Hino J05D & J08E Common Rail Engine Service Manual PDF (FR)

For DENSO Authorized ECD Service Dealer Only Diesel Injection Pump SERVICE MANUAL Common Rail System for HINO J05D/J08E Type Engine OPERATION October, 2003 00400041E -1 -1

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TABLE OF CONTENTS

TABLE OF CONTENTS 1. Product Application ------------------------------------------------------------------------------------- 1 1.1 Application ------------------------------------------------------------------------------------------------------------------- 1 1.2 System Components Parts Numbers --------------------------------------------------------------------------------- 1 2.

Outline ------------------------------------------------------------------------------------------------------ 2 2.1 Features of System ------------------------------------------------------------------------------------------------------- 2 [1] System Characteristics ------------------------------------------------------------------------------------------------ 2 2.2 Outline of System ---------------------------------------------------------------------------------------------------------- 4 [2] Comparison to the Conventional System ------------------------------------------------------------------------- 3 [1] Composition -------------------------------------------------------------------------------------------------------------- 4 [2] Operation ----------------------------------------------------------------------------------------------------------------- 4 2.3 Fuel System and Control System -------------------------------------------------------------------------------------- 5 [4] Control System ---------------------------------------------------------------------------------------------------------- 5 3.

Construction and Operation--------------------------------------------------------------------------- 6 [3] Fuel System -------------------------------------------------------------------------------------------------------------- 5 3.1 Description of Main Components ------------------------------------------------------------------------------------- 6 [1] Supply Pump (HP3, HP4) --------------------------------------------------------------------------------------------- 6 [2] Description of Supply Pump Components ------------------------------------------------------------------------ 13 [3] Rail -------------------------------------------------------------------------------------------------------------------------- 16 [4] Injector (G2 Type) ------------------------------------------------------------------------------------------------------- 17 [5] Engine ECU (Electronic Control Unit) ------------------------------------------------------------------------------ 22 3.2 Description of Control System Components ------------------------------------------------------------------------ 22 [1] Engine Control System Diagram ------------------------------------------------------------------------------------ 22 [2] Sensor and Relays ----------------------------------------------------------------------------------------------------- 23 3.3 Various Types of Controls ----------------------------------------------------------------------------------------------- 29 [1] Fuel Injection Rate Control ------------------------------------------------------------------------------------------- 30 [2] Fuel Injection Quantity Control --------------------------------------------------------------------------------------- 31 3.4 Other Relevant Engine Control ----------------------------------------------------------------------------------------- 36 [3] Fuel Injection Timing Control ----------------------------------------------------------------------------------------- 35 [1] EGR Control -------------------------------------------------------------------------------------------------------------- 36 3.5 Engine ECU ----------------------------------------------------------------------------------------------------------------- 37 [1] Diagnosis Codes -------------------------------------------------------------------------------------------------------- 37 [2] ECU External Wiring Diagram --------------------------------------------------------------------------------------- 44 [3] ECU Connector Diagram ---------------------------------------------------------------------------------------------- 45 0

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1.2 System Components Parts Number

1. Product Application 1.1 Application 1.2 System Components Parts Number 1 Vehicle Name Vehicle Model Engine Model Exhaust Volume Reference Medium Truck HINO145, HINO165, HINO185 J05D 4.73L Sales from Early ’04 HINO238, HINO268, HINO308, HINO338 J08E 7.68L Part Name Vehicle Name DENSO Part Number Car Manufacturer Part Number Reference Supply Pump Medium Truck HINO238, HINO268, HINO308, HINO338 294050-0011 22730-1311A Injector 095000-5281 23910-1360A Rail 095440-0480 22760-1180A Engine ECU 102758-3010 89560-6540A Accelerator Position Sensor 198800-3160 78010-1200A Coolant Temp.

Sensor 071560-0110 83420-1250A Crankshaft Position Sensor 029600-0570 89410-1280A Cylinder Recognition Sensor 949979-1360 89410-1590A Intake Air Pressure Sensor 079800-5890 89390-1080A EGR Valve 135000-7091 17350-1220A Air Flow Meter 197400-2000 22204-21010B For EGR Control Supply Pump Medium Truck HINO145, HINO165, HINO185 294000-0251 22730-1321A Injector 095000-5391 23910-1310A Rail 095440-0530 22760-1220A Engine ECU 102758-3010 89560-6540A Accelerator Position Sensor 198800-3160 78010-1200A Coolant Temp.

Sensor 071560-0110 83420-1250A Crankshaft Position Sensor 029600-0570 89410-1280A Cylinder Recognition Sensor 949979-1360 89410-1590A Intake Air Pressure Sensor 079800-5890 89390-1080A EGR Valve 135000-7071 17350-1210A Air Flow Meter 197400-2000 22204-21010B For EGR Control

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(4) EGR (Exhaust Gas Recirculation) Control

2. Outline 2.1 Features of System The common rail system was developed primarily to cope with exhaust gas regulations for diesel engines, and aimed for 1. further improved fuel economy; 2. noise reduction; and 3. high power output. [1] System Characteristics The common rail system uses a type of accumulation chamber called a rail to store pressur- ized fuel, and injectors that contain electronically controlled solenoid valves to spray the pres- surized fuel into the cylinders. Because the engine ECU controls the injection system (including the injection pressure, injection rate, and injection timing), the system is unaffected by the engine speed or load.

This ensures a stable injection pressure at all times, particularly in the low engine speed range, and dramatically decreases the amount of black smoke ordi- narily emitted by a diesel engine during start-up and acceleration. As a result, exhaust gas emissions are cleaner and reduced, and higher power output is achieved. (1) Injection Pressure Control a. Enables high-pressure injection, even in the low engine speed range. b. Optimizes control to minimize particulate matter and NOx emissions. (2) Injection Timing Control a. Optimally controls the timing to suit driving conditions. (3) Injection Rate Control a. Pilot injection control sprays a small amount of fuel before the main injection.

Common Rail System Injection Timing Control Injection Rate Control Optimization Pilot Injection Speed Injection Rate Common Rail System Main Injection Injection Timing Crankshaft Angle Injection Quantity Control Conventional Pump Cylinder Injection Volume Correction Speed 㧝㧟㧠㧞 QD0734E (4) EGR (Exhaust Gas Recirculation) Control a. By recirculating the exhaust gas into the intake side of the engine, the combustion temperature is reduced and NOx is decreased. 2 Injection Pressure Control Optimization, H Common Rail System Pressure Injection Conventional Pump Speed igh Pressurization Particulate NOx Injection Pressure imization, H igh Pressu

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