Hino J08C-TP and J08C-TR Engine Service Manual PDF (EN)

ENGINE

1 INDEX ENGINE 3-1-1 Models J08C-TP and J08C-TR 3-228E-05 3 3 CHAPTER ENGINE Models:

J08C-TP and J08C-TR TROUBLESHOOTING...............................................................3- 1-3 SPECIAL TOOLS ......................................................................3- 2-1 ENGINE OVERHAUL CRITERIA ..............................................3- 3-1 DISMOUNTING THE ENGINE ASSEMBLY ..............................3- 4-1 REMOVAL OF THE ENGINE COMPONENT PARTS ...............3- 5-1 CAMSHAFT HOUSING AND CYLINDER HEAD ......................3- 6-1 CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING ..............................................................3- 7-1 TIMING GEAR ...........................................................................3- 8-1 PISTON, CRANKSHAFT AND CYLINDER BLOCK .................3- 9-1 LUBRICATING SYSTEM ...........................................................3-10-1 COOLING SYSTEM...................................................................3- 11-1 FUEL SYSTEM ..........................................................................3-12-1 AIR INTAKE AND EXHAUST SYSTEM ....................................3-13-1 ENGINE CONTROL SYSTEM ...................................................3-14-1 ELECTRICAL PARTS................................................................3-15-1 AIR COMPRESSOR AND POWER STEERING PUMP ............3-16-1 INSTALLATION OF THE ENGINE COMPONENT PARTS .......3-17-1 ENGINE TUNE-UP ....................................................................3-18-1 MOUNTING THE ENGINE ASSEMBLY ....................................3-19-1 LIQUID GASKET AND APPLICATION POINTS .......................3-20-1 POWER TAKE-OFF (IF FITTED) ..............................................3-21-1

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TROUBLESHOOTING

1 page 1 Models J08C-TP and J08C-TR 3-1-2 ENGINE TROUBLESHOOTING (ENGINE) Symptom Possible cause Remedy/Prevention Engine overheating Coolant G Insufficient coolant ........................................ Add coolant ` G Defective thermostat ..................................... Replace the thermostat G Overflow of coolant due to leakage of .......... Repair exhaust into cooling system G Damaged rubber hose .................................. Replace rubber hose G Coolant leakage due to deteriorated............. Replace rubber hose rubber hose G Coolant leakage from coolant pump ............. Replace the coolant pump G Coolant leakage from rubber hose ...............

Retighten or replace clamp G Coolant leakage from cylinder head ............. Replace gasket connection gasket Coolant pump G Bearing seizure ............................................. Replace G Damaged (corroded) vane ............................ Replace vane Radiator G Clogged with rust and scale.......................... Clean radiator G Clogged with iron oxide due to leakage ........ Clean coolant passage and of exhaust into cooling system correct exhaust leakage G Coolant leakage ............................................ Repair or replace radiator G Damaged cooling fan .................................... Replace cooling fan G Clogged radiator core due to mud or ............

Clean radiator G Defective radiator cap pressure valve .......... Replace radiator cap other debris G Incorrect injection timing ............................... Adjust injection timing G Reduced injection pressure .......................... Adjust injection pressure G Poor fuel........................................................ Use good quality fuel G Poor nozzle spray ......................................... Adjust or replace nozzle G Unsatisfactory automatic timer...................... Repair or replace timer advance angle Abnormal combustion

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TROUBLESHOOTING

1 page 1 ENGINE 3-1-3 Models J08C-TP and J08C-TR Symptom Possible cause Remedy/Prevention Engine overheating Other problems G Defective or deteriorated engine oil .............. Change engine oil G Unsatisfactory operation of oil pump ............ Replace or repair G Insufficient oil ................................................ Add oil G Brake drag .................................................... Adjust Severe operating conditions G Lugging the engine ....................................... Operate engine properly Excessive oil consumption Pistons, cylinder liners and piston rings G Wear of piston rings and cylinder liner ..........

Replace piston rings and cylinder liner G Worn, sticking or broken piston rings ............ Replace piston rings and cylinder liner G Insufficient tension on piston rings ................ Replace piston rings and cylinder liner G Unsatisfactory break-in of piston rings .......... Replace piston rings and G Unsuitable oil (viscosity too low) ................... Change oil as required and cylinder liner replace piston rings and cylinder liner G Incorrectly fitted piston rings (upside down) .. Replace piston rings G Gaps of piston rings in line with each other .. Reassemble piston rings Valves and valve guides G Worn valve stem ...........................................

Replace valve and valve guide G Worn valve guide .......................................... Replace valve guide G Incorrectly fitted valve stem seal................... Replace the stem seal G Excessive lubricant on rocker arm ................ Check clearance of rocker arm and shaft Excess oil feed G Defective oil level gauge ............................... Replace oil level gauge G Oil level too high ........................................... Drain excess oil

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TROUBLESHOOTING

1 page 1 Models J08C-TP and J08C-TR 3-1-4 ENGINE Symptom Possible cause Remedy/Prevention Excessive oil consumption Oil leakage from miscellaneous parts G Oil leakage from oil seal................................ Replace oil seal G Cracks or blowhole in cylinder block ............. Replace cylinder block G Oil leakage from connections of oil lines ...... Tighten connections of oil lines G Oil leakage from oil cooler ............................ Replace oil cooler G Oil leakage from oil pan gasket .................... Replace oil pan gasket G Oil leakage from O-ring ................................. Replace O-ring Other problems G Overcooled engine ........................................

Warm up engine before moving (low temperature wear) vehicle Check cooling system NOTE: If oil consumption is excessive, the problems above will occur. Complaints from the customer are often related to such problems. 1. White smoke is emitted continuously when the engine is run at high speed. 2. White smoke is emitted only immediately after the engine speed is abruptly raised when idling. 3. The tail pipe is blackened with oil. 4. Oil leaks from the flanges of the exhaust manifold. 5. Lack of power. 6. Excessive blow-by gas. Piston seizure and cylinder liner cylinder liner and piston pin as required and cylinder liner and cylinder liner Pistons, cylinder liners and piston rings

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