino K13C Hino K13D

Unit: mm {in.}

Inspection Item Gear Backlash

Standard

Limit

0.100-0.245 {0. 0040-0. 0096}

0.40 {0.0157}

Remedy Replace.

Inspection Procedure Measure.

SM3-1117

Drive Gear Shaft Outside Diameter

22 {0.866}

Oil Pump Cover Inside Diameter

22 {0.866}

Measure. Replace the oil pump case and/or the oil pump cover.

�

� SM3-1123

Clearance between Drive Gear Shaft and Oil Pump Cover

0.043-0.077 {0.0017-0.0030}

0.19 {0.0074}

SM3-971

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE Hino K13C Hino K13D

EN-69

OIL COOLER AND OIL FILTER

OVERHAUL

T= 19.6-28.9 {200-300, 15-21} 3

14 14

3 12 15 3 16

15 3

16 T= 14.7-19.7 {150-200, 11-14) Â· T= 39.2-49.0 {400-500, 29-36)

T = Tightening torque: N-m {kgf-cm, lbf-ft} S6-K 13-0044

Oil cooler element Gasket O-ring Oil cooler case Oil cooler safety valve 363-421 kPa {3.7-4.3 kgf/cm2, 53-61 lbf/in2.) 6. Oil filter safety valve 118-176 kPa {1.2-1.8 kgf/cm2, 18-25 lbf/in2.}

1. 2. 3. 4. 5.

7. Warning device for clogging of oil filter 8. Spring 9. Holder 10. Valve 11. Oil filter upper cover 12. Oil filter element 13. Washer 14. Oil filter element lower cover

15. Center bolt 16. Drain plug 17. Regulator valve 363-421 kPa {3.7-4.3 kgf/ cm2, 53-61 lbf/in. 2}

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-70

ENGINE

Hino K13C Hino K13D Inspection Item Oil Cooler Air Tightness Air Pressure: 980.67 kPa {10 kgf/cm2, 142 lbf/in.2}

Valve and Springs of Oil Cooler and Oil Filter: Wear and Damage

INSPECTION AND REPAIR Standard

Limit

Remedy Replace. if necessary.

Replace. if necessary.

Inspection Procedure Visual check

AIR PRESSURE GAUGE ï¿½ Air Water I Element

SM3-1088

Visual check 1. Sliding face of valve for possible damage. 2. Valve move smoothly

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ENGINE Hino K13C Hino K13D

EN-71

FUEL SYSTEM

FUEL SYSTEM DIAGRAM

1. Water separator (If so equipped) 2. Fuel feed pump 3. Fuel filter 4. Fuel injection pump 5. Injection nozzle A. From fuel tank B. To fuel tank

��=========�==--

B A

S6-K 13-0045

OVERHAUL T = 15-17 {150-180, 11-13}

1. 2. 3. 4. 5. 6.

Injection nozzle Packing ring Nozzle holder gauge Fuel filter Injection pump drive Fuel injection pump

S6-K 13-0046

T = Tightening torque: N-m {kgf-cm, lbf-ft}

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EN-72

Hino K13C Hino K13D

ENGINE

BLEEDER t!!@F====eâ&#x20AC;¢/ PLUG

FUEL FILTER

TO INJECTION NOZZLE

AIR BLEEDING FROM FUEL SYSTEM 1. 2. 3. 4.

PRIMING PUMP FROM FUEL TANK S6-K 13--004 7

Loosen the bleeder plug on the fuel filter. Loosen the priming pump knob. Operate the priming pump knob until the air will not come out from the bleeder plug. Tighten the bleeder plug.

Tightening Torque: 3.93-5.88 N-m {40-60 kgf-cm, 3-4 lbf-ft} NOTE: The bleeder plug should be tightened while the priming pump knob is operated.

5. 6.

Once again, operate the pump knob several times. Push back the priming pump knob and tighten it.

NOTE: Wipe off any splashed fuel around the bleeder plug.

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ENGINE Hino K13C Hino K13D

EN-73

INJECTION NOZZLE

OVERHAUL T:15-19 {150-200, 11-14}

T:50-58 {500-600, 37-43}

T:59-68 {600-700, 44-50} ,,,,.--

� f4 �

br'

T:59-78 {600-800, 44-57}

S6-K 13-0049

T = Tightening torque: N-m {kgf-cm, lbf,ft} 1. 2. 3. 4. 5. 6.

Nozzle holder Connector Gasket Stem Spring Adjusting screw

7. Cap nut

8. Gasket

9. Joint bolt 10. Gasket

11. Retainer nut

12. Nozzle

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EN-74

Hino K13C Hino K13D

ENGINE

IMPORTANT POINTS- INSPECTION CHECK THE NOZZLE OPERATING PRESSURE. 1.

Install the nozzle holder assembly to the nozzle tester, and operate the lever at the rate of about 50 to 60 times per minute.

WARNING o Diesel fuel is flammable. This nozzle adjusting should be done a well ventilated room and away from any open flames or electric spark. o The spray must always be covered. Keep your face and body away from the spray. This is because of the risk of fuel oil getting in your eyes or passing into your body. 2.

At this time, check that the nozzle operating pressure is in the specified value. If not, disassemble and adjust the nozzle holder assembly. Opening pressure: With reused parts: K13C-T: 21.57 MPa {220 kgf/cm2, 3,128 lbf/in2.} K13D-T: 19.61 MPa {200 kgf/cm2, 2,844 lbf/in2.} With new parts: K13C-T: 22.5-23.0 MPa {230-235 kgf/cm2, 3,270-3,340 lbf/in2 .} K13D-T: 20.1-20.5 MPa {205-210 kgf/cm2, 2,915-2,985 lbf/in2 .} TEST THE SPRAV PROFILE.

GOOD

COARSE

In the case of the new nozzle, operate the lever at the rate of 30 to 60 strokes per minute, and for a used nozzle, operate the lever at the rate of 15 to 60 strokes per minute. If spray is coarse, replace or clean the nozzle.

COARSE SM3-J182A

TEST THE FUEL LEAKAGE. When checking for fuel leakage from the nozzle, apply a pressure of about 0.98-1.96 MPa {10-20 kgf/cm2, 142-284 lbf/in2} lower than the correct injection pressure to the nozzle by means of the nozzle.

GOOD

,, h FAULTY

SM3-J183 TEST THE NOZZLE SINKING. 1. 2.

SM3-J185

Wash the nozzle proper with diesel fuel oil, then immerse it in diesel fuel oil. Slide the needle inside the nozzle proper and ensure that it moves smoothly. The needle valve should fall under its own weight when withdrawn vertically about 1/3 and released. If its motion is sluggish, replace the nozzle with a new one.

Hino K13C Hino K13D

ENGINE

EN-75

IMPORTANT POINTS - MOUNTING INSTALL THE NOZZLE HOLDER.

� GAUGE

I :�

. JI

NOZZLE HOLDER

Insert a packing ring to the underside of the nozzle holder flange, fit a new nozzle holder gasket to the tip of the nozzle holder and insert the nozzle holder into the adapter.

NOTE:

S6-K13-0050

2. GAUGE

PACKING RING

o When mounting the nozzle holder, direct the high pressure inlet connector towards the engine front side (timing gear side). o The projection of the packing ring towards the ex haust manifold side.

Place the nozzle holder gauge on the upper surface of the nozzle holder flange, align holes of the gauge, holder flange and adapter, and tighten the bolt.

Tightening torque: 15-17 N•m (150-180 kgf,cm, 11-13 lbMt} NOTE:

S6-K13-0051

After tightening the bolt, confirm that the clearance be tween the upper surface of the nozzle holder adapter and lower surface of the holder flange is 4.5-5.0 mm {0.1772-0.2165 in2 .}, and the gauge is free from deflection and bending. (The nozzle holder gauge is used for locat ing to the nozzle holes.)

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-76

ENGINE Hino K13C Hino K13D

FUEL INJECTION PUMP

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have this special tool. INJECTION PUMP COUPLING WRENCH

ST-0040 09819-1705

IMPORTANT POINT - DISMOUNTING A

TIMER OR COUPLING

REMOVE THE FUEL INJECTION PUMP. 1. 2. 3.

SM3-1799

Disconnect the fuel lines, oil lines and engine control lines. Remove the through bolt "B" and the two flange bolts "A" (in slotted holes) at the coupling. Remove the pump mounting bolts and then dismount the pump.

NOTE: Cover open end of the pipes and pump to prevent entry of dirt. Special Tool: Wrench (09819-1705)

IMPORTANT POINT- MOUNTING INSTALL THE FUEL INJECTION PUMP. 1.

SM3-519

Adjust the injection timing. Turn the crankshaft counterclockwise viewed from the fly wheel side . Align the injection timing mark "A 0 " on the flywheel before top dead center for No.1 cylinder on com pression stroke with pointer on the flywheel housing.

Injection Timing (A0 ): Refer to SECTION DATA AND SPECIFICA TION.

Check the push rods on No.1 cylinder are loose and push rods on No.6 are tight.

NOTE: If not, adjust the push rods on No.1 and No.6 cylinder are the same condition as above turning the crankshaft. 3.

Remove the coupling flange from the fuel injection pump assembly, then slip it onto the drive shaft.

NOTE:

Do not tighten the through bolt.

Hino K13C Hino K13D

ENGINE

EN-77

Slowly turn the coupling to clockwise viewed from coupling side to align the injection timing mark on the coupling jaw with pump body pointer.

Position the pump on the pump bracket and adjust the position of the pump so that its mounting holes align with those of the bracket and then tighten the mounting bolts evenly in following order.

S6-K13-0052

Tightening order:

1-2-3-4 Unit: N-m {kgf-cm, lbf-ft} Tightening torque

TIMING OR COUPLING

1st stage

2-4 {20-50, 1.4-3.6}

2nd stage

10-14 {100-150, 7.2-10.8}

3rd stage

19-25 {190-260, 14-18)

PUMP BODY

S6-K13-0053

Using the special tool, tighten the two flange bolts (in slotÂ ted holes) at the coupling.

NOTE: There should not be any gap between the laminated plates or be any deformation of the flange due to presÂ sure the laminated plates.

Special Tools: Injection Pump Coupling Wrench (09819-1705) Tightening Torque: 59-63 N-m {600-650 kgf-cm, 44-47 lbf-ft}

S6-K13-0054

Tighten the through bolt at the flange.

NOTE:

Do not tighten the through bolt before tightening the two flange.

Tightening torque: 59-63 N-m {600-650 kgf-cm, 44-47 lbf-ft} 8. Connect the fuel lines, oil lines and engine control lines. BLEED AIR FROM FUEL SYSTEM.

EN-78

ENGINE

Hino K13C Hino K13D

COOLING SYSTEM

DATA AND SPECIFICATION Coolant pump Type ................................................................. Forced circulation by volute pump Drive ................................................................ By gear Thermostat Type ................................................................. Wax type, bottom bypass type

COOLING SYSTEM DIAGRAM

S6-K 13-0056

Radiator cap Radiator Coolant pump Cylinder block 5. Oil cooler

1. 2. 3. 4.

6. Cylinder head 7. Thermostat 8. Bypass hose 9. Thermostat cover 10. Drain cock

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ENGINE Hino K13C Hino K13D

EN-79

COOLANT PUMP OVERHAUL

DESCRIPTION A

T= 17.7-21.6 {180-220, 14-15} T= 122-132 {1,250-1,350, 91-97}

B SM3-K0021 T = Tightening torque: N-m {kgf-cm, lbf-ft}

8. Oil seal

1. Pump case cover 2. Gasket 3. Vane 4. Spacer 5. Coolant seal 6. Straight pin 7. Pump case

9. Shaft 10. Ball bearing 11. Coolant pump gear 12. Bearing retainer 13. Coolant drain hole A. From thermostat (Bypass)

B. From radiator C. To cylinder block

SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have these special tools.

COOLANT SEAL PRESS

OIL SEAL PRESS

ST-0244

ST-0239 09482-1160

09482-2310

Hino K13C

EN-80 Hino K13D

ENGINE VANE

IMPORTANT POINTS- DISASSEMBLY REMOVE THE VANE FROM THE SHAFT. The vane is screw in type, so it is removed by turning the vane clockwise.

SM3-K0022

REMOVE THE BEARING RETAINER. Loosen the bearing retainer fitting bolts and remove the bearing retainer with the shaft.

S6-K13-0059

REMOVE THE SHAFT. Press to the end of the shaft on the retainer side and remove the ball bearing.

S6-K13-0094

CLEAN THE WATER DRAIN HOLE OF THE PUMP CASE.

S6-K 13-0060

IMPORTANT POINTS - ASSEMBLV INSTALL THE OIL SEAL. Apply engine oil to the pump case side and using a special tool, install the oil seal to the case. Special Tool: Oil seal press (09482-1160) NOTE:

o Install the oil seal with the lip positioned to the bearÂ ing retainer side. o Apply grease to the main lip and between main and sub lips.

Hino K13C Hino K13D

ENGINE

EN-81

INSTALL THE SHAFT. Install the shaft to the pump case and fasten the bearing retainer with four bolts. NOTE:

Before installing the shaft to the case, apply engine oil to the shaft to prevent the oil seal from damage.

S6-K 13-0089

INST ALL THE COOLANT SEAL. Using the special tool and a press, install the coolant seal to the case. Special Tool: Coolant Seal Press (09482-2310) NOTE:

When installing the coolant seal, Three Bond No.1104 to the outer and circumference of the coolant seal cage and install the seal using a press.

S6-K 13-0062

INST ALL THE VANE TO THE SHAFT.

VANE

Install the vane to the shaft by turning the vane counter clockwise. NOTE:

Make sure that the vane rotates smoothly.

SM3-K0022A

INSPECTION AND REPAIR Inspection Item Bearing wear and damage

Standard

Limit

Remedy Replace, if necessary.

Inspection procedure Visual check

�� S6-K13-0095

EN-82

ENGINE Hino K13C Hino K13D

THERMOSTAT

OVERHAUL 1. 2. 3. 4. 5. 6.

Thermostat cover Thermostat Gasket Thermostat case O-ring Pipe S6-K13-0063

T1 : VALVE OPENING TEMPERATURE T2 : VALVE OPENED TEMPERATURE

10mm {0.41 in}

____________....-------

I LL _J

0° c

° �10 c _,

T2°c

TEMP SM3-F0197

IMPORTANT POINT - INSPECTION AND REPAIR INSPECT THE THERMOSTAT FUNCTION. 1.

Place the thermostat in hot water and check the valve open ing temperature and the valve lift. NOTE: The thermostat valve opening temperature (T ,) is en graved on the thermostat seat, and it should be confirmes. Thermostat valve opening temperature; Thermostat valve Service standard opening temp. IT,) °

76.5 C

74.5-78.S'C {166-173'F}

82 C

80-84 C {145-215 F}

Thermostat valve opening temperature; Thermostat valve Measuring temp. opining temp. (T,I (T,) L 1: WHEN COLD L2 WHEN (T2) ° C L3: VALVE LIFT L1

SM3-F0198

ASKET /� �-SEAT

76.S'C °

82 C 2.

90 C {194 F} 95 C {203 F}

Valve lift (L3) 10 mm {0.394 in.} or more

Immerse a heated thermostat in water of normal tempera ture. If it completely closes within 5 minutes it is satisfac tory. If it remain even slightly open, it is defective and must be replaced.

IMPORTANT POINT-ASSEMBLY ASSEMBLE THE THERMOSTAT CASE. THERMOSTAT

SM3-K0023

NOTE:

o Remove the water and dirt adhering to the thermo stat case. o Replace the gasket without fail if it is corroded, dam aged or flattened. o Before installing the hose, apply liquid gasket to the hose installation of the thermostat case cover. o In order to prevent clogging of the radiator, do not use a large amount of liquid gasket. o Be sure to that the hole faces upward when installing.

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EN-83

ENGINE

RADIATOR

1. Radiator

SM3-F0209

IMPORTANT POINTS-DISMOUNTING DISMOUNT THE RADIATOR. WARNING To avoid the danger of burns and scalds, do not drain the coolant while the engine and radiator are still hot. NOTE: When dismounting and mounting the radiator, do not damage the radiator core.

INSPECTION AND REPAIR Inspection item

Standard

Limit

Remedy Check the dimension D after caulking. If necessary. replace the radiator.

Coolant Leakage (when the air pressure of 100kpa (1kgf/cm2) is applied.)

Unit: kPa {kgf/cm 2, lbf/in. 2} Inspection procedure Visual check

Clean.

Clogging of Fins

SM3-F0209 Radiator Cap Valve Opening Pressure

Mark 0.5

39-58 {0.4-0.6, 5.7-8.5}

Replace.

Measure. �

Mark 0.9

73-100 {0.75-1.05, 10.7-14.9}

"'/ '-,

��

� -�0210

NOTE:

The coolant filler cap valve opening pressure is indicated on the cap and it should be confirmed. If the cap pressure is incorrect, there is a risk of abnormally high pressure being generated in the cooling system, which may cause the hose to drop off or burst and may result in the damage of the engine.

EN-84

ENGINE

Hino K13C Hino K13D

COOLING FAN

OVERHAUL

T: 35-39 {350-400, 26-28}

S6-K13-0090

T = Tightening torque: N-m {kgf-cm, lbf-ft}

1. 2.

Cooling fan (Blowoff type) Cooling fan drive assembly

Belt tension pulley assembly

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EN-85

ENGINE Hino K13C Hino K13D

OVERHAUL

SUCTION TYPE

BLOWOFF TYPE

T: 34-39 {350-400, 25-28}

S6-K13-0071 S6-K13-0072

T = Tightening torque: N-m {kgf,cm, lbf,ft}

Shock to the fan clutch and fan. During maintenance and inspection, be careful not to drop or strike the fan clutch or fan itself. The resulting damage may lower the performance of the fan. Also, note that the fan is made of plastic and may become damaged or de足 formed if force is applied to it.

Replacing the fan Do not replace the fan unless it is faulty. When replacing the fan, replace it with the same type as the one which was removed. If the fan is replaced with one of a larger capacity because of overheating or, conversely is replaced with one of a smaller capacity due to overcooling, the cooling perfor足 mance may in fact reduced and durability may be jeopar足 dized.

Other items Check the temperature detector (bimetal) to see if there is any mud or dust on it. If the bimetal is covered with mud of dust, the fan perfor足 mance will be erratic and any result in overheating or overcooling. In such case, carefully remove mud and dust adhering to the surface of the bimetal, using a wire brush, or the like. Take care not to apply excessive force particular. Do not paint the fan. Do not place any paint or other reagents which are likely to dissolve plastic in contact with the fan.

EN-86

Hino K13C Hino K13D

ENGINE

IMPORTANT POINT-MOUNTING

DIRECTION u OF ROTATION

ENGINE SIDE- \

FAN BLAD�

AIR URRENT �

INSTALL THE COOLING FAN. NOTE: The cooling fan should be installed rightly as shown.

Il �

DIRECTION OF ROTATION

ENGINE SIDE -

S6-K13-0073

(=]11

AIR CURRENT

COOLING FAN

CRANKSHAFT PULLEY

S6-K13-0074

GENERATOR

S6-K13--0070

ADJUST THE V-BELT. 1.

Install the V-belts, and adjust the belt tension.

NOTE:

o Do not under any circumstances apply the lever di rectly against the generator body owing to the risk of damaging the generator. o When installing a new V-belt or adjusting the tension, be sure to repeat the adjustment two or three times, after running the engine for several minutes each time.

V-belt deflection Apply a load of about 98 N (10 kgf, 221bf} by pressing with your finger or the special tool. Assembly standard (A): 15-20 mm {0.60-0.78 in.} (B): 10-15 mm {0.40-0.59 in.} 2.

Special Tool: V-belt Tension Gauge (09444-1210) NOTE:

o If the belt is excessively tensioned, there is a risk of damaging the bearing of the generator and also short ing the life of the V-belt. o Conversely if there is insufficient tension on the V belt, the belt will slip, unusual noise will be emitted, the battery may run down and the engine may over heat.

INSPECTION AND REPAIR Inspection Item Cooling Fan: Deformation and Damage

Standard

Limit

Remedy Replace, if necessary.

Inspection Procedure

ENGINE Hino K13C Hino K13D

EN-87

AIR INTAKE AND EXHAUST SYSTEM

OVERHAUL Model: K13C-T T = 44-49 {450-500, 32-36}

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

O-ring Oil inlet pipe Soft washer Joint bolt Gasket Exhaust manifold connector Seal ring Turbocharger Heat insulator Exhaust manifold Intake manifold Intake hose Clamp Intake pipe Air intake heater (If so equipped) Bracket Air cleaner Oil outlet pipe

S6-K 13-0067

T = Tightening torque: N-m {kgf-cm, lbf-ft}

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ENGINE

EN-88 Hino K13C Hino K13D

Model K13D-T 4

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Exhaust manifold connector Gasket Seal ring Turbocharger 0-ring Oil inlet pipe Oil outlet pipe Exhaust manifold Seal ring Heat insulator Gasket Intake manifold Air intake heater (If so equipped) Intake pipe 0-ring Bracket Air hose Dust indicator Air cleaner

S6-K13-0069

S6-K 13-0068

T = Tightening torque: N-m {kgf,cm, lbf,ft}

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Hino K13C Hino K13D

EN-89

ENGINE IMPORTANT POINTS-ASSEMBLY ASSEMBLE THE EXHAUST MANIFOLD. 1.

When installing seal rings on the exhaust manifold, fit new seal rings in such a way that the gaps are equally spaced, as shown, to prevent gas leakage.

S6-K13-0076

2. Install the exhaust manifold as shown. NOTE: o Tighten the exhaust manifold with nut, putting the spacer beneath it. o Before tightening, make sure that the spacer do not slip out from the spot facing "A" section. o Fit the spacer positioning the small inside diameter side (with white paint) at the nut side. Tightening Torque: 45-49 N-m {450-500 kgf-cm, 33-36 lbf-ft} EXHAUST MANIFOLD S6-K13-0077

INSPECTION AND REPAIR Unit: mm {in.} Inspection Item

Standard

Limit

Exhaust Seal Ring Wear or Damage

Remedy Replace

Inspection Procedure Visual check

Q3-F0323

Intake and Exhaust Manifolds Flatness

Less than 0.10 {0.0039}

0.5 {0.0197}

Resurface or replace Resurface limit: 0.1 {0.0039} per flange S6-K13-0079

Intake and Exhaust Manifolds Crack or Damage * Using a dye penetrant

Replace

Visual check

;,·

•·.,

' �. '

SM3-F0324

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EN-90

ENGINE

ELECTRICAL PARTS GENERATOR SPECIAL TOOL Prior to starting an engine overhaul, it is necessary to have this special tool.

V-BELT TENSION GAUGE

ST-0085 09444-1210

IMPORTANT POINT - MOUNTING ADJUST THE V-BELT. 1.

Install the V-belts, and adjust the belt tension.

NOTE:

COOLING FAN

GENERATOR

CRANKSHAFT

PULLEY

S6-K 13-0070

o Do not apply the lever directly against the generator body owing to the risk of damaging the generator under any circumstances. o When installing a new V-belt or adjusting the tension, be sure to repeat the adjustment two or three times, after running the engine for several minutes each time.

V-belt deflection. Apply a load of about 98 N {10kgf, 22 lbf} by pressing with your finger or special tool. Assembly standard (A): 15-20 mm {0.5905-0.7874 in.} (Bl: 10-15 mm {0.3937-0.5905 in.}

Special Tool: V-belt Tension Gauge (09444-12101 NOTE: o If the belt is excessively tensioned, there is a risk of damaging the bearings of the generator or coolant pump and also shorting the V-belt. o Conversely, if there is insufficient tension on the V belt, the belt will slip, unusual noise will be emitted, the battery may run down and the engine may over heat. Through Bolt Tightening Torque: 127.5-137.2 N-m {1,300-1,400 kgf-cm, 94-101 lbf-ft}

ENGINE

EN-91

STARTER IMPORTANT POINT - DISMOUNTING REMOVE THE STARTER FROM THE ENGINE. 1. 2. 3. "C" TERMINAL

SM3-F0261

Disconnect the battery cable from the negative(-) terminal of battery. Make the match marks on the harness and starter terminals with a pen and then disconnect the harness. Remove the starter from the engine.

IMPORTANT POINT- DISASSEMBLY AND ASSEMBLY Refer to CHAPTER ST, STARTER for details. IMPORTANT POINT- MOUNTING INSTALL THE STARTER ON THE ENGINE. 1. Install the starter on the engine. Fitting nuts tightening torque: 108-147 N-m {1,100-1,500 kgf-cm, 80-108 lbf-ft} 2. Connect the harness to match the marks. Connect the battery cable. 3. Terminal nut tightening torque: 16.2-22.0 N-m {165-225 kgf-cm, 12-16 lbf-ft} for "B" terminal. 1.9-2.4 N-m {19-25 kgf-cm, 1.4-1.8 lbf-ft} for "C" terminal.

OTHER PARTS IMPORTANT POINT- INSPECTION AND REPAIR Refer to CHAPTER EE, ELECTRICAL EQUIPMENT and CHAPTER TE, TOTAL ELECTRONICS SYSTEM.

EN-92 Hino K13C Hino K13D

ENGINE

ENGINE TUNE-UP METHOD FOR DETERMINING IF THE NO.1 PISTON IS AT THE TOP DEAD CENTER ON COMPRESSION STROKE. NOTE: o Turn the crankshaft to align the mark "1/6" on the flywheel with the pointer of the flywheel housing. o In this position the No.1 or No.6 piston is at the top dead center on compression stroke. The pointer and mark "1-6" are engraved on some model timing gear cover and on the torsional damper, so use these pointer and marker if so equipped when adjusting the engine.

Move both the intake and the exhaust rocker arms of the No.1 or No.6 cylinder by hand; if both rocker arms can be moved, the piston is at top dead center on the compression stroke. If the injection timing mark is nearly aligned with the pointer, the No.1 piston is at top dead center on compression stroke.

NOTE:

PUSH RODS: MOVE (COMPRES SION STROKE)

PUSH RODS STANDING (OVERLAP PING STROKE)

If not, turn the crankshaft one complete revolution and align the marks as above.

While locking the push rods of No.1 and No.6 pistons, turn the crankshaft counterclockwise and clockwise about 30° to 40° as shown in the figure. If the piston whose exhaust and intake push rods do not move during the interval, it is at the top dead center on compression stroke. If the piston whose push rods have moved, it is at the completion of the exhaust and begun of the intake stroke (overlapping stroke).

NOTE: Always loosen the lock nut and raise the adjusting screws fully to the top. If the adjusting screws are too low, the piston and valves may strike each other during valve clearance adjustment.

SM3-F0263

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Hino K13C Hino K13D

EN-93

ENGINE VALVE CLEARANCE

[Valve clearance adjusting procedures] BEFORE ADJUSTING 1. 2.

3. SM3-K0024

Before adjusting, make sure that the heads and the rocker support bolts are tightened with the specified torque. Make sure that there are no foreign matter and dust be tween the cross heads and the valve stems, and between the rocker arms and the cross heads. Set the piston in the particular cylinder to adjust for top dead center on the compression stroke.

ADJUSTING 1.

With the No.1 piston positioned at top dead center on com pression stroke, adjust the No.1 valve clearance using a thickness gauge. The thickness gauge should move with a very slight pull.

Valve Clearance (When cold):

Intake

Exhaust

Unit: mm {in.} 0.4{0.0157} (K13C-Tl 0.4{0.0157} (K13D-T) 0.5{0.0197} (K13C-T) 0.4{0.0157} (K13D-T)

VALVE CLEARANCE

Adjust the other valves. ° Turn the crankshaft counterclockwise 120 viewed from fly wheel side. Adjust the valve clearance for each cylinder in the firing order.

Firing order: 1-4-2-6-3-5 SM3-715

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Hino K13C

EN-94 Hino K13D

ENGINE INJECTION TIMING

TIMING MARK

INSPECT THE INJECTION TIMING. FLYWHEEL POINTER 0

t->-...-+➔ A BTDC

Turn the crankshaft counterclockwise viewed from the fly wheel side. Align the injection timing mark "A° " on the flywheel or crankshaft pulley damper before top dead cen ter for No.1 cylinder on compression stroke with the pointer. Injection timing (A 0 ): Refer to SECTION DATA AND SPECIFICA TION. 1.

SM3-K0025

Check that the injection timing mark (the scribe line, not the notch) on the timer housing is aligned with the pointer (the scribe line) timing plate on the pump housing. If not, adjust the injection timing.

NOTE:

When adjusting the injection timing, refer to "FUEL INJECTION PUMP" for details.

AIR BLEEDING FROM FUEL SYSTEM 1. a. b. c. d.

Bleed air from the fuel filter. Loosen the bleeder plug on the fuel filter. Loosen the priming pump knob. Operate the priming pump knob until the air does not come out from the bleeder plug. Tighten the bleeder plug.

Tightening Torque: 4-5 N-m {40-60 kgf,cm, 3-4 lbf,ft} NOTE: 2. 3.

The bleeder plug should be tightened while the priming pump knob is operated.

Once again, operate the priming pump knob several times. Push back the priming pump knob and tighten it.

NOTE: Wipe off any splashed fuel.

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Hino K13C Hino K13D

ENGINE

EN-95

INJECTION NOZZLE INSPECT AND ADJUST THE INJECTION PRESSURE. Refer to "INJECTION NOZZLE" in section FUEL SYSTEM. TEST THE SPRAY PROFILE. Refer to "INJECTION NOZZLE" in section FUEL SYSTEM. TEST THE FUEL LEAKAGE. Refer to "INJECTION NOZZLE" in section FUEL SYSTEM. S6-K13-0081

THERMOSTAT

EXAMPLE

INSPECT THE THERMOSTAT FUNCTION.

STIRRING ROD

THERMOMETER

1. 2. 3.

HEATER�

S6-K13-0082

Place the thermostat in hot water and check the opening temperature and the lift. Using a thermometer, check to see the thermostat opens at ° the specified temperature: 74.5-78.5 C {166-173"F}. Immerse the thermostat in hot water of a temperature of 90"C {194"F}, and measure the lift of the pellet after a period of 5 minutes using vernier calipers. Measure the position of the bottom of the pellet before and after heating the thermostat.

Lift: At least 10 mm{0.4 in.} [90"C {194'F}] Tl: Valve opening temperature T2: Valve opened temperature

10 mm {0.4 in}

Immerse a heated thermostat in water of normal tempera ture. If it remains even slightly open, it is defective and must be replace. Refer to "THERMOSTAT" in section COOLING SYSTEM.

LIFT

o•c Tl

,o·c

{50°F}

TEMP.S6-K13-0083

COOLANT FILLER CAP INSPECT THE COOLANT FILLER CAP FUNCTION.

S6-K13-0084

Check the coolant filler cap using cap tester. Cap pressure: 0.5: 39.23-58.83 kPa {0.4-0.6 kgf/cm2 , 5.69-8.53 lbf/in2} 0.9: 73.55-102.96 kPa {0.75-1.05 kgf/cm2, 10.67-14.93 lbf/in2} NOTE: o The cap pressure is shown on the coolant filler cap, and it should be confirmed. o If the cap pressure is incorrect, there is a risk of abnormally high pressure being generated in the cool ing system, which may cause the hose to drop off or burst and, in turn, damage the engine. WARNING Do not remove the cap while the engine and cooling system are still hot. If the cap is removed while the engine and cooling system are still hot, scalding water and steam under pressure can be blown out. This can result in personal injury.

EN-96

Hino K13C Hino K13D

ENGINE ENGINE STOP CONTROL SYSTEM WITH SOLENOID INSPECTION OF SOLENOID AND LINK ROD. SOLENOID \

NUT (cl

Connect the battery to the solenoid terminals and confirm that the link rod is pulled by the solenoid. Push fully the solenoid plunger by hands and confirm that there is a clearance between the stopper and the stop lever.

Standard clearance: 2-3 mm {0.07874-0.1181 in} If there is no clearance, adjust it by the position of the link rod. NOTE: o If the clearance adjustment is unsatisfactory or the action of the solenoid is sluggish, solenoid will be burnt out and its output will be insufficient or insuffiÂ cient engine stoppage may result. o Install the link rod with its nut upward.

ENGINE STOP

LEVER

A S6-K13-0083

BOOST COMPENSATOR CANCEL SYSTEM WITH SOLENOID (IF SO EQUIPPED) INSPECTION OF SOLENOID AND LINK ROD.

BOOST COMPENSATOR CANSEL LEVER

1. 2.

Standard clearance: 2-3 mm {0.07874-0.1181 in} If there is no clearance, adjust it by the position of the link rod. NOTE: o If the clearance adjustment is unsatisfactory or the action of the solenoid is sluggish, solenoid will be burnt out and its output will be insufficient result. o Install the link rod with its nut upward.

S6-K13-0083

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ENGINE Hino K13C Hino K13D

EN-97

ENGINE TUNE-UP ON TEST BENCH NOTE: Starting the engine when the alternator is not connected to the battery may damage the alternator. Always conÂ nect to the battery.

RN ALTERNATOR

SM3-J741

SET THE ENGINE ASSEMBLY ON A TEST BENCH. 1. 2.

Add the proper amount of the specified engine oil through the oil filler cap on the cylinder head cover. Add coolant. Bleed out air from inside the coolant gallery through the cylinder block drain plug.

BLEED AIR FROM FUEL SYSTEM. CHECK THE INJECTION TIMING. SM3-F0333

SM3-F0334

Refer to "FUEL INJECTION PUMP". CHECK THE VALVE CLEARANCE. START THE ENGINE. NOTE: Before starting the engine, make sure that the fuel cut lever of the fuel injection pump operates normally.

FACE A

1. a. b.

SM3-F0335

Check the oil feed to rocker arms. Set the engine speed to 500-550 r/min. After starting the engine for one minute, oil should flow to the head (Face A) of all push rods and the head (Face B) of all valves. If it takes longer for the oil to flow to the rocker arm, various troubles such as seizing, abnormal wear and unusual noise may occur.

Hino K13C

EN-98 Hino K13D

ENGINE RETIGHTENING OF CYLINDER HEAD BOLT

S6-K 13-0087

w 0 Cf) a: <(

w 0 cii

--' w w I

w (9

ďż˝ i= SM3-K0005

Retighten the cylinder head bolts according to the following instructions. Retightening schedule ( 1) Retightening at the first 30 hours following servicing which involves the loosening or removal of any cylinder head bolt. Such servicing includes replacement of the cylinder head gasket, servicing of the valve gear parts, and the like. Retightening procedure (2) Step 1: Warm up the engine in the same way as in engine turning. Step 2: Following the cylinder head bolt tightening order as shown, loosen the first cylinder head bolt by 1/4 to1/ 2 turns as shown (S6-K13-0087), then tighten it to its specified torque. Repeat until all the bolts have been retighten. Tightening order, Tightening torque and special tool: Refer to "CYLINDER HEAD" in SECTION ENGINE MOVING PARTS. NOTE: o Be sure to loosen one bolt at a time, then retighten it before going on the next bolt. o By retighten, face pressure of cylinder head is reÂ stored from point B to C as shown. RECHECK THE VALVE CLEARANCE, WHEN ENGINE IS COLD.

Pressure on gasket just after assembling Pressure on gasket

I----+--+--"-+-",,--- Minimum necessary pressure on gasket Pressure drops after engine tiring

Engine firing -Time

S6-K 13-0088

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TURBOCHARGER

TU-1

Hino K13C Hino K13D

TU-Y66E-01

CHAPTER TU TURBOCHARGER DATA AND SPECIFICATION ......................................................... TU- 2 DESCRIPTION ............................................................................... TU- 2 TROUBLESHOOTING ................................................................... TU- 3 SPECIAL TOOL ............................................................................. TU- 4 OVERHAUL CRITERIA .................................................................. TU- 5 TURBOCHARGER ......................................................................... TU- 6

TU-2

TURBOCHARGER

Hino K13C Hino K13D

DATA AND SPECIFICATION

Parts No. .................................................................... 24100-1850, 24100-2100, 24100-2470 Type ............................................................................ RHC 7 Turbine type ............................................................... Radial flow type Blower type ............................................................... Centrifugal type Lubricating method .................................................. External lubrication type Bearing type .............................................................. Full floating type Maximum allowable continuous revolution .......... 120,000 r/min Direction of rotation ................................................. Counterclockwise as seen from the turbine side Maximum allowable continuous inlet temperature ............................................................... 750°C {1,382° F}

DESCRIPTION

C.i�--.--P

SM51-214

1. 2. 3. 4. 5.

Turbine case Turbine rotor Heat protector Bearing case Blower case 6. Blower impeller

A. Exhaust gas inlet B. Exhaust gas outlet

C. Oil inlet D. Oil outlet E. Air inlet

TURBOCHARGER

Hino K13C Hino K13D

TROUBLESHOOTING

Symptom Dense black smoke

TU-3

Possible cause

Remedy/Prevention

----,.----t Insufficient air intake • Air cleaner is choked with dust, causing ...... Disassemble and clean or greater intake air resistance. replace the air cleaner element. • Air inlet is choked . .......................................... Repair. • Air is leaking from intake manifold . .............. Repair. Turbocharger does not rotate smoothly. • Engine oil impurities deposited on rotor, ..... Overhaul and clean resulting in heavy rotation or sticking. turbocharger and/or change engine oil. Bearing sticking. • Insufficient lubrication or blockage of ........... Check lubricating oil system, lubricating oil lines. and/or repair. • Abnormal wear or damage of seal ring ........ Repair. caused by wear of journal bearing, due to insufficient lubrication. • Temperature of lubricating oil too high ........ Check cooling system. • Unbalanced rotating parts ............................. Check rotating parts. • Incomplete warming-up, failure to idle ......... Operate vehicle properly. before stopping engine, or jack rabbit starts. 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 like noise.

White smoke

Exhaust gas leaking before turbocharger, .... Check and repair connections. therefore insufficient revolution. Deformed or blocked exhaust gas lines ........ Repair. therefore insufficient revolution. Choking defects, or deformation of ............... Repair and replace the lines. oil return lines so that oil leaks around blower or turbine sides. Seal ring may be broken or worn due .......... Replace the thrust washer. to abnormal wear of thrust washer.

TU-4

Hino K13C Hino K13D

TURBOCHARGER Possible cause

Symptom

Remedy/Prevention

Gas leakage from exhaust system ................ Repair. Air leakage from air manifold ........................ Repair.

Poor response of turbocharger

-----�L-

Clogged air cleaner element .......................... Clean or replace. Turbocharger dirty or damaged ..................... Repair or replace. Carbon accumulation on the turbine ............ Change engine oil, clean side seal ring and heavy rotation turbocharger. Poor combustion ............................................. Check fuel system and improve combustion.

High pitched noise-- - -�-------1 Noise and vibration • So called "surging" ......................................... Overhaul and clean Surging sometimes occurs when the gas turbocharger. passage at the nozzle of the turbine housing is choked or when compressed air does not flow in proper responses to acceleration. • 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. unbalanced rotating parts, etc.

SPECIAL TOOL Prior to starting a turbocharger overhaul, it is necessary to have these special tools.

RADIAL PLAY GAUGE

BOOST PRESSURE GAUGE

ST-0259 09444-1230

BOOST PRESSURE GAUGE HOSE

ST-0081 09444-1250

ST-0082 17108-1040

TURBOCHARGER Hino K13C Hino K13D

TU-5

OVERHAUL CRITERIA CONDITIONS WHICH DETERMINE WHEN A TURBOCHARGER OVERHAUL 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 {176° F}. o Air cleaner element should be clean. WARNING When making a pressure test, be sure that personnel are adequately protected against any stream of pressurized air that might be released by a leak or the rupture of a house.

Special tools: Pressure gauge (09444-1250) Hose (17108-1040) 2.

Run the engine at maximum rpm.

Read boost pressure. If the boost pressure is below the normal value, turbo-

charger overhaul is needed. Boost pressure: Less than 15.69 kPa {0.16 kgf/cm2, 2.28 lbf/ in2 .} at no load with maximum revolution. OTHER FACTORS 1. 2. 3. 4. SM51-016

Noisy of excessive vibration of the turbocharger. Excessive engine oil consumption. Gas leakage at the turbine end or blower end. Oil leakage from the turbocharger.

TU-6

Hino K13C Hino K13D

TURBOCHARGER

OVERHAUL 7

T= 7.4-8.3 {75-85, 5.5-6.1}

T=A: 27.5-28.5 {280-290, 20.3-20.9} T=B: 27.0-29.0 {275-295, 19.9-21.3} SM51-228

T=Tightening torque: N-m {kgf-cm, lbf-ft} 1. 2. 3. 4. 5. 6.

Retainer ring Turbine rotor assembly Oil thrower Seal ring Back plate Lock plate

7. Blower case

8. Lock nut 9. Blower impeller 10. T hrust bearing 11. T hrust bushing 12. Journal bearing

13. 14. 15. 16. A. B.

Turbine case Turbine shaft Heat protector Bearing case 24100-1850, 24100-2470 24100-2110

IMPORTANT POINTS-INSPECTION 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.

SM51-133

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. Axial play A: 0.06-0.09 mm {0.0023-0.0035 in.} Service Limit:0.11 mm {0.0043 in.}

SM51-134

Hino K13C Hino K13D

TURBOCHARGER 3.

TU-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: Radial play gauge (09444-1230) Radial Play: 0.11-0.18 mm {0.004-0.007 in.} Service Limit:0.215 mm {0.0085 in.)

SM51-135

IMPORTANT POINTS-DISASSEMBLY REMOVE THE BLOWER CASE. NOTE: o Make matching marks on the blower case and bear ing case to aid alignment during reassembly. o If the blower case cannot easily be removed by hand, tap it carefully all around using a plastic ham mer 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.

SM51-217

REMOVE THE TURBINE CASE.

SM51-229

SM51-230

NOTE: o Make matching marks on the turbine, case and bear ing case to aid alignment during reassembly. o Because the bolts on the turbine side are exposed to high temperature, if they have seized, do not apply an unreasonable force to remove them be cause 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 and shaft. o If the turbine case cannot easily be removed by hand, tap it carefully all round using a plastic ham mer and carefully remove it. o Be careful not to drop the turbine shaft when re move the bearing case and turbine shaft.

TU-8

Hino K13C Hino K13D

TURBOCHARGER DISASSEMBLY THE BEARING CASE.

Remove the seal plate. Pull out the seal plate using the attachment and a sliding hammer. Remove the oil thrower from the seal plate.

,., I)

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.

Remove the retainer rings of each bearing.

NOTE: When removing the retainer ring, be careful not to dam足 age the front face of the hole in the bearing case.

Remove the bearings.

SM51-104

OIL THROWER

TURBINE ROTOR

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 POINTS-ASSEMBLY CLEAN ALL PARTS.

1. 2.

Before cleaning, the disassembled parts should be visu足 ally inspected to check for burning, abrasion, carbon de足 posits, gas and oil leakage. 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 at足 tack aluminum. o Never use a wire brush.

Hino K13C Hino K13D

TURBOCHARGER

TU-9

ASSEMBLE THE JOURNAL BEARINGS.

OIL INLET 0

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.

TURBINE ROTOR

Install the bearing in the bearing case.

NOTE: Apply clean engine oil.

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.

Repeat step 1) through 4) to install the second bearing.

SM51-147

�1 0

ASSEMBLE THE TURBINE ROTOR.

Install a new seal ring in the seal ring groove of the tur bine shaft. Position the heat protector on the bearing case.

HEAT PROTECTOR

�

SEAL RING

SM51-231

Coat the journals of the turbine rotor with clean engine oil and install the turbine rotor in the bearing case.

NOTE:

o o o

SEAL RING GAP SM51-223

The gap in the seal ring of the turbine shaft must face towards the oil inlet. Insert the seal ring concentric with the turbine shaft. If it is inserted with unreasonable force, it may be damaged. When inserting the turbine shaft, be very careful not to damage the journal bearing.

ASSEMBLE THE THRUST BEARING.

Install the thrust spacer on the turbine shaft.

NOTE: Lubricate thrust spacer surface.

Coat the thrust bearing with clean engine oil and install the thrust bearing.

NOTE: Always use new screws and lock washers.

SM51-128

SM51-221

TU-10

Hino K13C Hino K13D

TURBOCHARGER INSTALL THE SEAL PLATE. 1. 2.

Insert two new seal rings on the oil thrower. Install the oil thrower in the seal plate.

NOTE: T he openings of seal rings should be positioned as shown.

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.

FIT THE BLOWER IMPELLER ON THE TURBINE ROTOR AND TIGHTEN THE LOCK NUT. NOTE: Remember that this nut has left-hand threads.

SM51-224

INSTALL THE TURBINE CASE TO THE BEARING CASE, BEING SURE TO ALIGN THE MATCHING M ARKS. NOTE: Always use new lock plates. ASSEMBLE THE BLOWER CASE. 1.

SM51-225

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.

2. 3.

Rotate the blower impeller by hand to see if it turns smoothly. Refer to page TU-6. Check the turbine rotor for axial play (A). Refer to page TU-6. Check the turbine rotor for radial play using a special tool. Refer to page TU-7.

TU-11

TURBOCHARGER Hino K13C Hino K13D

INSPECTION AND REPAIR Unit: mm {in.}

Inspection Item

Limit

Standard

Remedy

Inspection Procedure

Turbine Shaft Outside Diameter

12.28 {0.4835)

Replace

Measure

Turbine Shaft Bend

0.011 {0.0004)

Replace

Measure

Seal Ring Groove Width of Turbine Shaft

1.63 {0.0642)

Replace shaft assembly.

SM51-034

Bearing Case Inside Diameter

18.55 {0.7303) B: 17.11 {0.6736)

Journal Bearing Inside Diameter

12.36 {0.4866)

Journal Bearing Outside Diameter

16.98 {0.6685)

Thrust Spacer Height

4.68 {0.1843)

Replace

ï¿½ SM51-036

Replace

SM51-037

Measure

SM51-008

Seal Ring Groove Width of Oil Thrower

G1:

1.75 {0.0689)

G2:

1.52 {0.0598)

Replace

TURBOCHARGER

TU-12 Hino K13C Hino K13D

Unit: mm {in.}

Inspection Item

Standard

Limit

Remedy

Inspection Procedure

Thrust Bearing Thickness

4.48 {0.1764)

Replace

Measure

Sealing Bore of Seal Plate

H1: 16.05 {0.6319) H2: 14.05 {0.5531)

Replace

Measure

SM51-038

H2 SM51-013

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FUEL INJECTION PUMP Hino K13C Hino K13D

IP-1 IP-Y191E-01

CHAPTER IP FUEL INJECTION PUMP

(Model: ZEXEL, P-TVPE)

DESCRIPTION ..................................................................... IP- 2 TROUBLESHOOTING ......................................................... IP- 3 SPECIAL TOOL ................................................................... IP- 6 INJECTION PUMP P-TYPE PUMP .............................................................. IP- 8 BOOST COMPENSATOR ................................................... IP-17 TIMER SP-TYPE TIMER .......................................................... IP-19 FEED PUMP FR/K-P TYPE FEED PUMP .......................................... IP-23 ADJUSTMENT .................................................................... IP-25

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FUEL INJECTION PUMP

IP-2 Hino K13C Hino K13D

DESCRIPTION

11 12 13 14 IIIL---+---15 16

8 9

SM4-762 FUEL INJECTION PUMP Nut Washer 0-ring Deflector Snap ring 0-ring 7. Camshaft

1. 2. 3. 4. 5. 6.

8. 9. 10. 11. 12. 13. 14.

Taper roller bearing Cover Delivery valve holder Delivery valve gasket Adjusting shim Delivery valve Flange sleeve

15. 16. 17. 18. 19.

Plunger barrel Plunger Control rack Control sleeve Tappet

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FUEL INJECTION PUMP Hino K13C Hino K13D

Symptom

IP-3

TROUBLESHOOTING Possible cause

Remedy/Prevention

Engine does not start ----,-----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 ........................ Repair connections. connections of fuel line between fuel tank and feed pump • Filter incorporated in inlet side ........................ Remove foreign material. of feed pump clogged • 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 ..................... Repair connection. cable to pump adjusting lever • 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 .................... Repair it. cable to pump stop lever Nozzle faulty • Fuel leakage caused by loosened .................... Inspect and tighten it. nozzle holder • 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 .............. Check engine timing and installation of pump correct it. • Woodruff key for pump camshaft cut off ........ Replace it. • Improper pre-stroke adjustment ...................... Correct it to obtain specified injection timing.

IP-4

Hino K13C Hino K13D

FUEL INJECTION PUMP Possible cause

Symptom

Remedy/Prevention

Excessive smoke-- - - - �-, Black smoke • Excessive fuel delivery caused by ................... Adjust fuel delivery on test incorrect adjustment of full-load stand. stopper screw • 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 ................ Correct it. irregular Bad fuel spray characteristic of nozzles .......... Check and repair them. Incorrect injection timing ................................. Correct it. Incorrect initial tension setting of .................... Adjust or replace it. idling spring or the spring broken Control rack not smoothly move ..................... Disassemble pump and repair it.

Engine always runs at high speed

Engine starts and stops

---�L-

Large spread in fuel delivery ........................... Adjust it. Plunger worn ..................................................... Replace it. Governor linkage not moving smoothly ......... Correct it. Defective feed pump ......................................... Disassemble and repair it. Accelerator cable sticking ................................ Check and correct it. . . Governor i·inkage st1c · king ................................ D1sassemble and repair · the governor. Control rack sticking ......................................... Check and correct it. Fuel lines clogged ............................................. Clean or replace fuel lines. Air in fuel caused by damaged fuel ................. Repair fuel lines or replace fuel lines or improper connection of fuel lines lines and gaskets.

Hino K13C Hino K13D Symptom

FUEL INJECTION PUMP Possible cause

IP-5 Remedy/Prevention

Engine has low power ------r--t Pump out of timing • Excessive advanced timing .............................. Check and correct it. resulting in loud knocking • Excessively retarded timing ............................. Check and correct it. resulting in black smoke • Defective injection pump overflow valve ....... Repair or replace it. • Feed pressure too low ...................................... Repair the feed pump. • Improper 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 ........................... Adjust it. nozzle holder, resulting in low opening pressure • Nozzle pressure spring broken ........................ Replace it. Pump faulty • Fuel leakage from delivery valve holder ......... Retighten the delivery valve holder if it is loosened or re place 0-ring if the 0-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 ................... Adjust it. full-load stopper screw Loud knocking------�- Improper injection timing ................................ Correct it. Bad fuel nozzle spray pattern ........................... Check and correct it. after-dribble High nozzle opening pressure ......................... Adjust the opening pressure. Incorrect fuel deliveries to . .............................. Readjust the fuel deliveries. some nozzles

IP-6

FUEL INJECTION PUMP

SPECIAL TOOL Prior to starting a fuel injection pump overhaul, it is necessary to have these special tools.

MEASURING DEVICE

BEARING REMOVER

ST-0294

MEASURING PLATE

ï¿½0267

09500-1160

09500-1310

09511-1330

SOCKET WRENCH

WRENCH

BRACKET

ST-0271 09511-1340

09511-1350

09511-1380

OUTER RACE PULLER

EXTRACTOR

MOUNTING DEVICE

ST-0273 09511-1700

09511-1710

09511-1800

CLAMP PLATE

EXTRACTOR

O-RING INSERT

ST-0275 09511-1820

ST-0276 09511-1830

09511-1850

FUEL INJECTION PUMP

HOLDING WRENCH

TAPPET HOLDER

ST-0278

IP-7

TIMER EXTRACTOR

ST-0280

ST-0279

09511-2040

09511-1930

TIMER HOLDER

HOLDING WRENCH

09511-1300

09511-1290

09511-1920

IP-8

FUEL INJECTION PUMP

P-TYPE PUMP

HINO K13C T INJECTION PUMP PARTS HINO K13D T INJECTION PUMP PARTS

OVERHAUL

= 107.88-117.67

{1,100-1,200, 80-86}

6- T = 39.23-44.12 {400-450, 29-32}

�

15 SM4-763

T = Tightening torque: N-m {kgf-cm, lbf,ft}

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Plunger block assembly 0-ring Delivery valve spring Gasket Delivery valve Plunger barrel Plunger Adjusting shim Collar 0-ring Deflector Snap ring

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

0-ring Valve holder lock plate Sleeve Oil seal Bearing cover Shim 0-ring Taper roller bearing Camshaft Control sleeve Upper spring seat Plunger spring

Lower spring seat Tappet Center bearing Taper roller bearing Bearing holder Shim Control rack Screw bushing Pin Delivery valve holder A. Injection pump No. plate

25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

FUEL INJECTION PUMP Hino K13C Hino K13D

IP-9

IMPORTANT POINTS-DISASSEMBLY WARNING o Breaking of the lead seals or crimp caps by anyone than HINO or pump manufacture authorized service stations to make these adjustment will void the warranty. o If fuel pump or governor difficulties are suspected, con sult only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injection pump lead seals and crimp caps can be rein stalled as required. o Measure and record the fuel delivery characteristics of the pump before disassembling it. o 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 T IMER ASSEMBLY. Refer to "SECTION TIMER". REMOVE THE GOVERNOR. Refer to "CHAPTER GV. 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 (09511-20401

SM4-765

3. 4.

Remove the bearing cover fixing bolt. Using the special tools, take out the bearing cover.

Special Tools: Bracket (09511-1380) Extractor (09511-1710)

IP-10

Hino K13C Hino K13D

FUEL INJECTION PUMP 5.

SM4-767

Remove the center bearing fixing bolts and pull out the camshaft with the center bearing.

SM4-768

REMOVE THE TAPPE T ASSEMBLY . 1. 2.

Set up the mounting device on bottom of the pump hous ing. Operate the lever to push up the tappet and pull out tap pet holder.

Special Tool: Mounting Device (09511-1800)

1n '-�'-:\----

,_;;---.;_7 '.J

=17:>--,- ��

!\ r-4

REMOVE THE LOWER SPRING SEAT WITH PLUNGER. Using small pincers, pull out lower spring seat together with plunger.

NOTE: P ut the plunger in order in a tray containing clean diesel fuel.

SM4-770

REMOVE THE PLUNGER SPRING, UPPER SPRING SEAT AND CONTROL SLEEVE. NOTE: To do this, it is essential to line up the sleeve ball with the groove in the pump housing; otherwise the con trol sleeve will not come out.

REMOVE THE PLUNGER BLOCK ASSEMBLY. Fasten extractor to the delivery valve holder, and remove the plunger block assembly.

Special Tool: Extractor (09511-1830) NOTE: P ut the plunger block assembly and adjusting shims in a tray containing clean diesel fuel, paired with cor responding plunger which was previously extracted. SM4-772

Hino K13C Hino K13D

FUEL INJECTION PUMP

IP-11

REMOVE THE CONTROL RACK. 1.

Using the wrench, remove the screw bush .

Special Tool: Wrench (09511-13501 2.

Remove the pin from the control rack and pull out the con trol rack.

DISASSEMBLE THE PLUNGER BLOCK ASSEMBLY. Fix the clamp plate in vise and place the plunger block assembly on it, then remove the delivery valve holder. Special Tool:

Clamp Plate (09511-18201

REMOVE THE TAPER ROLLER BEARING FROM THE CAM SHAFT. 1.

Remove the taper roller bearing from the drive end of the camshaft.

Special Tool: Bearing Remover (09500-1160)

Use the guide to remove the taper roller bearing at the governor side.

REMOVE THE OUTER RACE FROM THE BEARING COVER. Use the outer race puller to tap out the outer race from the bearing cover.

OUTER RACE PULLER

Special Tool: Outer Race Puller (09511-1700)

SM4-778

IP-12

Hino K13C Hino K13D

FUEL INJECTION PUMP

IMPORTANT POINTS-ASSEMBLY WARNING o Wash all parts with clean diesel fuel before installing o o

o o

them, and any defective or damaged parts must be re placed. Do not allow dust or other foreign matter to enter the pump during assembly. Apply grease to O-rings and oil seals before installing them. Assemble the parts in correct order and to correct tight ening torques, assembled dimensions etc. Assembly takes place in the reverse order of disassembly.

ASSEMBLE THE PLUNGER BLOCK. 1.

Before installing the plunger barrel, inspect the plunger barrel and plunger for wear, scratches, or discoloration.

Tilt the plunger to about 60 . Pull the plunger out approxi mately 10-15 mm {0.39-0.59 in} and release it to see if it slides down smoothly from its own weight.

Assemble the plunger barrel into the flange sleeve.

SM4-780

NOTE: Be sure that the knock pin of the flange sleeve is fit ted into the guide groove on the plunger barrel.

SM4-781 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.

Hino K13C Hino K13D

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 .

Install the collar, 0-ring, deflector, ring and 0-ring.

NOTE: The deflector should not be installed upside down with the hole near to its lower edge. O-RING

RING .,,__...,-- O-RING

SM4-783

Install the small 0-ring in the housing by with the inserter.

Special Tool: O-ring Inserter (09611-1850)

n L----------

()

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)

SM4-785

NOTE: Tightening should be made in three steps in the order of 117.68 ➔ 0 ➔ 117.68 ➔ 0➔ 117.68 N-m {1,200, 87} {1,200, 87} {1,200, 87} {kgf-cm, lbf-ft}

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

IP-14

Hino K13C Hino K13D

FUEL INJECTION PUMP INSTALL THE CONTROL RACK AND THE CONTROL SLEEVE. Assemble the control sleeve, inserting it until the ball on the sleeve is perfectly 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 SPRING SEAT, THE PLUNGER SPRING AND THE PLUNGER. Insert the plunger in the barrel. Make sure that the alignÂ ing 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. Use the mounting device to press in the tappet and hold it in with the tappet holder.

Special Tools: Mounting Device (09511-1800) Tappet Holder (09511-2040)

INSTALL THE CAMSHAFT. Place the center bearing on the camshaft and insert the camshaft into the pump housing.

SM4-768

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 camshaft starts).

Special Tool: Measuring Plate (09511-1330) Standard length:

13.3-14.3 mm {0.524-0.563 in}

Hino K13C Hino K13D

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.

SM4-789 MEASURE 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)

If the specification is not met, use appropriate shim plates at the drive end of camshaft until the specification is met.

BEARING COVER

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 "SECTION TIMER". INSTALL THE GOVERNOR. Refer to "CHAPTER GV. GOVERNOR".

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

IP-16

FUEL INJECTION PUMP

Hino K13C Hino K13D

INSPECTION AND REPAIR Unit: mm {in}

Inspection item Tappet Wear

Standard

Limit

Remedy

0.2 {0.008}

Replace, tappet assembly.

Inspection procedure Measure. TAPPET ROLLER ROLLER BUSHING ROLLER PIN SM4-793

Tappet Surface Wear

Camshaft Wear

0.2 {0.008}

Replace, tappet.

Replace, camshaft.

Visual check KEY GROOVES

OIL SEAL CONTACT SURFACE SM4-795

Roller and Center Bearing Wear, any Other Damage

Replace, if necessary.

Visual check

SM4-796

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

FUEL INJECTION!P�UM��p

-------�

IP-17

BOOST P C��UENSATOR IPPEDI (IF SO � �---

Hino K13C Hino K13D

1_ 2_ 3_ 4.

Cover Eye bolt Screw Plug

5_ 6. 7. 8.

9. Spring

Screw Plug Nut Nut

A. Manual start increase lever

ADJUSTMENT OF BOOST CO MPENSATOR. 1. 2.

Inst ll the ·r hose to cover (1) w1"th eye bolt (2). a a Securely t1g . ,hten the mew (3).

NOTE: Manual start increase lever is at usual pos�lon.

3. 4.

Remove the plug . terfere w1"th Loosen the scr \�; and maintain it n �� the control rac . ee that it is not over f�� to fall off.

IP-18

Et .sz

Hino K13C Hino K13D

FUEL INJECTION PUMP

PUMP REVOLUTION: Na r.p.m. Rbt-----------c.------

Remove the plug (6) and install the measuring devise. (105782-6130)

Adjustment of the position at start to move. (1) Maintain the pump speed at "Na" (500 rpm in case of nothing to note). Fix the control lever to full load po足 sition.

0 E Cf) 0 Q. '"' u <( a: _j 0 a: f足 z 0 u

BOOST PRESSURE (mmHg)- SM4-801

(2) When boost pressure is "P1 ", and control rack start to move from "Ra", fix the screw (3) with nut (7).

rf .sE LJ.J a: ::::, Cf) Cf) LJ.J a:

7. PUMP REVOLUTION Rs

Rb Ra

Adjustment of boost compensator stroke. Maintain the pump revolution at "Nd" rpm, under boost pressure is not acting condition. Then adjust the control rack position to "Ra" from "Rb" with screw (5) and lock with nut (8).

NOTE:

Use measuring devise (105782-6090).

fCf)

0 0 (lJ

CONTROL RACK POSITION (mm) -

..sLJ.J a: ::::, Cf) Cf) LJ.J a:

t;:; 0 0 (lJ

SM4_803

-------------#

PUMP REVOLUTION: Na r.p.m. I

Rat-----<

CONTROL RACK POSITION (mm)

-SM4_804

Confirm the control rack position "Ra" when boost pres足 sure is "Pl". Increase the boost pressure to "P2" then confirm the con足 trol rack position is "Rb". If it does not work out to the above condition, replace the spring (9).

FUEL INJECTION PUMP

Hino K13C Hino K13D

IP-19

TIMER

SP-TYPE TIMER

OVERHAUL T = 21.58-23.53 {220-240, 16-17} T = 127.49-147.09 {1,300-1,500, 95-1081

T = Tightening torque: N-m {kgf-cm, lbf-ft}

SM4-805

1. 2. 3. 4. 5. 6. 7. 8. 9.

Screw plug Gasket Plug Timer body 0-ring Timer weight Bushing Roller Spacer

10. 11. 12. 13. 14. 15. 16. 17.

Timer spring Round nut Shim Support Retainer Hub Oil seal Timer cover

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

IP-20

Hino K13C Hino K13D

FUEL INJECTION PUMP

IMPORTANT POINTS-DISASSEMBLY REMOVE THE TIMER FROM THE INJECTION PUMP.

1. a) b) 2.

Remove the screw plug. Drain the lubricating oil from the timer. Remove the plug. Remove the round nut.

Special Tool: Holding Wrench (09511-1930)

Remove the timer from the injection pump using the timer extractor.

Special Tool: limer Extractor (09511-1920)

SM4-807

DISASSEMBLE THE TIMER. 1. 2.

Secure the timer holder in a vice. Fit the timer on the timer holder.

Special Tool: limer Holder (09511-1300)

Remove the timer cover with oil seal.

Remove the spacer, roller and bushing from the flyweight.

Special Tool: Holding Wrench (09511-1290)

SM4-810

Hino K13C Hino K13D

FUEL INJECTION PUMP 5.

Pull the hub of the timer body.

Remove the support from the timer weight.

NOTE:

IP-21

The support is equipped with a slim for the t imer spring.

SM4-812

Remove the timer weight from the timer body.

SM4-813

IMPORTANT POINTS-ASSEMBLY ASSEMBLE THE TIMER.

Install the timer weight, support and shim.

Special Tool: Timer Holder (09511-1300)

SM4-812

Install the timer spring and timer hub.

NOTE:

The key groove on the timer hub should be positioned opposite (away from) the screw plug (oil port) of the timer hub.

Install the roller and bushing.

Special Tool: H olding Wrench (09511-1290)

SM4-810

IP-22

Hino K13C Hino K13D

FUEL INJECTION PUMP 4.

Install the timer cover.

NOTE: Apply the anaerobic adhesives on time cover set bolts threads.

INSTALL THE TIMER ON THE INJECTION PUMP BODY. 1.

Install the key in the camshaft, and insert the timer. Then, install the conical spring washer and round nut.

NOTE: Be sure concave side of the conical spring washer faces the pump body.

CONICAL SPRING WASHER

SM4-814

Tighten the round nut.

Fill the timer with gear oil.

Special Tool: Holding Wrench (09511-1930)

Oil capacity: 250-270 cm3 {15.3-16.4 cu.in} 4. 5.

Tighten the screw plug. Install the gasket and plug, then tighten the plug.

FUEL INJECTION PUMP

HINO K13C T FUEL FEED PUMP HINO K13D T FUEL FEED PUMP

IP-23

FP/K-P TYPE FEED PUMP

OVERHAUL

T = 39.23-44.12 {400-450, 29-32}

5------------

T = 39.23-44.12 {400-450, 29-32}

T = 12.75-14.70 {130-150, 9-10} for M14, Nylon gasket T = 19.62-24.51 {100-250, 14-18} for M14, Comet packing, Copper gasket T = 24.52-29.41 {250-300, 18-21} for M18

K.:'_::,_}---6 �t-----7

11-----8

�

13 9

T = Tightening torque: N-m {kgf-cm, lbf-ft} SM4-817

1. 2. 3. 4. 5. 6. 7. 8.

Retainer ring Tappet Plug O-ring Priming pump Gasket Spring Check valve

9. Joint bolt 10. Gasket 11. Housing 12. Push rod 13. Piston 14. Spring 15. Gasket 16. Plug

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

IP-24

Hino K13C Hino K13D

FUEL INJECTION PUMP

IMPORTANT POINTS-DISASSEMBLY REMOVE THE TAPPET. Remove the retainer ring and pull out the tappet.

SM4-818

REMOVE THE FILTER F RO M INLET PIPE JOINT. Clean the filter with clean diesel fuel.

IMPORTANT POINTS-ASSEMBLY INSTALL THE TAPPET. INSTALL THE RETAINER RING.

SM4-820

INSTALL THE PISTON. Insert the push rod, piston and spring in the housing and screw in the plug with a new gasket.

INSTALL THE CHECK VALVE AND P RI MING PUMP.

Hino K13C Hino K13D

FUEL INJECTION PUMP

IP-25

ADJUSTMENT PREPARATION 1.

Mount the injection pump correctly on the pump tester.

Attach a rack measuring device to the control rack and set to "0". Install calibration nozzles and lines.

Nozzle and lines: Refer to "CHAPTER C. CALIBRATION".

SM4-824 ADJUST THE PRE-STROKE OF NO. 1 PLUNGER. 1. 2. 3.

Remove the 1st cylinder delivery valve holder, spring deÂ livery 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 1st cylinder to its bottom dead cenÂ ter, and set the dial indicator zero.

SM4-825

OVERFLOW PIPE

HIGH PRESSURE

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.

Move the angle dial to set the 1st cylinder of the pump to bottom dead center and adjust the pre-stroke gauge to zero.

SM4-826

SM4-827

Hino K13C Hino K13D

IP-26

·FUEL

PLUNGER BARREL

. -e,e SIBO�e

FUEL INJECTION PUMP 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.

Pre-stroke:

Refer to "CHAPTER C. CALIBRATION".

" SM4-828 ·---�·

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 in jection. ° ° Injection Interval: 59 45'-60 15' Injection Order: 1-4-2-6-3-5

If the injection intervals are not within specification, ad just the intervals in the same manner as pre-stroke adjust ment.

Set the No. 1 cylinder at the injection starting point, and check that the marks on the timer 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.

Hino K13C Hino K13D

FUEL INJECTION PUMP

IP-27

MEASURE AND ADJUST THE INJECTION VOLUME. 1.

Measure the injection volume for each control rack posi tion and pump speed.

Injection volume: Refer to "CHAPTER C. CALIBRATION".

SM4-832

To adjust the injection volume, loose the flare nut of injec tion pipe and the lock nut of the plunger block assembly and turn to left or right the plunger block assembly.

SM4-833

INSPECT AND ADJUST THE TIMER ADVANCE. 1. 2.

Set a stroboscope on a pump tester. Check the timer advance.

Advance angle:

Refer to "CHAPTER C. CALIBRATION".

If angle in not within specification, adjust with proper shim.

SM4-835

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

MEMO

GOVERNOR

GV-1 GV-Y38E-03

CHAPTER GV INJECTION PUMP

HINO K13C T GOVERNOR HINO K13D T GOVERNOR

MODEL: ZEXEL, RSV DESCRIPTION ............................................................................. GV- 2 SPECIAL TOOL ........................................................................... GV- 3 GOVERNOR ................................................................................ GV- 4

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

GV-2

GOVERNOR

Hino K13C Hino K13D

DESCRIPTION

[MODEL: RSV]

SM4-742

Representative model RSV

1. 2. 3. 4.

5. 6. 7.

Governor spring Control rack Knuckle Swivel lever Maximum speed stopper bolt Camshaft Control lever

10. 11. 12. 13. 14.

Stop lever Supporting lever Flyweight Sleeve Link Start spring Guide lever

15. 16. 17. 18. 19.

Tension lever Idle subspring Full load stopper bolt Idle spring Floating lever

Explanation of governor stated this shop manual is basic models. See to "Chapter C", CALIBRATION about adjusting points.

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

GOVERNOR Hino K13C Hino K13D

Prior

GV-3

SPECIAL TOOL

to starting an injection pump governor overhaul, it is necessary to have these special tools.

FLYWEIGHT EXTRACTOR

ROUND NUT WRENCH

ST-0265

09511-1900

09511-1500

GV-4

GOVERNOR

Hino K13C Hino K13D

GOVERNOR

[MODEL: RSV]

SM4-743

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Governor housing Maximum speed stopper bolt Woodruff key Flyweight Sleeve Bearing Shim Guide lever Link Start spring Supporting lever Tension lever Full load stopper bolt

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Idle spring (Idling screw) Lock nut Governor cover Swivel lever Governor spring Gasket Pin Plug Control lever Woodruff key Collar Oil seal Bushing

27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

0-ring Snap ring Stop lever Cap Idle stopper bolt Idle subspring (Idling subsetting screw) Nut Cap nut Closing cover 0-ring Cap nut

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

GOVERNOR Hino K13C Hino K13D

GV-5

IMPORTANT POINTS-DISASSEMBLY WARNING o B reaking of the lead seals or crimp caps by any other than HINO or pump manufacture authorized service sta tions to make these adjustment will void the warranty. o If fuel pump or governor difficulties are suspected, con sult only HINO or pump manufacture authorized service stations, where the problem can be corrected and the injection pump lead seals and crimp caps can be rein stalled as required. REMOVE - THE GOVE RNOR COVE R FROM PUMP BODY. 1.

Remove the shackle from the control rack.

NOTE : W hen removing the governor cover fitting bolt, hold the governor cover.

Disconnect the start spring.

REMOVE THE FLYWEIGHT ROUND NUT. NOTE: Use the holding wrench to keep the camshaft from rotating. Special Tool: Round Nut Wrench (09511-15001

SM4-746

REMOVE THE FLYWEIGHT, USING THE FLYWEIGHT EXTRACTOR . Special Tool: Flyweight Extractor (09511-1900)

GV-6

GOVERNOR

Hino K13C Hino K13D

IMPORTANT POINTS-ASSEMBLY WARNING

o Wash all parts with clean diesel fuel before installing them, and any defective or damaged parts must be replaced.

o Do not allow dust or other foreign matter to enter the pump during assembly .

o Apply grease to O-rings and oil seals before installing them. o Assemble the parts in correct order and to correct tight ening torque, assembled dimensions etc.

o Assembly takes place in the reverse order of disassembly.

INSTALL THE ADJUSTING LEVER. Install the shaft of the adjusting lever so that wide side of the shaft head surface is toward the pump body. NOTE: I nstalling in reverse may cause the floating lever to contact the speed control spring, resulting in opera tional malfunction.

TOWARD PUMP HOUSING

SM4-748

CHECK THE GOVERNOR LINKAGE FOR SMOOTH OPERATION.

Hook under the guide lever, and pull upwards, using a spring balance. Starting force:

140-180 g {4.9-6.3 oz}

SM4-749

INSTALL THE F LYWEIGHT TO PUMP CAMSHAF T. Using the special tool, tighten the round nut. Special Tool: R ound N ut Wrench (09511-1500)

SM4-746

INSTALL THE GOVERNOR HOUSING TO PUMP BODY. 1. 2.

SM4-750

Connect the start spring. Connect the shackle to control rack.

GOVERNOR Hino K13C Hino K13D

GV-7

ADJUSTMENT OF THE GOVERNOR [MODEL: RSV] PREPARATION 1. 2. 3. 4.

Connect the rack measuring device to the control rack and set to "O". Connect the fuel line. Refill the camshaft chamber with engine oil. Install the angle gauge on the adjusting lever.

STEPS IN GOVERNOR ADJUSTMENT. Perform governor testing and adjustment in the following sequence (For values on N and R, refer to "CHAPTER C. CALIBRATION").

MAXIMUM SPEED STOPPER BOLT SWIVEL LEVER ADJUSTING SCREW

1. 2. 3. 4. 5.

Adjustment of maximum speed control. Adjustment of speed. (reduce) Adjustment of idling speed control. Adjustment of torque control. (If so equipped) Adjustment of boost compensator. (Refer to "CHAPTER FUEL INJECTION PUMP BOOST COMÂ PENSATOR.")

FULL LOAD STOPPER BOLT

STOP LEVER

IDLING SUB SETTING SCREW

SM4-751

ADJUSTMENT OF MAXIMUM SPEED CONTROL NOTE: The control lever should be in full load position.

E 5 z B Ra 1------.....---,

Adjust the full load stopper bolt. a) At a pump speed of Na r/min, adjust the rack position to Ra mm with the full load stopper bolt.

Adjust the maximum speed stopper bolt. a) At a pump speed of Nb r/min, adjust the rack position to Rb mm with the maximum speed stopper bolt.

u5 0 (L

"' u <{

a:: Q '-- .._ ___ N a

PUMP SPEED (r/min)

E 5 z

0 f'= u5

FULL LOAD STOPPER BOLT

SM4-752

----.

O _____ _..._b_ N PUMP SPEED (r/min)

NOTE: The control rack should start to be pulled.

SM4-753

Hino K13C Hino K13D

GV-8

GOVERNOR ADJUSTMENT OF SPEED (REDUCE) At a pump speed of Ne r/min, adjust rack position to Re mm with the swivel lever adjusting screw.

SWIVEL LEVER ADJUST SCREW PUMP SPEED (r/min)

SM4-754

0 E Cf) 0 Q.

'"' u <( 0: _J 0 0: f z 0 u

ADJUSTMENT OF IDLING SPEED CONTROL. 1. With the pump not operating, position the control lever so that the control rack position is Rf mm. 2. Operate the pump at Nd r/min, and adjust the idling subspring with a screwdriver so that the control rack posi tion is Rd mm. 3. Lock it with the nut.

o�--:-,N�d------PUMP SPEED (r/min) - SM4-755

�t

0 E Cf) 0 Q.

Rg -- Ra

'"'

u <( a: _J 0 a: f z 0 u

o -----�------

Ng PUMP SPEED (r/min) - SM4-758

NOTE: o If the idling subspring is o vertightened, engine speed will exceed specifications at no-load maxi mum speed, resulting in engine damage. o The control lever angle, refer to "CHAPTER C. CALI BRATION".

ADJUSTMENT OF TORQUE CONTROL (IF SO EQUIPPED) 1. Operate the injection p ump at a speed slightly less than Ng r/min. 2. Set the control lever so that it contacts the maximum speed stopper bolt. 3. Install the torque control spring capsule in the tension le ver and adjust using the wrench so that the control rack moves from Ra mm to Rg mm. 4. Set the torque control spring capsule in this position us ing the lock nut.

Hino K13C Hino K13D

GOVERNOR 5.

GV-9

Increase pump speed to Nh (Ni) r/min and set the torque control spring so that the control rack position is Rh (Ri) mm.

NOTE: In case of shim(sl adjusting type, adjust by replacing the shim(s).

�

Ag O t Rh E Ra en

� "' u <( a: _J 0 a: f z 0 u

O'------,-N"'"h_____ PUMP SPEED (r/min) - SM4-760

�t E

en 0 Q_ "' u <( a: _J 0 a: f z 0 u

6. TORQUE CONTROL STROKE: Rg-Ra

Rg--Ra ---

�

--1-- -1 I I

O'----""Ng-----,N_..a____

PUMP SPEED (r/min) - SM4-761

Gradually increase the pump speed and confirm that pump speed is Na r/min when the control rack position reaches Ra mm. Gradually decrease pump speed and confirm that pump speed and confirm that pump speed is Ng r/min when the control rack position reaches Rg mm.

NOTE: o If the torque control stroke is not to specifications, readjust the torque control spring capsule. o If Ng and Na are not to specifications, replace the torque control spring capsule.

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

MEMO

GE-1

GENERATOR GE-Y151E-02

CHAPTER GE GENERATOR

(24V-45A)

DATA AND SPECIFICATION ................................................ GE- 2 DESCRIPTION ...................................................................... GE- 2 TROUBLESHOOTING .......................................................... GE- 3 OVERHAUL .......................................................................... GE- 4

GE-2

GENERATOR

DATA AND SPECIFICATION Nominal voltage

24V

Nominal output

24V-45A

Max. output

45A at 28V, 5,000 r/min

Max. idling speed

900 r/min at 27V

Max. rotating

8,400 r/min

Rotating direction

Clockwise(seen from pulley side)

Regulator

Mount-on

DESCRIPTION

5 6

SM21-037

1. 2. 3. 4. 5.

Rotor shaft Ball bearing Rotor assembly Stator assembly Diode assembly

6. 7. 8. 9.

Rear cover Rear bracket assembly I.C.regulator Front bracket assembly

GENERATOR

GE-3

CHARGING SYSTEM CIRCUIT

ďż˝

SM21-036

1. 2. 3. 4.

Generator I.C. regulator Coupler Charging warning lamp

Symptom Ammeter does not move to negative side (remains at the neutral position) . h to be wit . h starter sw1tc turned on and engine off.

5. Starter switch 6. Load 7. Battery

TROUBLESHOOTING

Possible cause

Remedy/Prevention

Fuse blown ....................................................... Determine cause and replace fuse. . . . Wiring connection loose ................................. Tighten loose connections. . . IC regulator faulty ............................................ Replace IC regulator.

Ammeter indicates the- - ďż˝ - -Drive belt loose or worn ................................. Adjust or replace drive belt. negative side with starter Battery cable loose, corroded or worn .......... Repair or replace cables. switch on and engine running Fuse blown ....................................................... Determine cause and replace . fuse. Fusible link blown ........................................... Replace fusible link. IC regulator or alternator faulty ..................... Check charging system. Wiring faulty .................................................... Repair wiring.

GENERATOR

GE-4

OVERHAUL 1824N 1-No.58

T = 3.3-4.4 {33-45, 2.4-3.2}

0��20

✓

/28-156 T,�3�0-1,600, 94-115} SM21-033

T = Tightening torque: N-m {kgf-cm, lbf-ft}

1. Cover 2. Insulator 3. Plate

4. Coupler assembly 5. Rectifier assembly 6. I.C. regulator

7. Needle roller bearing

8. Rectifier end frame

9. Field coil assembly 10. Stator coil assembly

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Through bolt Rotor assembly Retainer plate Felt Felt cover Ball bearing Drive end frame Collar Fan Pulley

GENERATOR

GE-5

IMPORTANT POINTS-DISASSEMBLY REMOVE THE I.C. REGULATOR AND RECTIFIER. Unsolder the soldered part of these lead wires.

SM21-004

REMOVE THE ROTOR. 1. Place the pulley in a soft jaw vise. Remove the fan and pulley. NOTE: Do not hold the rotor assembly in a vise when disasÂ semble the fan and pulley.

SM21-005

Remove the rotor. Using a press, remove the rotor and collar.

SM21-006

REMOVE THE BALL BEARING. 1. Remove the retainer plate. 2. Using a press, remove the ball bearing. 3. Remove the felt cover and felt.

SM21-007

REMOVE THE NEEDLE ROLLER BEARING. Using a press, remove the needle roller bearing.

SM21-008

GE-6

GENERATOR

IMPORTANT POINTS - TESTING RECTIFIER

Test the each positive side rectifier condition.

Rectifier Terminal - Lead + Lead

Holder + Lead - Lead

Resistance About 7-10

con

Test the each negative rectifier condition.

Rectifier Terminal - Lead + Lead

Holder + Lead - Lead

Resistance

con

About 7-10 n

SM21-010

IMPORTANT POINTS - ASSEMBLY !INSTALL THE I.C. REGULATOR, CONNECTOR AND COUPLER.

1. 2.

Solder the I.C. regulator lead wire. Solder the connector lead wire.

NOTE: Protect rectifier from heat.

SM21-004

INSTALL THE BALL BEARING. 1. 2. 3.

Install the felt and felt cover. Using a press, install the ball bearing. Install the retainer plate.

INSTALL THE ROTOR. 1.

SM21-013

Using a press, install the rotor.

GENERATOR 2.

GE-7

Place the pulley in a soft jaw vise. Install the collar, fan and pulley.

NOTE:

Do not hold the rotor assembly in a vise when as semble the fan and pulley.

SM21-005 PERFORMANCE TEST NOTE: o 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 a large current to flow through and damage the diodes and IC regulator as well as burning the wiring harness. o Take care not to make wrong connections of termi nals. o When charging the battery with a quick charge, dis connect the battery terminals. o Do not perform tests with high voltage insulation resistance tester. o When in operation, never disconnect the battery.

SW2

a: 0

sw, V

GENERATOR PERFORMANCE TEST

2. 0 <( 0 _J

Turn switch SW, on and SW2 off to increase the revolu tion of the generator slowly. When voltage reaches 28V, turn on switch SW2 to regulate load resistance. Increase the revolution of the rotor keep ing voltage at 28V.

Standard output speed: 4,000 r/min at 27.5V 45A

w (.'J�-��

SM21-015A

VOLTAGE REGULATOR TEST

Turn switch SW, on and SW2 off to increase the revolu tion of the rotor to 4,000 r/min

Standard voltage: 28.0-29.0V

GE-8

GENERATOR

INSPECTION AND REPAIR

Inspection Item

Standard

Limit

Remedy

Inspection Procedure

Resistance of the rotor coil

Continuity

If no continuity, replace the rotor coil.

Conductance of the stator coil wire

Continuity

If no continuity, replace the stator coil assembly.

Measure.

If continuity, replace the stator coil assembly.

Measure.

Replace.

Measure.

Insulation between the stator coil wire and the body

Condenser capacity

No continuity

0.5 ÂľF

GE-1

GENERATOR GE-Y152E-02

CHAPTER GE GENERATOR

(24V, 20A)

GE-2

GENERATOR

DATA AND SPECIFICATION 24V 24V-20A 20A at 28V, 5,000 r/min 900 r/min at 27V 7,200 r/min

Nominal voltage Nominal output Max. output Max. idling speed Max. rotating Rotating direction

Right (seen from pulley side)

Regulator

Mount-on

DESCRIPTION 1

SM21-223

Brush

2. I. C. Regulator 3. Stator

4. Rotor 5. Pulley

GENERATOR

GE-3

---� 5. 6. 7. 8.

1. Generator 2. I.C regulator 3. Field coil 4. Starter switch

Charging warning lamp Battery Fuse Load

SM21-228

TROUBLESHOOTING Symptom

Possible cause

Remedy/Prevention

Ammeter does not move --�- Fuse blown ....................................................... Determine cause and replace fuse. to negative side (remains at the neutral position) Lamp burned out ............................................. Replace lamp. with starter switch to be Wiring connection hose .................................. Tighten loose connection. turned on and engine off Charge lamp relay faulty ................................ Check relay. IC regulator faulty ............................................ Replace IC regulator.

Ammeter indicates the ---�-Drive belt loose or worn ................................. Adjust or replace drive belt. negative side with starter Battery cable loose, corroded or worn .......... Repair or replace cables. switch on and engine running Fuse blown .......................................................Determine cause and replace fuse. Fusible link blown ........................................... Replace fusible link. IC regulator or alternator faulty ..................... Check charging system. Wiring faulty .................................................... Repair wiring.

---- GENERATOR!!____________ 0 V-R=H. E A'UL

GE-4

----

T- 45-49 {4-50-500, 33-36}

1. Through bolt 2. Front bracket assembly 3. Nut 4. Rotor 5. Pulley 6. Fun 7. Collar 8. Bolt 9. Bearing reta1Âˇner 10. Retainer plate 11. Front ball bearing 12. Felt cover 13. Felt e 14. Drive end 15. Rear brae t::ssembly e 16. Cover

17.

Regulator assembly

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

SM21-224 . TIQ htening torqueÂˇ N-m { kgf,cm, lbf,ft}

. Terminal with lead wire Brush holder assembly Brush holder Brush Brush spring Stator coil Condenser Insulator Connector w1"th lead wire Rectifier Insulator Gasket . Rear ball bearing O-ring Insulator Rectifier end trame Cover

GENERATOR IMPORTANT POINTS - DISASSEMBLY REMOVE THE REGULATOR AND THE BRUSH HOLDER. 1. 2.

Unsolder the lead wire from the regulator. Remove the regulator and brush holder assembly.

SM21-225

REMOVE THE ROTOR. Using a press, remove the rotor.

SM21-006

REMOVE THE FRONT AND REAR BEARINGS. 1. 2. 3.

Remove the retainer plate. Using a press, remove the front ball bearing. Remove the felt cover and felt.

Using a press, remove the rear ball bearing.

SM21-007

SM21-226

REMOVE THE STATOR ASSEMBLY. 1.

SM21-180

Unsolder the regulator lead wire.

GE-5

GENERATOR

GE-6

Unsolder the each terminal of stator coil then remove the stator coil assembly.

SM21-196

GOOD

BAD

IMPORTANT POINTS-TESTING RECTIFIER. Test the each positive side rectifier condition. Connect the circuit tester+ lead to the rectifier holder and the - lead to the rectifier terminal.

GOOD

BAD

+ lead to the rectifier terminal and - lead to the rectifier holder.

GOOD

BAD

Test the each negative rectifier condition. Connect the circuit tester+ lead to the rectifier terminal and the - lead to the rectifier holder.

GOOD

BAD

+ lead to the rectifier holder and - lead to the rectifier terÂ minal.

GENERATOR

GE-7

IMPORTANT POINTS - ASSEMBLY INSTALL THE STATOR COIL ASSEMBLY. 1.

Install the stator coil assembly, and then solder the each terminal of stator coil.

Solder the regulator lead wire.

SM21-196

SM21-180

INSTALL THE FRONT AND REAR BALL BEARINGS. 1.

Using a press, install the rear ball bearing.

2. 3. 4.

Install the felt and felt cover. Using a press, install the front ball bearing. Install the retainer plate.

Using a press, install the rotor.

SM21-227

SM21-012

GE-8

GENERATOR INSTALL THE REGULATOR AND THE BRUSH HOLDER ASSEMBLY.

1. 2.

Install the brush holder assembly and regulator. Solder the lead wire to the regulator.

SM21-225

PERFORMANCE TEST NOTE: o 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 a large current to flow through and damage the diodes and IC regulator as well as burning the wiring harness. o Take care not to make wrong connections of termi nals. o When charging the battery with a quick charge, dis connect the battery terminals. o Do not perform tests with high voltage insulation resistance tester. o When in operation, never disconnect the battery.

SW2

a: 0

SW1

GENERATOR PERFORMANCE TEST.

1. 2.

0 <l'. 0 _J

Turn switch SW, on and SW2 off to increase the revolution of the generator slowly. When voltage reaches 28V, turn on switch SW2 to regulate load resistance. Increase the revolution of the rotor keep ing voltage at 28V.

Standard output speed:

w (!)�--�

5,000 r/min at 28V, 20A

SM21-159

VOLTAGE REGULATION TEST.

Turn switch SW, on and SW2 off to increase the revolu tion of rotor to 5,000 r/min. Standard voltage:

27.5-28.SV

GENERATOR

GE-9

INSPECTION AND REPAIR

Inspection Item

Standard

Limit

Remedy

Resistance of the rotor coil

Continuity

If no continuity, replace the rotor coil.

Insulation between the slip ring and the core

No continuity

If continuity, replace the rotor.

Conductance of the stator coil wire

Continuity

Insulation between the stator coil wire and the body

Condenser capacity

No continuity

0.5 ÂľF

Inspection procedure

If no continuity, replace the stator coil assembly.

Measure.

If continuity, replace the rotor.

Measure.

Replace.

Measure.

SM21-020

MEMO

ST-1

STARTER ST-Y116E-02

CHAPTER ST STARTER (24 V, 7 .0 kW)

DATA A ND SPECIFICATIONS ............................................ ST-2 DESCRIPTION ..................................................................... ST-2 TROUBLESHOOTING ......................................................... ST-3 OVERHAUL ......................................................................... ST-5

ST-2

STARTER

DATA AND SPECIFICATION Reduction gear type 24 V, 7.0 kW

Type Rated output Number of teeth of pinion Module Rotating direction

3.5

Clockwise (Seen from pinion side)

DESCRIPTION

The starter parts number is engraved at the commutator end frame SM22-072A

Brush

Field coil

2. Commutator 4. Armature 5. Magnetic switch

6. 7. 8. 9.

Pinion shift lever Reduction gear Clutch and pinion Pinion stopper

ST-3

STARTER

TROUBLESHOOTING Symptom

Possible cause

Remedy/Prevention

Engine does not crank,- - �---< Key switch � - - � or cranks slowly. • Poor contact ...................................................... Polish or replace contacts. Battery • Discharged battery ............................................ Charge. • Short circuited between electrodes ................. Replace battery. • Poor contact at battery terminal ...................... Polish or retighten. Engine oil • Improper viscosity oil ....................................... Change oil. Magnetic switch • Poor contact caused by burnt contact plate ..... Polish or replace contact plate. • Contact plate worn out ..................................... Repair. • Holding coil disconnected ................................ Replace field coil. (Overrunning clutch moves back and forth) • Pull-in coil disconnected or short circuited .... Replace. Starter relay • Defective or poor contact ................................. Repair or replace. Starter • Brush worn out ................................................. Replace. • Commutator burnt out ..................................... Correct on lathe. • Commutator worn out ...................................... Correct by undercutting. • Field winding shorted or grounded ................. Rewind or replace. • Armature winding shorted or grounded ......... Replace armature. • Insufficient brush spring tension ..................... Replace brush spring. • Poor contact between magnetic switch .......... Repair. and field windings • Armature contact pole core because of worn bearing bush or bent armature shaft .... Replace bearing brush or mature. • Overrunning clutch malfunction ...................... Replace. Engine does not crank while starter is running in good condition.

Overrunning clutch • Overrunning clutch malfunction ...................... Replace. • Pinion teeth worn out ....................................... Replace. • Poor sliding of spline teeth .............................. Remove foreign particles, dirt, replace.

STARTER

ST-4

Symptom

Starter does not stop running.

Possible cause

Remedy/Prevention

Key switch • Contacts keep closing ....................................... Replace the parts. • Key switch sticks ............................................... Replace the parts. • Overrunning clutch sticks to armature ............ Repair or replace overrunning clutch or the armature. Starter relay • Contacts keep closing ....................................... Repair or replace the parts.

ST-5

STARTER

OVERHAUL

T= 4-5 {37-50, 3-4}

' ' ,/

'-,

12 T= 14-16 {140-160, 10-12) /

""'",.____,--<

I /

T= 14-16 {140-160, 10-12}

:----- 1

DETAIL "A"

SM22-080A T= lightening torque: N-m {kgf-cm, lbf-ft}

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Yoke assembly Brush Brush Commutator end frame Brush holder assembly Brush Brush spring Set bolt Armature assembly Ball bearing Ball bearing Set bolt Gear housing Shim

15. Drive shaft assembly 16. Shim 17. Bearing housing 18. Clutch and pinion assembly 19. Pinion stopper 20. Hook 21. Clip 22. Set bolt 23. Gasket 24. Drive pinion lever 25. Lever pinion 26. Lever holder 27. Holder spring 28. Insert

29. Drive housing assembly 30. Bushing 31. Magnetic switch assembly 32. Contactor with terminal 33. 34. 35. 36. 37. 38. 39. 40.

cover assembly Terminal assembly Contactor assembly Moving core assembly O-ring Contactor spring Bolt Plug M terminal

STARTER

ST-6

IMPORTANT POINTS - DISASSEMBLY When disassembling the starter, prepare a work stand as shown in the figure. D : Diameter =130 mm{5.118in.} T : Thickness = 10 mm {0.394 in.} = 120 mm {4.724 in.} H: Height

SM22-114

REMOVE THE MOVING CORE. Remove the moving core in the direction of the marked arrow in the order 1 and 2.

SM22-004

REMOVE THE ARMATURE ASSEMBLY. Using a press, remove the armature assembly.

SM22-010

REMOVE THE PLUG. Remove the drive housing plug using a press. D: Diameter=16 mm {0.620 in.}

:::=�== ·:=i=I= \ : '! .) \"' I SM22-006

REMOVE THE MAGNETIC SWITCH. Unsolder the "COIL" terminal and "C" terminal.

SM22-007

STARTER

ST-7

IMPORTANCE POINTS - ASSEMBLY LUBRICATION Before reassembling, apply the recommended grease in the following and replace the 0-ring with a new one. 1. Bushing 2. Clutch and pinion assembly 3. Bushing and shim 4. Drive shaft 5. Gear housing and shim 6. Bearing 7. Drive pinion lever 8. Moving core 9. Lever holder and pin

SM22-067

REPLACEMENT OF BUSHING 2

o£a v

1. Remove the bushing using a press. 2. Replace the bushing with a new one using a press. NOTE: In the case of the bearing housing bushing, also re place the bearing housing bushing.

SM22-009

INSTALL THE MAGNETIC SWITCH. Solder the "COIL" terminal and "C" terminal.

SM22-007

STARTER

ST-8

•

INSTALL THE ARMATURE ASSEMBLY. Using a press, install the armature assembly.

SM22-011

TO REASSEMBLE, FOLLOW THE DISASSEMBLY PROCE DURE IN REVERSE ORDER. NOTE: When assembling the starter, pay attention to the fol lowing points.

BRUSH HOLDER POSITIONING

NOTC4

�-� iZ\

When installing the drive pinion lever on the shaft, pay attention to the direction in which the lever is installed.

Match the positioning of the brush holder with the "M" lead. Match the end frame positioning guide with the notch of the brush holder positioning guide.

\/�i ,.�,. ,- I

��

SM22-013A

MEASURE THE THRUST GA� After assembling the starter (without the magnetic switch), use a dial gauge to measure the thrust gap as you move the drive shaft in and out by hand.

Standard: 0.1-0.5 mm {0.004-0.0196 in.} If the thrust gap exceeds the standard, adjust by decreas ing or increasing the shim thickness. SM22-014

AFTER MEASURING THE NO-LOAD TEST OF THE STARTER, INSTALL THE DRIVE HOUSING PLUG. NOTE: Use a new plug.

SM22-015A

ST-9

STARTER INSTALL THE MOVING CORE.

Install the moving core in the direction of the marked ar row in the order A and B.

SM22-016

�TTERY

�SW2

�

AFTER ASSEMBLING THE STARTER, MEASURE THE TIMING GAP. 1. 2. 3.

Arrange the circuit. Close switches SW1 and SW2. Open SW2 alone when the pinion pops out.

In the above condition, push pinion back to measure the gap.

SM22-095

Standard:

0.5-3.0

mm {0.020-0.118 in.}

If the gap exceeds the standard, check the following parts and, if necessary, replace them. 1. Lever holder 2. Lever pin 3. Drive pinion lever 4. Gasket 5. Insert

SM22-075

IMPORTANT POINTS- INSPECTION MAGNETIC SWITCH TEST

The following test should be performed with the starter assembled without the "M" terminal lead with specified voltage applied.

NOTE: Each test should be performed for a short time (3 to 5 sec.) to prevent the magnetic switch from burning.

STARTER

ST-10

Pull-in test Connect the test leads as shown. When the switch is closed, the pinion gear moves outward. If the pinion gear does not move, replace the magnetic switch.

Holding test With the same procedure as the pull-in test, disconnect the "B" terminal. Check that the pinion gear remains out. If the pinion gear returns inward, replace the magnetic switch.

Return-test With the same procedure as in the hold-in test, discon nect the "EARTH" jumper wire. Check that the pinion gear returns inward. If the pinion gear does not return, replace the magnetic switch.

SM22-020

SM22-021

SM22-023

PERFORMANCE TEST The following test should be carried out after reassem bling the starter. If suitable equipment is not available, at least the no-load test should be carried out. No-load test o With the starter securely clamped in a vise. o Using a battery and suitable ammeter. o Connect the positive lead to the ammeter, "B" and "C" terminal. o Connect the negative lead to the starter body. The starter should show smooth and steady rotation im mediately after jumping out of the pinion and should draw less than the specified current. Revolution Current

SM22-024

4,000 r/min or more 120 A or less

ST-11

STARTER

INSPECTION AND REPAIR Unit: mm {in.} Inspection Item Armature Short Circuit Test

Standard

Limit

If the iron rod does not vibrated, the armature is good.

Remedy Replace.

Inspection Procedure Visual check

SM22-163

Armature Insulation

Runout of the Commutator

More than 1MQ

0.05 {0.0020}

Less than 0.5MQ

Replace.

Measure.

0.1 {0.0039}

Replace.

Measure.

0Outside Diameter of the Commutator

Depth of Under Cut of theMica

44 {1.732}

42 {1.654} or less

Replace.

Measure.

0.5-0.8 {0.0197-0.0315}

0.2 {0.0078}

Repair.

Measure. COMMUTATOR UNDERCUT

"':::;-

Conductance between the Brush Should be and the "M" Terminal conducted

Insulation between the Brush and the Yoke Body

More than 1MQ

:::'SM22-160

Replace.

Less than 0.5MQ

Replace.

Measure.

\�I

(E--2� I � I ({\,I � -

SM22-107

STARTER

ST-12

Unit: mm {in.}

Inspection Item Bend of the Drive Shaft

Standard

Limit

0.05 {0.0019}

0.1 {0.0039}

Remedy

Inspection Procedure

Replace. 1/ďż˝ rl-,,"1-Âˇ \ :,;_,-"

Drive Housing Bushing Inside Diameter

20.0 {0.7874}

20.2 {0.7952}

Replace.

Measure.

Bearing Housing Inside Diameter

35.0 {1.3780}

35.2 {1.3858}

Replace.

Measure.

More than 1MQ

Less than 0.5MQ

Replace.

20.0 {0.7874}

15.0 {0.5905}

Replace.

17.7N {1.8 kgf, 3.97 lbf}

12.4 N {1.26 kgf 2.78 lbf}

Replace.

SM22-066

Insulation between the Brush Holder and Bracket

Brush Length

Tension of the Brush Springs

Conductance between the C Terminal and the Body (Holding Coil)

0.2-0.6 n

Should be Replace. conducted

ST-13

STARTER

Unit mm {in.} Inspection Item Conductance between the C Terminal and Coil Terminal (Pulling Coil)

Rotating Torque of Pinion

Standard

Limit

0.1-0.3 n

Should be conducted

0.59-0.78 N-m {6-8 kgf-cm, 0.44-0.57 lbf-ft}

Remedy

Inspection Procedure

Replace.

Measure. 'C'

Replace, if both side turn or does not turn at all.

Measure.

SM22-040 Commutator End Frame Inside Diameter

35.0 {1,378}

35.1 {1.382} or more

Replace.

SM22-041

MEMO

CALIBRATION Hino K13C Hino K13D

CHAPTER C INJECTION PUMP

CALIBRATION K13CTB-NSZA, K13CTB-HAJA ................................................. C-2 K13CTJ-NSAC ........................................................................... C-4 K13CTB-EWAA .......................................................................... C-6 K13CUC-EVBA ........................................................................... C-8 K13CUC-EWBA ........................................................................ C-10 K13DTA-NSAA, K13DTB-EWBB ............................................. C-12 K13DTB-EVBA ......................................................................... C-14 K13DTB-EUAA, K13DTB-EWBA ............................................. C-16

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

C-1

C-2

Hino K13C Hino K13D

CALIBRATION

INJECTION PUMP NUMBER: 22020-3641 USE FOR GENERATOR SET (50 Hz, 1,500 r/min and 60 Hz, 1,800 r/min) INJECTION PUMP SPECIFICA TION

TEST CONDITION

Engine model

K13CTB-NSZA, K13CTB-HAJA

Injection pump parts number

22020-3641

Injection pump type

NP-PE6P120/320L

Governor type

NP-EP/RSV200-1300

Timer type

105100-5720

Feed pump type

NP-FP/K-PS

Test nozzle type

105100-5720

Test nozzle opening pressure

21.6 MPa {220 kgf/cm2 , 3,129 lbf/in2 .}

Injection pipe

Calibration oil

OVERFLOW VALVE

INJECTION TIMING

Outer diameter

6.0 mm {0.236 in.}

Inner diameter

2.0 mm {0.078 in.}

Length

750 mm {29.5 in.}

Type

SAE J967C

Oil temperature

40-45 C {104-113 F}

Fuel feed pressure

157 kPa {1.6 kgf/cm 2, 22.8 lbf/in 2 .}

Overflow valve opening pressure

147-177 kPa {1.5-1.8 kgf/cm2, 21.33-25.60 lbf/in 2 .}

Rotation

Clockwise viewed from governor side

Injection order

1-4-2-6-3-5

Injection interval

60 ±15'

Pre-stroke Rack position mm {in.} INJECTION VOLUME

C-Y162E-04

4.34-4.40 mm {0.171-0.173 in.} Pump speed (r/min)

Measuring strokes

Injection volume cc {cu.in.}

Max variation limit(%)

8.9 {0.350}

1,000

500

90.35-92.35 {5.514-5.635}

±2

8.9 {0.350}

650

500

(91.6-94.6 {5.590-5.772})

±5

About 4.5 {0.177}

360

500

5.9-8.9 {0.361-0.543}

±15

CONTROL LEVER ANGLE

ADJUSTING POSITION

IDLING SUB SETTING SCREW

MAXIMUM SPEED STOPPER BOLT

IDLING

CONTROL

GOVERNOR AD JUSTMENT

STOP LEVER ANGLE

RUN STOP LEVER

IDLING SCREW

STOPPER BOLT

STOP TOUCH THE INSIDE STOPPER CONTROL RACK POSITION: 4.0 mm OR LESS PUMP SPEED: 0 (r/min) -TOUCH THE OUTSIDE / STOPPER

Hino K13C Hino K13D

C-3

CALIBRATION

GOVERNOR CHARACTERISTIC DIAGRAM NOTE: Recommended setting of swivel adjusting screw: about 13 clinks from bottom end.

TIMER ADVANCE CHARACTERISTIC DIAGRAM 14.0 or more

IDLING SUB SPRING SET: 3.3-3.8 mm

E E z 0

CJJ 0 a..

�

4.5

C 1-------

3.8 1------+---------+--ii

u <x: rr: -' 0 rr: 1z 0 u

oo NO o� ... ... 00 � r- oO -... �

00 <O M M-.,.

0 0) M

PUMP SPEED (r/min)

___.

C-V162E-04

C-4

Hino K13C Hino K13D

CALIBRATION C-Y333E-03

INJECTION PUMP NUMBER: 22020-4931 K13CT J-NSAC

Engine model INJECTION PUMP SPECIFICA TION

TEST CONDIT ION

Injection pump part number

22020-4931

Injection pump type

NP-PE6P120/321/L

Governor type

NP-EP/RSV200-1300

Timer type

NE-EP/SPG750-900Z2/L

Feed pump type

NP-FP/K-PS

Test nozzle type

105100-5720

Test nozzle opening pressure

21.6 MPa {220 kgf/cm 2, 3,129 lbf/in2 .}

Injection pipe

Calibration oil

OVERFLOW VALVE INJECTION TIMING

6.0 mm {0.236 in.}

Inner diameter

2.0 mm {0.079 in.}

Length

750 mm {29.5 in.}

Type

SAE J967C °

Oil temperature 40-45 C {104-113 F}

Fuel feed pressure

157 kPa {1.6kgf/cm 2 , 22.8 lbf/in2 .}

Overflow valve opening pressure

147-177 kPa {1.5-1.8 kgf/cm 2, 21.33-25.60 lbf/in 2 .}

Rotation

Clockwise viewed from governor side

Injection order

1-4-2-6-3-5

Injection interval

60 ±15'

Pre-stroke

4.34-4.40 mm {0.171-0.173 in.}

Rack position mm {in.} INJECTION VOLUME

Outer diameter

Pump speed Measuring strokes (r/min)

Injection volume cc {cu.in.}

Max

variation limit(%)

8.6 {0.339}

900

500

96-98 {5.859-5.980}

±2

10.35 {0.407}

900

500

(129-132 {7.872-8.054})

±5

10.85 {0.427}

550

500

( 161-166 {9.825-10.129})

4.8 {0.189}

360

500

5.9-8.9 {0.361-0.543}

±15

(R1)

100

500

11.05 {0.435}

100

500

(152.5-157.5 {9.306-9.610})

CONTROL LEVER ANGLE

ADJUSTING POSITION MAXIMUM SPEED STOPPER BOLT

SWIVEL LEVER ADJUST SCREW \ r-

IDLING SUB SETTING SCREW

FULL SPEED (900 r/min SET) 5°±5�

IDLING(750 r/min SET) -' � 1/"'

GOVERNOR ADJUSTMENT

19°±5° 5°± 5°

STOP LEVER ANGLE

RUN·

STOP TOUCH THE INSIDE STOPPER CONTROL RACK POSITION: 5.1 mm OR LESS PUMP SPEED: 0 (r/min)

53":!:_50 70±5: �

_ TOUCH THE OUTSIDE STOPPER

About 11°

Hino K13C Hino K13D

C-5

CALIBRATION

GOVERNOR CHARACTERISTIC DIAGRAM NOTE: Recommended setting of swivel adjusting screw: about 7 clinks from bottom end.

BOOST COMPENSATOR OPERATION: R1 ± 0.1 mm 14.0 or more ---

BOOST COMPENSATOR STROKE: 2.75 ± 0.1 mm GOVERNOR SPRING SET

10.8 ---i------1�----�--I-_.,.,._

9.8 �

- - -1---- - - +--+-+---""I-.----..+----+

E E

z 0 i= u'i 0 Cl.. :,;:'. u <( a:: -' 0 a:: � z 0 u

-------0-----r--t--<o-------t----(O (")

0 LO r--

0 0

PUMP SPEED (r/min)

TIMER ADVANCE CHARACTERISTIC DIAGRAM

LJ.J

0 (0

.......

BOOST COMPENSATOR CHARACTERISTIC DIAGRAM

-' 0 a:: � 0

z <(

(")

o E � E

1.7-2.3

(!)

z <(

IDLING SUB SPRING SET

5.6 5.5 ± 0.2---i-------�---4--4---1---1------1--4 4.0±0.1

Less than 0.3

z O i= u'i 0 Cl..

8.55 0

r--

PUMP SPEED (r/min)

r--

(0 0 N

..., £:'. ::,

0 ..0 <(

(")

�

s r-r--

,ii ci 0 LO

�

s 0 6 0 � � U")

BOOST PRESSURE kPa {mmHg}

C-Y333E-03

C-6

Hino K13C Hino K13D

CALIBRATION

INJECTION PUMP NUMBER: 22020-5240

INJECTION PUMP SPECIFICA TION

TEST CONDITION

Engine model

K13CTB-EWAA

Injection pump part number

22020-5240

Injection pump type

NP-PE6P120/321L

Governor type

NP-EP/RSV200-1300

Timer type

105101-5720

Feed pump type

NP-FP/K-PS

Test nozzle type

105101-5720

Test nozzle opening pressure

21.6MPa {220 kgf/cm2, 3,129 lbf/in2.}

Injection pipe

Calibration oil

OVERFLOW VALVE INJECTION TIMING

Outer diameter

6.0 mm {0.236 in.}

Inner diameter

2.0 mm {0.078 in.}

Length

750 mm {29.5 in.}

Type

SAE J967C °

Oil temperature 40-45 C {104-113 F}

Fuel feed pressure

157 kPa {1.6kgf/cm2, 22.8 lbf/in2 .}

Overflow valve opening pressure

147-177 kPa {1.5-1.8 kgf/cm2, 21.33-25.60 lbf/in2.}

Rotation

Clockwise viewed from governor side

Injection order

1-4-2-6-3-5

Injection interval

60 ± 15' 4.34-4.40 mm {0.171-0.173 in.}

Pre-stroke Rack position mm {in.} INJECTION VOLUME

C-Y352E-02

Pump speed Measuring (r/min) strokes

Injection volume cc {cu.in.}

Max variation limit(%) ±2

R,(9.2) {0.362}

900

500

92-94 {5.614-5.735}

R2(9.7) {0.382}

900

500

102.5-105.5 {6.255-6.437}

±5

About 5.6 {0.220}

360

500

5.9-8.9 {0.361-0.543}

±15

100

500

(102.5-112.5) {6.255-6.846}

D 10.0-10.2 {0.394-0.401}

CONTROL LEVER ANGLE

ADJUSTING POSITION MAXIMUM SPEED STOPPER BOLT

SWIVEL LEVER ADJUST SCREW \ r-

IDLING SUB SETTING SCREW

FULL SPEED° (3o)±5 o (18")±5

IDLING

GOVERNOR ADJUSTMENT

STOP LEVER ANGLE STOP TOUCH THE INSIDE STOPPER CONTROL RACK POSITION: 5.1 mm OR LESS PUMP SPEED: 0 (r/min) , --TOUCH THE OUTSIDE STOPPER ABOUT 11 °

Hino K13C Hino K13D

C-7

CALIBRATION

GOVERNOR CHARACTERISTIC DIAGRAM NOTE: Recommended setting of swivel adjusting screw: about 5 clinks from bottom end.

TIMER ADVANCE CHARACTERISTIC DIAGRAM RACK LIMIT: 10.0-12.2 mm 14.0 or more

GOVERNOR SPRING SET

t E E z 0

10.9±0.1 9.7 9.2

0 a_

0 0 a,

�

u <! a: ...J 0 a: 1z 0 u

PUMP SPEED (r/min) 5.7 5.6

C 5-10 30-35

0 0

oa <.O � M st

PUMP SPEED (r/min)

Lf)

..... C-Y352E-02

C-8

Hino K13C Hino K13D

CALIBRATION

INJECTION PUMP NUMBER: 22020-5320 K13CUC-EVBA(For VIET NAM)

Engine model INJECTION PUMP SPECIFICA TION

TEST CONDITION

Injection pump part number

22020-5320

Injection pump type

NP-PE6P120 /321L

Governor type

NP-E P/RSV200-1200

Timer type

105635-0350

Feed pump type

NP-FP/K-PS

Test nozzle type

105015-5720

Test nozzle opening pressure

21.6 MPa {220 kgf/cm2 , 3,129 lbf/in2 .}

Injection pipe

Calibration oil

OVERFLOW VALVE INJECTION TIMING

Outer diameter

6.0 mm {0.236 in.}

Inner diameter

2.0 mm {0.078 in.}

Length

750 mm {29.5 in.}

Type

SAE J967C

Oil temperature

40-45 C {104-113 F}

Fuel feed pressure

157 kPa {1.6 kgf/cm2, 22.8 lbf/in2 .}

Overflow valve opening pressure

147-177 kPa {1.5-1.8 kgf/cm2 , 21.33-25.60 lbf/in 2 .}

Rotation

Clockwise viewed from governor side

Injection order

1-4-2-6-3-5

Injection interval

60 ± 15'

4.34-4.40 mm {0.171-0.173 in.}

Pre-stroke

Pump speed Measuring (r/min) strokes

Rack position mm {in.} INJECTION VOLUME

C-Y390E-01

R ,(9.5) {0.374}

B R 2(10.1){0.398} D About 5.6 {0.220} E (Ri+0.2)+02

Max variation Remarks limit(%)

900

500

100-102 {6.103-6.224}

±2

900

500

111-114 {6.774-6.965}

750

500

±5

360

500

5.9-8.9 {0.361-0.543}

±15

100

500

SWIVEL LEVER ADJUST SCREW \ r-

Basis -

Rack limit

CONTROL ANGLE

ADJUSTING POSITION MAXIMUM SPEED STOPPER BOLT

Injection volume cc {cu.in.}

IDLING SUB SETTING SCREW

FULL SPEED900 r/min SET <:, _.,.._,.._ ,6\

-!:-

"-"1/�

(20 ) ± 0.5 IDLING 750 r/min SET

GOVERNOR ADJUSTMENT

STOP LEVER ANGLE

/�,0

STOP_L_53 :-;i_RUN CONTROL RACK POSITION 5.1 mm OR LESS PUMP SPEED: 0 r/min

Hino K13C Hino K13D

C-9

CALIBRATION

GOVERNOR CHARACTERISTIC DIAGRAM NOTE: Recommended setting of swivel adjusting screw: about 13 clinks from bottom end.

TIMER ADVANCE CHARACTERISTIC DIAGRAM 0 UJ ...J (.9 z <{ UJ u �

14.0 or more

t E E

R2 (10.1) R1 (9.5)

6<i:

1----...._---+-------➔ A

0.5 or less

o�-��----900

PUMP SPEED (r/min)

0 i= ui 0 [L

�

u <{ a: ...J 0 a: 1z 0 u

5.7 ---------------+--+--+--<I

IDLING SUB SPRING SET

5.61----------1.

3.0 ± 5

900 ± 5

410 ± 20

360

750 ± 5

PUMP SPEED (r/min)

C-Y390E-01

C-10

Hino K13C Hino K13D

CALIBRATION

INJECTION PUMP NUMBER: 22020-5320

INJECTION PUMP SPECIFICA TION

TEST CONDITION

Engine model

K13CU C-EWBA

Injection pump part number

22020-5320

Injection pump type

NP-PE6P120/321L

Governor type

NP-EP/RSV200-1200

Timer type

105635-0350

Feed pump type

NP-FP/K-PS

Test nozzle type

105015-7020

Test nozzle opening pressure

21.6 MPa {220 kgf/cm2, 3,129 lbf/in2 .}

Injection pipe

Calibration oil

OVERFLOW VALVE INJECTION TIMING

Outer diameter

6.0 mm {0.236 in.}

Inner diameter

2.0 mm {0.078 in.}

Length

750 mm {29.5 in.}

Type

SAE J967C °

Fuel feed pressure

157 kPa {1.6kgf/cm2, 22.8 lbf/in2 .}

Overflow valve opening pressure

147-177 kPa {1.5-1.8 kgf/cm2, 21.33-25.60 lbf/in2.}

Rotation

Clockwise viewed from governor side

Injection order

1-4-2-6-3-5

Injection interval

60 ± 15'

Pre-stroke

4.34-4.40 mm {0.171-0.173 in.}

Pump speed Measuring (r/min) strokes

Injection volume cc {cu.in.}

Max variation limit(%)

R,(9.5) {0.374}

900

500

100-102 {6.103-6.224}

±2

R2(10.1) {0.398}

900

500

111-114 {6.774-6.965}

±5

(R2)

750

500

About 5.6 {0.220} (R2 +0.2)•0·1

360

500

5.9-8.9 {0.361-0.543}

±15

100

500

ADJUSTING POSITION MAXIMUM SPEED STOPPER BOLT

GOVERNOR ADJUSTMENT

Oil temperature 40 - 45 C {104-113 F}

Rack position mm {in.} INJECTION VOLUME

C-Y364E-02

SWIVEL LEVER ADJUST SCREW \ r---

CONTROL LEVER ANGLE IDLING SUB SETTING SCREW

FULL SPEED900 r/min SET (6° )±5_ 0

?�

__,_...,._

IDLING 750 r/min SET

STOP LEVER ANGLE

l.\

(27° )±5°

STOP CONTROL RACK POSITION 5.1 mm OR LESS PUMP SPEED: 0 r/min

�RUN

Hino K13C Hino K13D

CALIBRATION

C-11

GOVERNOR CHARACTERISTIC DIAGRAM NOTE: Recommended setting of swivel adjusting screw: about 3 clinks from bottom end.

TIMER ADVANCE CHARACTERISTIC DIAGRAM 14.0 or more

UJ ...J (.9

z <{

t E E

0 i= ui 0 [L � u <{ a: ...J

0 a: 1z 0 u

u �

R2 (10.1) R1 (9.5)

<i:

1----...._---+-------➔A

5.7 --------------+--+-

-+---<I

0.5 or less

o�-��----900

PUMP SPEED (r/min)

IDLING SUB SPRING SET

5.61---------1.

3.0± 5

800± 5

410 ±20 360

750±5

PUMP SPEED (r/min)

C-Y364E-02

C-12

Hino K13C Hino K13D

CALIBRATION

INJECTION PUMP NUMBER : 22020-4920/5800 22020-4920

Governor type

NP-EP/RSV200-1300

NP-PE6P120/321L

Injection pump type

NP-EP/SP800-1000Z1.5L

Timer type

Feed pump type

NP-FP/K-P

Test nozzle type

105101-5850

Injection pipe

6.0 mm {0.31 in.}

Length

665 mm {23.6 in.} °

Oil temperature 40-45 C {104-113 F}

157kPa {1.6kgf/cm2 , 22.8 lbf/in2 .}

Overflow valve opening pressure

147-177 kPa {1.5-1.8 kgf/cm2 , 21.33-25.60 lbf/in2 .}

Rotation

Clockwise viewed from governor side

Injection order

1-4-2-6-3-5 °

60 ±15'

Injection interval

3.20-3.30 mm {0.126-0.129 in.}

Pre-stroke

Rack position mm {in.} INJECTION VOLUME

2.0 mm {0.12 in.}

SAE J967C

Type

Fuel feed pressure

INJECTION TIMING

19.6MPa {200 kgf/cm2 , 2,844 lbf/in2 .}

Outer diameter

Inner diameter

Calibration oil

OVERFLOW VALVE

Injection volume cc {cu.in.}

Pump speed Measuring (r/min) strokes

9.4 {0.370}

900

500

9.6 {0.378}

750

500

101.5-104.5 {6.194-6.376}

500

(167.5-172.5 {10.222-10.526})

750

9.0 {0.354}

About 4.7 {0.185}

500

360

12.9-13.1 {0.508-0.515}

500

100

MAXIMUM SPEED STOPPER BOLT

96.9-98.9 {5.914-6.035}

89.4-92.4 {5.456-5.638} 5.9-8.9 {0.361-0.543}

IDLING SUB SETTING SCREW

SWIVEL LEVER ADJUST SCREW

FULL SPEED (900 r/min SET) (30)±50 (750 r/min SET) - 7

\ �:;:::-i--

CONTROL

If' jq

�;

�-�

��i,,.r;,

'.'-�

b\ o... ll,"""

±4 ±4

±15

�,

50 )±50

STOP LEVER ANGLE

\_., FULL LOAD IDLING STOPPER SCREW BOLT

IDLING (20°±5°)

�

,�.,._, �j' fulk��-�� v

;��

STOP LEVER

\ �• �

��- ��

�l � µ

» •

-�

�:�

LEVER

Max variation limit(%)

CONTROL LEVER ANGLE

ADJUSTING POSITION

GOVERNOR ADJUSTMENT

122020-5800

Injection pump part number

Test nozzle opening pressure TEST CONDITION

I K13DTB-EWBB

K13DTA-NSAA

Engine model INJECTION PUMP SPECIFICATION

C-Y332E-03

53° ±5 °

RUN�•

STOP TOUCH THE INSIDE STOPPER CONTROL RACK POSITION: 4.2 mm OR LESS PUMPSPEEDcOl,/m;o)

/-TOUCH THE OUTSIDE / STOPPER / 11 °

Hino K13C Hino K13D

CALIBRATION

C-13

GOVERNOR CHARACTERISTIC DIAGRAM NOTE: Recommended setting of swivel adjusting screw: about 6 clinks from bottom end.

BOOST COMPENSATOR OPERATION: 13.0±0.1 mm BOOST COMPENSATOR STROKE: 0.8±0.05 mm IDLING SUB SPRING SET GOVERNOR SPRING SET

F 10.5±0.1

9.6 ---.---1----------,li.._--,4---..I---'....--------+ 9.4 9.0±0.1 7.7

E E

0 a..

--,

ci +I ":

I I \

z 0

E C/l

..-t----1t-------,f-t-r--+-t-11----- A

6.3±1.5 i----�----,t----�----+--++--1

�

u <I: a: ...J 0 a: 1z 0 u 0 <O N

0 <O M

� -

L()

!:::.

0 L() r--

M 00 r--

PUMP SPEED (r/min)

0 0 er,

......

BOOST COMPENSATOR CHARACTERISTIC DIAGRAM

�

u E

<I: a: ...J 0 a: Iz 0

R1: (11.3)

z 0

E C/l

0 u a.. R1-0.8 0

r-u:i 0 0 <O ::, 0 .0

<I:

!£

0 0

�

0 I!)

cl, 6 u:i 00

r--

I!)

BOOST PRESSURE kPa {mmHg}

C-Y332E-03

C-14

Hino K13C Hino K13D

CALIBRATION

INJECTION PUMP NUMBER : 22020-5450

INJECTION PUMP SPECIFICA TION

TEST CONDITION

Engine model

K13DTB-EVBA (For VIETNAM)

Injection pump part number

22020-5450

Injection pump type

NP-PE6P120/320LS3000

Governor type

NP-EP/RSV200-1200

Timer type

Not equipped

Feed pump type

NP-FP/K-P

Test nozzle type

105101-5850

Test nozzle opening pressure

19.6 MPa {200 kgf/cm2 , 2,844 lbf/in 2.}

Injection pipe

Calibration oil

OVERFLOW VALVE INJECTION TIMING

INJECTION VOLUME

C-Y391E-01

Outer diameter

6.0 mm {0.24 in.}

Inner diameter

2.0 mm {0.08 in.}

Length

665 mm {26.18 in.}

Type

SAE J967C

Oil temperature

40-45 C {104-113 F}

Fuel feed pressure

157 kPa {1.6 kgf/cm2, 22.8 lbf/in 2 .}

Overflow valve opening pressure

147-177 kPa {1.5-1.8 kgf/cm2, 21.33-25.60 lbf/in 2.}

Rotation

Clockwise viewed from governor side

Injection order

1-4-2-6-3-5

Injection interval

60 ±15'

Pre-stroke

3.20-3.30 mm {0.126-0.129 in.}

Rack position mm {in.}

Injection volume cc {cu.in.}

Pump speed Measuring (r/min) strokes

Max variation Remarks limit(%)

10.6 {0.417}

750

500

96-98 {5.859-5.980}

±4

10.9 {0.429}

750

500

101.5-104.5 {6.194-6.376}

±4

360

500

5.9-8.9 {0.361-0.543}

±15

C About 6.0 {0.236}

Basis

CONTROL LEVER ANGLE

ADJUSTING POSITION

FULL SPEED -

MAXIMUM SPEED STOPPER BOLT

SWIVEL LEVER ADJUST SCREW \_c--,__ /.c

IDLING SUB SETTING SCREW

IDLING

° (4 ) ± 5'

(16 ) ± 5'

-� GOVERNOR ADJUSTMENT

STOP LEVER ANGLE

38' ± 5' STOP

53'± 5"

RUNNING POSITION

PACK POSITION: 6.3 mm or less PUMP SPEED: O(r/min.)

Hino K13C Hino K13D

CALIBRATION

C-15

GOVERNOR CHARACTERISTIC DIAGRAM NOTE: Recommended setting of swivel adjusting screw: about 11 clinks from bottom end.

14 or more

IDLING SUB SPRING SET

E E

en 0

10.9

u <l'. a:

10.6 ± 0.1

Cl..

� ....J

GOVERNOR SPRING SET

11.5±1.0

9.0

a: I-

6.7 ± 0.2 6.0

00 LO tO (') (')

PUMP SPEED (r/min)

......

C-Y391E-01

C-16

Hino K13C Hino K13D

CALIBRATION

INJECTION PUMP NUMBER : 22020-5450/5480 K13DTB-EUAA

Engine model INJECTION PUMP SPECIFICA TION

TEST CONDITION

Injection pump parts number

22020-5450

Injection pump type

NP-PE6P120/320LS3000

INJECTION TIMING

Governor type

NP-E P/RSV200-1200 Not equipped

Feed pump type

NP-FP/K-P

Test nozzle type

105101-5850

Test nozzle opening pressure

19.6 MPa {200 kgf/cm2 , 2,844 lbf/in2 .}

Injection pipe

Outer diameter

6.0 mm {0.24 in.}

Inner diameter

2.0 mm {0.08 in.}

Length

665 mm {26.18 in.}

Type

SAE J967C

Oil temperature

40-45 C {104-113 F}

Fuel feed pressure

157 kPa {1.6 kgf/cm 2 , 22.8 lbf/in2 .}

Overflow valve opening pressure

147-177 kPa {1.5-1.8 kgf/cm2 , 21.33-25.60 lbf/in2 .}

Rotation

Clockwise viewed from governor side

Injection order

1-4-2-6-3-5

Injection interval

60 ± 15' 3.20-3.30 mm {0.126-0.129 in.}

Pre-stroke

INJECTION VOLUME

I K13DTB-EWBA I 22020-5480

Timer type

Calibration oil

OVERFLOW VALVE

C-Y345E-03

Rack position mm {in.}

Pump speed (r/min)

Measuring strokes

Injection volume cc {cu.in.}

Max variation limit(%)

R1 (10.4 {0.409})

750

500

96-98 {5.859-5.980}

R2 (10.7 {0.421})

750

500

101.5-104.5 {6.194-6.376}

±4 ±4

R3 (6.0 {0.236})

360

500

5.9-8.9 {0.361-0.543}

±15

CONTROL LEVER ANGLE

ADJUSTING POSITION

FULL SPEED -

MAXIMUM SPEED STOPPER BOLT

SWIVEL LEVER ADJUST SCREW \_c--,._ /.c

IDLING SUB SETTING SCREW

IDLING

(50)±50

(16°)±5°

-� GOVERNOR ADJUSTMENT

STOP LEVER ANGLE

(38 °)±5 ° STOP

(53 ° )±5°

RUNNING POSITION

PACK POSITION: 6.3 mm or less PUMP SPEED: O(r/min.)

Hino K13C Hino K13D

CALIBRATION

C-17

GOVERNOR CHARACTERISTIC DIAGRAM NOTE: Recommended setting of swivel adjusting screw: about 13 clinks from bottom end.

14 or more

IDLING SUB SPRING SET

E E

GOVERNOR SPRING SET

en 0

ï¿½ a: ....J

R2 (10.7) R1 (10.4) R3+3.0

R3+0.7 R3 (6.0)

...

I{)

0 N

+I 0

+I 0 :;;:

PUMP SPEED (r/min)

I{)

......

C-Y345E-03

MEMO

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ELECTRICAL EQUIPMENT

EE-1

EE-V400E-01

CHAPTER EE HINO K13C T ELECTRICAL EQUIPMENT HINO K13D T ELECTRICAL EQUIPMENT DATA AND SPECIFICATION .................................................... EE- 2 LOCATION OF ELECTRICAL EQUIPMENT ............................ EE- 2 TROUBLESHOOTING ................................................................. EE- 5 GENERAL INSTRUCTION ......................................................... EE- 7 BATTERY .................................................................................... EE- 8 ENGINE STARTING CIRCUIT .................................................. EE- 9 INTAKE AIR HEATER CIRCUIT ............................................... EE-10 ENGINE STOP CIRCUIT ........................................................... EE-11 METER AND GAUGE CIRCUIT ............................................... EE-12 BOOST COMPENSATOR CANCEL SYSTEM WITH SOLENOID ....................................................................... EE-14 ELECTRICAL WIRING DIAGRAM ............................................ EE-15

EE-2

ELECTRICAL EQUIPMENT

Hino K13C Hino K13D

DATA AND SPECIFICATION

Electrical system Voltage ................................................................. Direct current 24 volts Ground ................................................................. Negative (-) ground

LOCATION OF ELECTRICAL EQUIPMENT For K13C-TJ Engine

1. Coolant temperature switch 2. Coolant temperature sender gauge 3. Oil pressure switch 4. Coolant temperature switch 5. Intake air heater relay 6. Oil pressure sender gauge 7. Pipe joint 8. Solenoid (Boost compensator cancel) 9. Solenoid (Engine stop) 10. Link rod 11. Lock nut 12. Clevis 13. Clevis pin 14. Plain washer 15. Cotter pin 16. Revolution sensor 17. Intake air heater 18. Starter switch 19. Glow controller 20. Starter block relay 21. Engine tachometer 22. Coolant temperature gauge 23. Oil pressure gauge 24. Ammeter

19 I

� T= Tightening torque : N-m {kgf-cm,lbf-ft }

SM20-2057

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ELECTRICAL EQUIPMENT

EE-3

Hino K13C Hino K13D

For K13C-TB,K13C-UC Engine M12: T:11.8-17.6 {120-180, 8.7-13.0} M16: T:29.5-39.2 {300-400, 21.7-28.9}

�·"1 /11" ��j �

� �

.��

I° 3

4� 22

1. Coolant temperature switch 2. Coolant temperature sender gauge 3. Oil pressure switch 4. Intake air heater relay (If so equipped) 5. Oil pressure sender gauge (If fitted) 6. Pipe joint (If so equipped) 7. Solenoid (Engine stop) 8. Link rod 9. Lock nut 10. Clevis 11. Clevis pin 12. Plain washer 13. Cotter pin 14. Intake air heater (If so equipped) 15. Starter switch 16. Glow controller (If so equipped) 17. Starter block relay 18. Emergency relay (If so equipped) 19. Engine tachometer 20. Battery switch (If so equipped) 21. Battery relay (If so equipped) 22. Oil pressure gauge 23. Oil temperature gauge 24. Coolant temperature sender gauge 25. Ammeter SM20-2056

T= Tightening torque: N-m {kgf.cm,lbf,ft }

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EE-4

ELECTRICAL EQUIPMENT

Hino K13C Hino K13D

® @�

® 4

�

1. Coolant temperature switch 2. Coolant temperature switch 3. Coolant temperature sender gauge 4. Oil pressure switch 5. Oil pressure sender gauge 6. Solenoid (Boost compensator cancel) (If so equipped) 7. Solenoid (Engine stop) 8. Link rod 9. Lock nut 10. Clevis 11. Clevis pin 12. Plain washer 13. Cotter pin 14. Intake air heater (If so equipped) 15. Revolution sensor (If so equipped) 16. Starter switch 17. Glow controller (If so equipped) 18. Starter block relay 19. Coolant temperature gauge 20. Oil pressure gauge 21. Ammeter 22. Engine tachometer 23. Engine hour-meter

SM20-2055A

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Hino K13C Hino K13D

ELECTRICAL EQUIPMENT

EE-5

TROUBLESHOOTING

Symptom

Possible cause

A lot of exhaust is emitted------1 but the engine does not • start or is difficult to start. (Auxiliary starting device: • Standard specifications) • (Auxiliary starting device: Option specifications)

Remedy/Prevention

Auxiliary starting device Loose wiring of glow controller or defective ..................... Repair or replace. glow controller. Defective glow controller ..................................................... Replace. Defective wiring between intake air heater and ................ Repair. glow controller

• Defective power relay .......................................................... Repair or replace. • Defective intake heater relay ............................................... Replace. Solenoid does not operate when engine is running, even if abnormal signal is input. (Engine does not stop.)

--�---1

Emergency stop relay

• Generator malfunctions ....................................................... Repair or replace. • Insufficient battery voltage .................................................. Charge or replace. • Faulty connection at N terminal of ...................................... Repair. emergency relay • Defective solenoid ................................................................ Replace.

Solenoid operates with ______, Emergency stop relay starter switch is turned • Faulty connection at R1 terminal ........................................ Repair. ON. • Faulty connection at B and C terminals .............................. Repair. When the starter switch -------1 Battery is turned OFF, the battery • Insufficient voltage ............................................................... Charge or replace. relay switch goes OFF and the solenoid fails to operate. Generator • Malfunctions ......................................................................... Repair or replace. Starter chattering or _______, Battery improper plunging • Insufficient voltage ............................................................... Charge or replace. Starter block relay • Faulty connection at terminals ............................................ Repair. • Internal circuit abnormal ...................................................... Replace. • Relay switch abnormality (faulty contacts), ....................... Replace. improper sliding between rod and moving core, or open-circuit or burnt out coil. Starter switch • Faulty connection at terminals

EE-6

ELECTRICAL EQUIPMENT

Hino K13C Hino K13D

Symptom

Possible cause

Remedy/Prevention

Improper disengagement----.----, Generator of starter or defective hold • Defective (correct voltage not generated) ............................ Repair or replace. function when engine is rotating Starter block relay • Improper terminal connection ............................................... Repair. • Reverse connections to terminals Band C ........................... Repair. Re-plunging during ------.----, Starter block relay inertial rotation • Reverse connections to terminals Band C ........................... Repair.

ELECTRICAL EQUIPMENT Hino K13C Hino K13D

EE-7

GENERAL INSTRUCTION WARNING Be sure to disconnect the ground cable before servicing the electrical circuits.

WIRING CODE

EXAMPLE:

3WB 3 mm2 (0.0047 in2.}

Wiring colors are indicated by a code. B Black Lg Light green Brown R Red Br G Green White W Yellow Blue L Y The first letter indicates the ground wire color and sec ond letter indicates the stripe color. Arabic numerals indicates the cross sectional area of wire.

WHITE

BLACK

2. 3. SM20-340

Example: 3 indicates 3 mm2 {0.0047 in2 .}

CONNECTOR

FEMALE

The connectors consists of the male and female connec tors. Male and female connectors are classified according to the shape of the terminals in the connector (Refer to the figure on the left). Male and female connectors are provided with a lock, so that they can not be separated easily. To separate the connectors, unlock the lock, then hold one connector with one hand and the other one with the other hand, and pull them.

MALE

NOTE: When the connector is disconnected by pulling the wires, the connection between the terminals and the wires will be damaged. 1. a. b.

2. a.

...

Removing the terminal from the connector. Insert a miniature screwdriver or a terminal puller be tween terminal and connector, and unlock the lock be tween terminal and connector. When the lock has been released, pull the wire to remove the terminal. Installing the terminal in the connector. Insert the terminal into the connector until a clicking sound of lock engagement can be heard. Pull the wire to confirm correct lock engagement.

FUSE The power supply must be switched off for fuse replace ment. Use a proper amperage fuse.

== SM20-348

NOTE: Wire burning may be caused when a fuse with an excessively large current capacity is used. If the fuse should blow frequently, investigate the cause and correct it.

EE-8

Hino K13C Hino K13D

BE SURE THAT THE BATTERY IS ALWAYS FULLY CHARGED

ELECTRICAL EQUIPMENT

BATTERY CONVERSION FORMULA FOR SPECIFIC GRAVITY 1.

The specific gravity of the electrolyte changes according to the temperature of the electrolyte itself, therefore a temperature of 20° C {68° F} is used as a reference tem perature. Consequently, if the temperature is not 20° C when the specific gravity is measured, it is necessary to convert the measured value to the equipment value at 20° c.

Temperature conversion formula: S20 = St + 0.0007 (t -20) Where, • "S20" is the specific gravity at 20° C(Reference tern perature) • "St" is the specific gravity at the measuring temperature • "t" is the temperature during measurement • "0.0007" is the temperature coefficient of the electrolyte

NOTE: As a rough guide, if the temperature of the electrolyte rises or falls by 15 °C {59°F}, the specific gravity of the electrolyte will vary by about 0.01. BATTERY CHARGING 45•c {173° FI

1. 1)

2) 3)

Be careful to the following points. While the battery is being charged, ensure that the tem perature of the electrolyte does not rise above 45 ° C {113° F}. While the battery is being charged, be particularly care ful to keep it away from sources of fire. The amount of electrolyte must be within the specified level.

Specific gravity when battery is fully charged: 1.250 - 1.270 at 20° c {68°F} CLEANING THE BATTERY 1. 2.

If the terminals at the top of the battery are dirty, clean them with cold water or lukewarm water. Apply a light coating of grease to the terminals to pre vent them from rusting so as to prevent faulty contact.

CONNECTING THE BATTERY CABLES 1. 2.

Clamp the cables securely to prevent improper contact between the cables and the battery terminals. Be very careful not to connect the(+) and(-) leads in reverse.(Because this may cause damage to the equip ment and batteries.)

ELECTRICAL EQUIPMENT

Hino K13C Hino K13D

EE-9

ENGINE STARTING CIRCUIT STARTER SWITCH INSPECTION Check the continuity between terminals.

Type-I

Terminals � B Switch position � PRE-HEAT 0

SM20-2059

-0

OFF ON

START

V -v

u-rv

ACC

V 'V

Type-II Switch position

Terminals

OFF II Ill

STARTER BLOCK RELAY INSPECTION C

1. 2. 3. E SW

N--+-11::==----==:JrSM20-1530

Apply voltage to terminals; 24V to terminal SW, Ground to terminal E. If the relay is normal, terminal C and B switches on. Then apply voltage to terminals; 24V to terminal SW, 12V to terminal N, Ground to terminal E. If the relay is normal, relay does not operate. {Safety system operates.)

BATTERY SWITCH INSPECTION (IF SO EQUIPPED) 8

Check the continuity between terminals.

Terminals Switch position � ON OFF

Between terminals Continuity No continuity

SM20-1527

BATTERY RELAY INSPECTION (IF FITTED) 1. 2.

Apply voltage to terminals; 24V to terminal 1, Ground to terminal 2. If the relay is normal, terminals 3 and 4 switches on.

Hino K13C

EE-10 Hino K13D

ELECTRICAL EQUIPMENT

INTAKE AIR HEATER CIRCUIT (IF SO EQUIPPED) INTAKE AIR HEATER INSPECTION Check the continuity between terminals.

SM20-1236

GLOW CONTROLLER INSPECTION Check the continuity between terminals.

SM20-1323

INTAKE AIR HEATER RELAY INSPECTION (Type-I) 1.

(Type-II)

,.(SW

M�

Apply voltage to terminals; 24V to terminal SW, Ground to terminal L. If the relay is normal, terminals S and F switches on.

m�

Apply voltage to terminals; 24V to terminal SW, Ground to terminal L. If the relay is normal, terminals S and C or S and F switches on.

SM20-1327

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Hino K13C Hino K13D

ELECTRICAL EQUIPMENT

EE-11

ENGINE STOP CIRCUIT CHECK THE OPERATION OF THE SOLENOID AND ADJUST THE LINK ROD. 1. 2.

Connect the battery to the solenoid terminals and con firm that the link rod is pulled by the solenoid. Push fully the solenoid plunger by hands and confirm that there is a clearance between the stopper and the stop lever.

Standard clearance: 2 - 3 mm {0.0787 4 - 0.1181 in.}

SM20-1356

If there is no clearance, adjust it by the position of the link rod. NOTE: o If the clearance adjustment is unsatisfactory or the action of the solenoid is sluggish, solenoid will be burnt out and its output will be insufficient or in sufficient engine stoppage may result. o Install the link rod with its nut upward. COOLANT TEMPERATURE SWITCH (FOR EMERGENCY STOPI INSPECTION Check the continuity between terminals. Type-I

I� Temperature:

Terminals

oc {Of}

More than 100-104 {212-219} SM20-1151A

Less than 95 {203}

Type-II

Terminals Temperature: oc {Of} More than 53-57{128-134}

-0

Less than 48 {118}

----

OIL PRESSURE SWITCH (FOR EMERGENCY STOP) INSPECTION 1. 2.

Start the engine and disconnect the coupler. Check the continuity between terminal and engine ground. Engine stop

Terminal

Engine ground

....,

Engine running

SM20-037

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

EE-12 Hino K13C Hino K13D

ELECTRICAL EQUIPMENT

METER AND GAUGE CIRCUIT COOLANT TEMPERATURE SENDER GAUGE INSPECTION Warm up the sender gauge and measure the resistance between terminal and body ground. 80°C {176°F}

Temperature Resistance (Q)

13.1

��r�

100° c {212° FJ

37.7

�t�

SM20-042

COOLANT TEMPERATURE GAUGE INSPECTION 1. 2.

Wire gauges, battery and variable resistor as shown in figure. Check indicated value on gauge. 65 ��

36.5��

Standard gauge reading: °C { °F}

80 {176)

100 {212)

Allowable value: ° C { °F}

±5 {41)

±3 {37.4)

Resistance: Q

SM20-1152

OIL TEMPERATURE GAUGE INSPECTION (IF FITTED) 1.

Wire gauges, battery and variable resistor as shown in figure. Check indicated value on gauge.

Resistance: Q °

Standard gauge reading: C { F} °

Allowable value: C { F}

65 ��

36.5 ��

80 {176)

100 {212)

±5 {41)

±3 {37.4)

SM20-1360

OIL PRESSURE GAUGE INSPECTION (IF FITTED) 1. 2. 3.

PRESSURE

SM20-1534

Wire gauge, battery and the sender as shown in figure. Apply air pressure to the sender gauge and check the receiver. If it is not correct, replace the either one (receiver or sender) and check again.

Hino K13C Hino K13D

ELECTRICAL EQUIPMENT

EE-13

REVOLUTION SENSOR INSPECTION (IF SO EQUIPPED) Check the continuity between terminals. If the revolution sensor is normal, there will be continu ity between terminals.

TACHOMETER INSPECTION (IF SO EQUIPPED)

TYPE-I

1. 2.

Connect a turn-up test tachometer, and start the engine. Check the tester and tachometer indications. If the indi cated value of tachometer is not correct, replace the tachometer.

TYPE-I Standard revolution (r/min)

500

1,000

Allowable value Ir/min)

±50

1,500 2,000 2,500 ±75

±100

±125

SM20-2058

TYPE-II

Standard revolution (r/min)

500

1,000

1,500

2,000

Allowable value (r/min)

±25

±50

±45

±100

SM20-2061

AMMETER INSPECTION (IF SO EQUIPPED) Check the continuity between terminals 1 and 2.

SM20-1143

ENGINE HOUR-METER INSPECTION CONNECTOR (LAMP)

1. 2.

� �

SM20-2074

Wire the hourmeter, battery and resistor as shown in the figure at left. Check the operation of the hourmeter. If the operation is not correct, replace the hourmeter.

Hino K13C

EE-14 Hino K13D

ELECTRICAL EQUIPMENT PRESSURE SWITCH INSPECTION (HOURMETER CONTROL SWITCH) 1.

Check the continuity battery terminals. a. Check that there is no continuity when the engine is stopped. b. Check that there is no continuity when the engine is running. 2. If the continuity is not correct, replace the oil pressure switch. SM20-2075

BOOST COMPENSATOR CANCEL SYSTEM WITH SOLENOID INSPECTION OF SOLENOID AND LINK ROD 1. 2.

Connect the battery to the solenoid terminals and conÂ firm that the link rod is pulled by the solenoid. Push fully the solenoid plunger by hands and confirm that there is a clearance between the stopper and the cancel lever.

Standard clearance: 2-3 mm {0.07874-0.1181 in.}

LINK ROD CANCEL LEVER

If there is no clearance, adjust it by the position of the link rod.

NOTE: o If the clearance adjustment is unsatisfactory or the action of the solenoid is sluggish, solenoid will be burnt out and its output will be insufficient. o Install the link rod with its nut upward.

-tt---CLEARANCE

SM20-2060

Hino K13C Engine Parts Contact: email EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

Hino K13C Hino K13D

ELECTRICAL WIRING DIAGRAM INTAKE AIR HEATER

SOLENOID

HEAT RESISTING WIRE

rt---_;;,__,,.:;,_

-=OIL PRESS. SWITCH

COOLANT TEMP. SWITCH

2 STARTER BLOCK RELAY

FUSE BOX

INTAKE AIR HEATER RELAY

1.25 - 2.0

rn r rn n -I :lei

GENER ATOR

'='

0.85

1.25

rn z -I

5 2

0.85

OIL PRESS. SENDER GAUGE

"'Cl

:!!:

COOLANT TEMP. G AUGE

OIL PRESS . GAUGE

-=-

rn 1:1 C:

STARTER

STARTER SWITCH

-=STARTER SWITCH CONNECTION TABLE

� u,

MEMO

Hino Diesel Engine Parts contact: Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com Heavy Equipment Restoration Parts LLC 4730 118th Ave Fennville Michigan 49408 USA Engine Parts for Heavy Equipment Hino Diesel Engine Parts Mitsubishi Diesel Engine Parts Nissan Diesel Engine Parts Isuzu Diesel Engine Parts Mercedes Benz Industrial Diesel Engine Parts