INDEX: ENGINE GROUP
GENERAL INTRODUCTION ENGINE
WORKSHOP MANUAL
TURBOCHARGER INJECTION PUMP INJECTION PUMP GOVERNOR GENERATOR STARTER
INJECTION PUMP CALIBRATION
ELECTRICAL EQUIPMENT
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GI-5
GENERAL INTRODUCTION
SPECIFICATIONS DIESEL ENGINE FOR INDUSTRIAL USE
HINO
•
J08C-TI
7.961 liters, 4-cycle 6-cyl., water-cooled turbocharged
PERFORMANCE (STD. specs.)
GENERAL USE (JIS) J08CUD-KJGA,J08CUD-KJGD
J08CUD-KJGB,J08CUD-KJGE, J08CUD-KJGG
J08CUD-KJGC,J08CUD-KJGH
Output kW{PS} at r/min
Max.Torque N࣬m{kg࣬m} at r/min
Output kW{PS} at r/min
Max.Torque N࣬m{kg࣬m} at r/min
Output kW{PS} at r/min
Max.Torque N࣬m{kg࣬m} at r/min
148{202}/2,400
740{76}/1,400
165{224}/2,200
860{87}/1,400
184{250}/2,200
970{99}/1,400
•
ENGINE DESCRIPTION 1. Type
2. 3. 4. 5. 6. 7.
Combustion system Bore x Stroke Displacement Compression ratio Direction of rotation Dimensions (L x W x H)
8. Dry weight
•
FEATURES 1. Cylinder block 2. Cylinder head 3. Crankshaft 4. Piston and rings
5. Camshaft 6. Valves
Diesel, 4-cycle, 6cyl., in-line, overhead camshaft, 24valves, watercooled, Turbocharged Direct injection 114 x 130 mm {4.49 x 5.12 in.} 7.961 liters {485.8 cu. in.} 18.0 Counterclockwise viewed from flywheel Approx. L1,140 x W808 x H1,019 mm (W: from turbo to oil level gauge) {44.9x 31.8 x 40.1 in.} Approx. 580kg {1,279 lb}
Mono block cast iron with replaceable dry liner Single piece cast iron Induction-hardened, die forged special steel with counter weights Heat-resistance aluminum alloy Two compression rings, chrome plated One oil ring , chrome plated with coil expander Induction hardened carbon steel Heat resistance steel
EN-1
ENGINE
EN-Y291E-01
CHAPTER EN ENGINE J08C-TI DATA AND SPECIFICATION ................................................. EN- 2 TROUBLESHOOTING ........................................................... EN- 3 ENGINE TUNEUP ................................................................. EN- 8 ENGINE OVERHAUL CRITERIA ........................................... EN- 13 LIQUID GASKET AND APPLICATION POINTS ................... EN- 15 CYLINDER HEAD .................................................................. EN- 20 AIR INTAKE AND EXHAUST SYSTEM ................................ EN- 34 OIL PAN ................................................................................. EN- 37 CRANKSHAFT FRONT END, FLYWHEEL AND FLYWHEEL HOUSING .......................................................... EN- 38 TIMING GEAR ....................................................................... EN- 46 INJECTION PUMP DRIVE ..................................................... EN- 51 MAIN MOVING PARTS AND CYLINDER BLOCK ................ EN- 57 LUBRICATING SYSTEM ....................................................... EN- 74 OIL PUMP AND OIL STRAINER ................................... EN- 75 OIL FILTER AND OIL COOLER ..................................... EN- 77 FUEL SYSTEM ...................................................................... EN- 80 INJECTION NOZZLE (BOSCH MAKE) ......................... EN- 81 INJECTION NOZZLE (TWO-SPRING TYPE - BOSCH MAKE) ........................ EN- 86 FUEL INJECTION PUMP AND FUEL FILTER ............... EN- 98 COOLING SYSTEM ............................................................... EN- 100 COOLANT PUMP .......................................................... EN- 101 THERMOSTAT .............................................................. EN- 105 RADIATOR..................................................................... EN- 106 ELECTRICAL PARTS ............................................................. EN- 107 GENERATOR ................................................................. EN- 108 STARTER ....................................................................... EN- 108 ENGINE REVOLUTION SENSOR ......................................... EN- 109 DSY111A TSY106A TUY107A OCY107A LGY109A MPY113A LSY108A FSY109A CSY108A CPY108A
T=45 {459, 33}*
ENGINE
EN-21
ENGINE
OIL PAN
EN-37
EN-38
ENGINE
CRANKSHAFT FRONT END, FLYWHEEL AND FLYWHEEL HOUSING
ENGINE
EN-77
EN-86
ENGINE
INJECTION NOZZLE (TWO-SPRING TYPE - BOSCH MAKE)
ENGINE
EN-87
EN-92
ENGINE
ENGINE
THERMOSTAT
EN-105
EN-106
ENGINE
ENGINE
EN-107
EN-108
ENGINE
ENGINE
EN-109
CALIBRATION
CHAPTER C INJECTION PUMP
CALIBRATION C-Y411E-01 J08CUD-KJGA,J08CUD-KJGD(22020-6410) ....................... C- 2 C-Y412E-01 J08CUD-KJGB,J08CUD-KJGE,J08CUD-KJGG(22020-6400) ... C- 4 C-Y413E-01 J08CUD-KJGC,J08CUD-KJGH(22020-6460) ....................... C- 6
C-1
C-4
CALIBRATION
INJECTION PUMP NUMBER : 22020-6400
C-Y412E-01
Engine model E
J08CUD-KJGB,J08CUD-KJGE ,J08CUD-KJGG
Injection pump part number INJECTION Injection pump type PUMP SPECIFICATION Governor type Feed pump type
NP-FP/KEP-AD
Test nozzle and nozzle holder
105780-8140
Test nozzle opening pressure
17.2 MPa{175 kgf/cm2, 2,489 lbf/in2.}
Outer diameter
6.0 mm {0.236 in.}
Inner diameter
2.0 mm {0.079 in.}
Length
600 mm {23.6 in.}
Type of fuel
SAE J967C
Fuel temperature
40-45˚ C {104-113˚ F}
Fuel feed pressure
255 kPa {2.6 kgf/cm2, 37 lbf/in2.}
Overflow valve opening pressure
255kPa {2.6 kgf/cm2, 37 lbf/in2}
Rotation
Counterclockwise viewed from drive side
Injection order
1-4-2-6-3-5
Injection interval
60˚ ±15'
Pre-stroke
3.77-3.83 mm {0.149-0.150 in.}
Rack position mm {in.}
INJECTION VOLUME
NP-EP/RSV200-1350 —
Calibration
INJECTION TIMING
NP-PE6MD105/410LS2
Timer type
INJECTION Injection pipe VOLUME ADJUSTMENT
OVERFLOW VALVE
22020-6400
Pump revolution r/min
Measuring strokes
Injection volume cm3 {cu.in.}
Variation limit %
Boost pressure kPa {mmHg,inHg}
A
10.0{0.394}
700
500
58.75-60.75 {3.585-3.707}
±3.5
28.0 {210,8} or more
B
(10.0{0.394})
1,100
500
58.75-61.75 {3.585-3.768}
—
28.0 {210,8} or more
D
6.0 {0.236}
4 20
500
3.5-4.5 {0.214-0.274}
±10
—
E
—
100
500
70.0-80.0 {4.272-4.881}
—
—
ADJUSTING POSITION SWIVEL LEVER MAXIMUM ADJUST SCREW SPEED STOPPER BOLT
IDLING SUB SETTING SCREW
CONTROL LEVER
GOVERNOR ADJUSTMENT
STOP LEVER
IDLING SCREW
FULL LOAD STOPPER BOLT
SM4-070
C-6
CALIBRATION
INJECTION PUMP NUMBER : 22020-6460
C-Y413E-01
Engine model
J08CUD-KJG,J08CUD-KJGH
Injection pump part number INJECTION Injection pump type PUMP SPECIFICATION Governor type Feed pump type
NP-FP/KEP-AD
Test nozzle and nozzle holder
105780-8140
Test nozzle opening pressure
17.2 MPa{175 kgf/cm2, 2,489 lbf/in2.}
Outer diameter
6.0 mm {0.236 in.}
Inner diameter
2.0 mm {0.079 in.}
Length
600 mm {23.6 in.}
Type of fuel
SAE J967C
Fuel temperature
40-45˚ C {104-113˚ F}
Fuel feed pressure
255 kPa {2.6 kgf/cm2, 37 lbf/in2.}
Overflow valve opening pressure
255kPa {2.6 kgf/cm2, 37 lbf/in2}
Rotation
Counterclockwise viewed from drive side
Injection order
1-4-2-6-3-5
Injection interval
60˚ ±15'
Pre-stroke
3.77-3.83 mm {0.149-0.150 in.}
Rack position mm {in.}
INJECTION VOLUME
NP-EP/RSV200-1350 —
Calibration
INJECTION TIMING
NP-PE6MD105/410LS2
Timer type
INJECTION Injection pipe VOLUME ADJUSTMENT
OVERFLOW VALVE
22020-6460
Pump revolution r/min
Measuring strokes
Injection volume cm3 {cu.in.}
Variation limit %
Boost pressure kPa {mmHg,inHg}
A
10.3{0.406}
700
500
69.5-71.5 {4.241-4.363}
±3.5
36.0 {270,11} or more
B
(10.3{0.406})
1,050
500
66.0-69.0 {4.028-4.210}
—
36.0 {270,11} or more
D
6.0 {0.236}
3 90
500
3.5-4.5 {0.214-0.274}
±10
—
E
—
100
500
70.0-80.0 {4.272-4.881}
—
—
ADJUSTING POSITION SWIVEL LEVER MAXIMUM ADJUST SCREW SPEED STOPPER BOLT
IDLING SUB SETTING SCREW
CONTROL LEVER
GOVERNOR ADJUSTMENT
STOP LEVER
IDLING SCREW
FULL LOAD STOPPER BOLT
SM4-070
1-1, HINODAI 3-CHOME, HINO-SHI, TOKYO 191-8660 JAPAN
PRINTED IN JAPAN Pub. No. S6-Y011E-03 '13-3