New Holland Hino E385C Service Manual Download Page 1

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E385C

Print No. 84532047A

SERVICE MANUAL

SERVICE

MANUAL

E385C

Hino Diesel Engine

Supplement to Service Manual 84527569A

Hino Diesel Engine

Supplement to

Service Manual

84527569A

Summary of Contents for Hino E385C

Page 1: ...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 ...

Page 2: ...CONSTRUCTION SERVICEMANUAL E385C Hino Diesel Engine Supplement to Service Manual 84527569A Print no 84532047A 1st Edition English 09 11 Find manuals at https best manuals com ...

Page 3: ... 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 Find manuals at https best manuals com ...

Page 4: ... 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 Find manuals at https best manuals com ...

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Page 6: ...tening 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 Find manuals at https best manuals com ...

Page 7: ...o 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 reco...

Page 8: ...tc 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 describ...

Page 9: ... 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 befo...

Page 10: ... reused Tightening torque Service procedure Overhaul 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 P...

Page 11: ...left direction is left and the right direction is right 2 Standard value Basic dimension excluding tolerance and clearance generated by tolerances when two parts are joined 3 Repair limit It is the value requiring repair Symbol of or with the value means increase or decrease to the standard value 4 Operation limit It is the value requiring replacement Symbol of or with the value means increase or ...

Page 12: ...nt burn b Do not put your clothes or tools near the rotating part in particular cooling fan or V belt during operation of the engine c Remove the starter key when the engine is not started d Start the engine at a well ventilated place so that carbon monoxide may not be filled e Since gas from the fuel or the battery is flammable do not spark a fire or smoke a cigarette near the area f Since the ba...

Page 13: ...laced from parts to be reused 4 Washing of disassembled parts Clean and wash parts to be reused well 5 Inspection and measurement Inspect and measure parts to be reused as required 6 Assembly a Keep the specified standard values tightening torque adjusting values etc and assemble correct parts in the correct order b Be sure to use genuine parts for parts to be replaced c Use new packing gasket O r...

Page 14: ...eassemble it to the original position b When parts are assembled be careful not to pinch a wire harness 4 Handling of connector a When a connector is removed hold the connector as shown by the arrow in the left and pull it out Do not pull the wire harness b Unlock the locking connector before pulling c Insert the locking connector completely until it clicks d To insert a test lead into the connect...

Page 15: ...elding area Connect grounding from a bolt plated bolt or a frame near the welding area Remove paint of the frame for connection of grounding from the frame The seal and the bearing etc that please make sure do not enter between the weld and the ground section 7 Other precautions a Put a cover on rubber hoses wire harnesses pipes tires etc around the welding area so that they may not be exposed to ...

Page 16: ...71 5 1 750 216 2 210 M14 x 2 Coarse thread 154 1 570 199 2 030 Remark Bolt with number 7 on the head Bolt with number 9 on the head Screw diameter x Pitch 4T 7T 9T M6 x 1 Coarse thread 6 60 10 100 13 130 M8 x 1 25 Coarse thread 14 140 25 250 31 320 M10 x 1 25 Fine thread 29 300 51 520 64 650 M10 x 1 5 Coarse thread 26 270 47 480 59 600 M12 x 1 25 Fine thread 54 550 93 950 118 1 200 M12 x 1 75 Coar...

Page 17: ...le method 1 Precautions Some engines are tightened with the plastic region tightening method Since it is different from the conventional method tighten it according to the instruction in the text 2 Parts tightened Cylinder head bolt crankshaft main bearing cap bolt connecting rod bearing cap bolt etc CAUTION Measure the overall length of the bolt before assembly and replace the bolt if the length ...

Page 18: ...53 50 11 3 6 21 1 214 10 15 0 7 32 3 326 31 24 2 2 44 5 449 51 32 3 6 64 5 653 51 47 3 6 66 2 5 673 25 47 1 8 Hose outer diameter φ10 5 fitting Hose outer diameter φ13 φ20 φ22 fitting at packing Hose outer diameter PF3 8 fitting Air hose 21 5 1 5 215 15 15 1 46 2 5 469 25 33 1 8 Only meter gauge 10 100 7 Brake hose Packing 51 5 7 5 525 75 15 1 46 2 5 469 25 33 1 8 Screw nominal size M14 M16 M20 M2...

Page 19: ...ening torque in the table below Remove dirt completely from the mating part female before tightening CAUTION If your eye or skin comes in contact with sealant wash it off immediately with water Tightening torque of taper joint Unit N m kgf cm lbf ft 2 When a sealing tape is replaced with sealant remove the tape completely first as in 1 CAUTION Be careful to prevent entry of dirt or foreign matter ...

Page 20: ...ing apply the specified pressure to each pipe joint to ensure that there is no leak 4 Observe the values above for each tightening torque When assembled soft washer 4840FR N aluminum and rubber carbon pressure bonding is loosened or removed be sure to replace it with a new part This is not necessary for normal retightening Sealing method Gasket sealing method Aluminum Rubber or Copper Metal sealin...

Page 21: ... Gasket Sealing surface 5 places Sealing surface 3 places Nut Connector nipple Flare connector Gasket Sealing surface 5 places Joint bolt Sealing surface 8 places Lock washer Nut Bracket Sealing surface 1 place Nut Connector nipple Sealing surface 1 place Flare connector Box nut Sealing surface 8 places Joint pipe Nut Lock washer 3 way joint Bracket Sealing surface 3 places One piece eye joint wit...

Page 22: ...remove the liquid gasket and apply it again 4 Start the engine at least 15 minutes or more after assembly of parts 2 Removal of parts 1 When parts are removed do not pry one place only Remove parts by prying each other using collar or clearance on the flange When gasket is removed be careful to prevent entry of gasket offal into the engine 3 Others 1 When the liquid gasket is contained in a tube u...

Page 23: ...iston ring Replace piston ring and cylinder liner Faulty fixing of piston ring Replace piston ring and cylinder liner Faulty assembly of piston ring Replace piston ring and cylinder liner Faulty engine oil Replace engine oil Faulty piston ring joint Reassemble piston ring Large engine oil consumption valve and valve guide Wear of valve stem Replace valve and valve guide Wear of vavle guide Replace...

Page 24: ... Hino field support system operation manual 3 Deletion of cluster gauge past failure 1 Turn ON the starter switch during pushing the buzzer stop switch 2 When pushing the enter key 3 times during pushing the buzzer stop switch the failure history mode is displayed 3 Press work mode selecting switch and the buzzer stop switch at the same time for 10 seconds or more 4 When the display shows No error...

Page 25: ... 1 Connect the ECU side connector of the signal check harness After deleting the past failure output the diagnosis code again Standard Normal NG OK 1 Remove the connector of the main engine speed sensor and measure the resistance between No 1 and No 2 terminals at the sensor Standard value Approx 125 5 NG OK 1 Measurement of resistance between terminals B B6 B7 SAPH03Z010300010 3 Go to measurement...

Page 26: ... is used for inspection and adjustment of the system in addition to failure diagnosis 1 Hino DX 1 With Hino DX failure of the common rail fuel injection system can be diagnosed The interface box Hino Bowie and the special cable are required for connection to the vehicle SAPH300020100036 ...

Page 27: ... ROM NOTICE Install the software of the Hino Diagnostic eXplorer HinoDX in the PC For the installation method refer to the instruction manual accompanying the CD Hino Bowie 09993 E9070 PC interface CAUTION It is necessary to update hardware The cable between the personal computer and the Hino Bowie is bundled to the Hino Bowie Please use either RS 232C or USB Cable between machine and Hino Bowie S...

Page 28: ...al check connector of the signal check harness for meaurement a Disconnect the connector from the ECU CAUTION Do not break the locking tab of the connector b Connect the signal check harness to the engine harness machine harness and engine ECU Signal check harness for engine control system Part No 09843 E4010 Vehicle harness Signal check harness Test lead Signal check connector SAPH300020100040 ...

Page 29: ... the signal check harness connector the ECU terminal number in the text is treated as follows Engine ECU Engine side harness Machine side harness Engine harness Machine harness Signal check harness for engine control system SAPH30ZCE0100038 ...

Page 30: ...r 16 P is on the inside 2 Connection of HinoDX 1 Connect the engine failure diagnosis connector to the PC which installed Hino DX through the interface box Special tool 09993 E9070 Hino Bowie Interface box S0904 21220 09042 1220 Connecting cable CD ROM HinoDX 2 Set the starter key to ON and start HinoDX SAPH30ZCE0100039 SAPH30ZCE0100040 Failure diagnosis connector Connect to the failure diagnosis ...

Page 31: ...1 Engine type and engine number 1 Engine type and engine number are stamped at the left cylinder block when viewed from the cooling fan For order of parts information of this number will facilitate procedures smoothly Ex J08E TA10003 Stamp position Example SAPH300020100046 ...

Page 32: ...htening torque 2 3 Intake 2 4 Tightening torque 2 4 Engine Mechanical 2 4 Standard value 2 4 Tightening torque 2 11 Exhaust 2 12 Tightening torque 2 12 Cooling 2 12 Standard value 2 12 Lubrication 2 13 Standard value 2 13 Tightening torque 2 14 Starting and Charging 2 15 Standard value starter 2 15 Tightening torque starter 2 16 Standard value alternator 60A 2 17 Tightening torque alternator 60A 2...

Page 33: ... Fuel filter Engine side air bleeding bolt 1 7 2 26 17 3 23 1 3 1 7 Fuel filter Engine side drain plug 6 9 b 2 70 b 20 5 0 b 1 4 Fuel filter Engine side center bolt 29 4 b 4 9 300 b 50 21 7 b 3 6 Fuel filter Engine side case mounting bolt 55 560 40 Supply pump drive Flywheel housing 28 5 290 21 Common rail mounting bolt 28 5 290 21 Fuel filter Machine side air vent plug 1 7 2 3 18 23 1 3 1 6 Fuel ...

Page 34: ...item Standard value Remark V ribbed belt tension adjustment Deflection 3 5mm 0 1182 0 1968in Reference push force 98N 10kgf 22lbf Compression gauge S0944 41210 09444 1210 is used Tension 1 372 N 140kgf 308 lbf MITSUBOSHI BELTING LTD Belt Tension Meter DOCTOR TENSION TYPE III is used Tightening area Tightening torque Remark Starter mounting nut and bolt 154 1570 114 Alternator through bolt 83 850 6...

Page 35: ...cold 0 30 0 0118 0 45 0 0177 Cylinder liner protrusion IN 0 01 0 08 EX 0 003 0 0013 Cylinder block inner diameter A 117 117 008 4 6063 4 6066 B 117 008 117 014 4 6066 4 6068 C 117 014 117 022 4 6068 4 6072 Cylinder liner outer diameter A 116 982 116 99 4 6056 4 6059 B 116 99 116 996 4 6059 4 6061 C 116 996 117 004 4 6061 4 6064 Cylinder liner inner diameter 112 4 4094 112 15 4 4154 Cylinder Replac...

Page 36: ...Replace piston Second 2 0 0 0787 2 2 0 0866 Oil 4 0 0 1574 4 1 0 1614 Piston pin outer diameter 37 1 4567 36 96 1 4551 Replace piston pin Piston boss inner diameter 37 1 4567 37 05 1 4587 Replace piston Clearance between piston pin and piston boss 0 011 0 032 0 0005 0 0012 0 05 0 0020 Replace piston pin or piston Connecting rod bushing inner diameter 37 1 4567 37 1 1 4606 Replace connecting rod bu...

Page 37: ...ce crankshaft Crankshaft end play 0 05 0 270 0 0020 0 0106 0 5 0 0197 1 270 0 0500 Replace thrust bearing or crankshaft Crankshaft runout 0 0 1 0 0 0039 0 15 0 0059 Replace Camshaft Camshaft journal outer diameter 40 1 5748 39 85 1 5689 Replace camshaft or bearing Camshaft bearing inner diameter 40 1 5748 40 15 1 5807 Camshaft bearing oil Clearance 0 020 0 063 0 0008 0 0025 Cam height IN 50 067 1 ...

Page 38: ...2756 Oil clearance between valve guide and valve stem IN 0 023 0 058 0 0009 0 0020 Replace valve or valve guide EX 0 050 0 083 0 0020 0 0033 Valve sink IN 0 55 0 85 0 0217 0 0335 1 1 0 0433 Replace valve and valve seat EX 1 15 1 45 0 0453 0 0571 1 7 0 0669 Valve seat angle IN 30 Allowable anlge 30 30 35 Correction EX 45 Allowable anlge 45 45 30 Valve face angle IN 30 Allowable angle 29 30 30 EX 45...

Page 39: ... Free length 64 6 2 5433 61 6 2 4252 Replace spring Squareness 2 0 0 0787 Replace spring Outer Set length 46 8 1 8252 Set load 314N 32 0kgf Free length 75 7 2 9803 72 7 2 8622 Replace spring Squareness 2 0 0 0787 Replace spring Inspection item Standard value Repair limit Service limit Action ...

Page 40: ...haft outer diameter 57 2 2441 Bushing inner diameter 57 2 2441 Clearance between shaft and bushing 0 030 0 090 0 0012 0 0035 0 20 0 0079 Replace shaft or bushing Gear width 44 1 7322 Shaft length 44 1 7322 End play 0 114 0 160 0 0045 0 0063 0 30 0 0118 Replace shaft or gear Sub idle Shaft outer diameter 50 1 9685 Bushing inner diameter 50 1 9685 Clearance between shaft and bushing 0 025 0 075 0 00...

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