New Holland Hino E385C User manual
E385C
Print No. 84532047A
Print No. 84532047A
SERVICE MANUAL
SERVICE
MANUAL
E385C
Hino Diesel Engine
Supplement to Service Manual 84527569A
Hino Diesel Engine
Supplement to
Service Manual
84527569A
WARNING
Read this manual before operating the machine
Most accidents occurring during work are due to non-observance of simple safety norms and elementary
precautions.
Many accidents can be avoided if the causes are known and opportune cautions taken beforehand.
There is no device or protection, no matter how advanced, that may prove so effective at avoiding accidents
as a careful and attentive behaviour.
COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A.
Product Support
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY
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E385C
ENGINE
(HINO DIESEL ENGINE J08E-UV)
CONTENTS
Group 1 General ........................................................................................ W5-1
Group 2 Standard Value ............................................................................. W5-2
Group 3 Parts to be prepared .................................................................... W5-3
Group 4 Engine assembly/disassembly ..................................................... W5-4
Group 5 Fuel System ................................................................................. W5-5
Group 6 Emission Control .......................................................................... W5-6
Group 7 Electrical........................................................................................ W5-7
Group 8 Intake ............................................................................................ W5-8
Group 9 Engine Mechanical ....................................................................... W5-9
Group 10 Exhaust ...................................................................................... W5-10
Group 11 Cooling ........................................................................................W5-11
Group 12 Lubrication .................................................................................. W5-12
Group 13 Starting and Charging ................................................................ W5-13
Group 14 Turbocharger .............................................................................. W5-14
Group 15 Failure Diagnosis for each Engine Status .................................. W5-15
Group 16 Engine Diagnosis Code .............................................................. W5-16
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GENERAL E385C
W5-1-1
ENGINE
1 GENERAL
GeneralGeneral informa tion
Warning .................................................................. 1-2
How to read this manual ........................................ 1-3
Precautions for work ............................................... 1-7
Tightening of engine bolts and nuts...................... 1-11
Tightening of flare nuts and hoses........................ 1-13
Taper thread sealant for piping............................. 1-14
Assembly of joints and gaskets for piping............. 1-15
Handling of liquid gasket....................................... 1-17
Failure diagnosis table for each problem .............. 1-18
Failure diagnosis procedures................................ 1-19
Failure diagnosis using Hino-DX .......................... 1-21
Connection method of Hino-DX ............................ 1-24
Chassis number and engine number ................... 1-26
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GENERALE385C
W5-1-2
Warning
JP30002010102001
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the machine, but also put service
engineers and surrounding people in danger.
•Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
machine. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
•Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
•If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of machine
may be impaired. Never use a method or tool not recommended.
•This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to machine due to improper method may not impair safety and reliability
of machine. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.
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GENERAL E385C
W5-1-3
How to read this manual
JP30002010102002
1. Scope of repair work
(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly⋅disassembly and inspection⋅adjustment" and "Final inspection".
(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,
assembly⋅disassembly and inspection⋅adjustment" in the second process. Explanation of "Final inspection"
in the third process is omitted here.
(3) Although the following work is not described in this manual, it should be performed in actual work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual inspection
2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.
3. Items to be prepared
(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually
equipped in general service shop are omitted.
4. How to read sections and titles
(1) Sections are classified according to J2008, SAE standard.
(2) For areas that show system names like "Engine control system", "Inspection", "Adjustment",
"Replacement", "Overhaul", etc. of components are described.
(3) For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
(4) Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in
the illustration. Major names and tightening torque are listed in the table.)
! CAUTION
The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in June, 2010. (Some areas do not show exploded view. They
will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts
catalog for confirmation of illustrations and part numbers and for ordering parts.
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GENERALE385C
W5-1-4
5. How to read troubleshooting
(1) Failure diagnosis in this manual describes Step 2 and Step 3 below :
(2) Pre-inspection
(1) Question "Step 1" Hear from customers for conditions and environments of
failures and check the fact.
(2) Pre-inspection
(3) Reproduction method "Step 2"
Perform diagnosis inspection, status inspection,
function inspection and basic inspection. Check the
failure status. If it is difficult to reproduce the problem
with status inspection, use the reproduction method.
(4) Troubleshooting for each
diagnosis code
(5) Troubleshooting for each
failure status
"Step 3"
Summarize inspection results obtained from Step 2.
Perform inspection systematically according to
troubleshooting procedures for each diagnosis code or
failure status.
(6) Confirmation test "Step 4"
Check if failure occurs again after repair. If it is difficult to
reproduce a failure, perform the confirmation test under
the conditions and environment of the failure.
Pre-
inspection
•Pre-inspection is performed in the following steps :
Diagnosis inspection →Diagnosis deletion →Failure status check (Use the reproduction
method if not reproduced.) →Diagnosis reconfirmation
•Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with failure status. Refer to the troubleshooting chart for
estimated cause of a failure.
•An error code is displayed if a failure occurs instantaneously. If any specific failure is not
found, perform troubleshooting using the reproduction method.
•Failure status check
If failure is reproduced, perform Step 2 →Step 3 →Step 4.
If failure is not reproduced, use the reproduction method (simulation of external
conditions or check of each wire harness and connector, etc.)
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GENERAL E385C
W5-1-5
6. How to read explanation details
(1) Part layout
✩It is the ID number for parts to prepare electronic data. It is not required for repair work.
ENGINE MECHANICAL [J08E] 9–17
Timing Gear Cover and Flywheel Housing
Part layout
JP04117090402003
*Parts not to be reused.
Tightening torque
Service procedureOverhaul item
11308
Flywheel housing
11390
End plate
11309
Oil seal retainer
9828A
Front oil seal*
11357
Gasket*
9828B
Rear oil seal*
11357A
Gasket*
9069H
M14 : 171.5N m{1, 750kgf cm}
9419A
M16 : 196N m{2, 000kgf cm}
9069J
M12 : 97N m{990kgf cm}
9419B
M16 : 196N m{2, 000kgf cm}
SAPH041170900182
Example
Part name code
Part catalog Fig. No.
Description of
part name code
Left: Part name code (nut)
SAPH300020100001
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