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343 views386 pages

S1 134e 19 1

Uploaded by

Alexander Lopez
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© © All Rights Reserved
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FOREWORD This workshop manual has been prepared to provide information covering repairs on 2004 FD, FE, and SG series Hino trucks. To use Hino trucks for years, smoothly, safely, and economically without trouble, itis important to perform inspections. Maintenance required to be performed is the responsibility of the owner. Some recommended repairs of your truck are mentioned. When making any repair of your truck, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner's and Driver's Manual. Allinformation and specifications in this manual are based upon the latest product information available at the time of printing. HINO DIESEL TRUCKS (U.S.A.),INC. reserves the right to make changes at any time without prior notice. WORKSHOP MANUAL © 2004 HINO DIESEL TRUCKS (U.S.A.),INC. All rights reserved. This manual may not be reproduced or copied in whole or in part, without the written consent of HINO DIESEL TRUCKS (U.S.A),INC. GENERAL INTRODUCTION ENGINE CLUTCH CLUTCH CONTROL TRANSMISSION TRANSMISSION CONTROL PROPELLER SHAFT REAR AXLE FRONT AXLE STEERING SERVICE BRAKE PARKING BRAKE WHEELS & TIRES SUSPENSION CHASSIS FRAME CAB ELECTRICAL EQUIPMENT ALTERNATOR STARTER COMPRESSOR SPRING BRAKE POWER STEERING AUTOMATIC TRANSMISSION ANTILOCK BRAKE SYSTEM TOTAL ELECTRONICS SYSTEM SERVICE SPECIFICATIONS WIRING DIAGRAMS Models FD, FE and SG GENERAL INTRODUCTION 1-1 CHAPTER 1 GENERAL INTRODUCTION Models FD, FE and SG IDENTIFICATION INFORMATION. 1-2 GENERAL INTRODUCTION Models FD, FE and SG IDENTIFICATION INFORMATION 1. VEHICLE IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER (VIN) is comprised of 17 digits and letters. The VIN plate, as shown in Fig. 1, is affixed to the left-side door step of the cab. The following is an explanation of the items that are listed on the VIN plate. ROSH a or ens 1) VIN See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page. 2) P.S.CODE AND VEHICLE COMPONENTS mover | es. | cures | fees, TRANSMISSION RATIO GEAR | REAR | sevice senies| cone | swe. | WSSON hes | AMS | BRAKE ‘Senies | 1ST [ 2NO | SAD | aTH | sTH | eTH | senes | AATIO yaa) [Sener | ssomm | LrOss | 746] are | 242[ tae [too] - | sine] 336 |v saucr| = | ATs#5_| sas | 225 | 14 [100] - | - | SH12| 398 |v row [Saver | ssomm | Eros | 746 | ate | 22 sHi2 | 396 | A ShvcT | - | Ares | 35 225 | 141 sHie2 | 336) A roa) | SASFr | ssoun | Lr06s | 600 | 3.86 | 234 suiet | 512) A saver |= | teraioo | ssi] 190 ta | 100[o7e| = | siier | ag0_[ A rea) | SAOFT | ssomm | L065 | 609 | 477 | 200 [156 | 100] o77| shiet | S12 | A SAAFT | - | Lcraa0 | Sst] 1.90 | 144100 | ors) - | sit | 565) A sa7S7 | seo um | wrOss | 7.30 [ 475 | 307] 199 | 134 | 100 | sHe1| 410 FH sow [ saus7 [mososor | 300 [196 [ar | oo [ors] - | sniet | saa |r 4 savs7 | 380 i | RTav00 | 916 | 6.59 | aao| 957 | 258 | ves) sHie1 | ai0| —F cove SERVICE BRAKE CONTROL CODE PARKING BRAKE CONTROL CODE V: VACUUM SERVO C : ACTING ON TRANSMISSION OUTPUT SHAFT ‘A: AIR OVER HYDRAULIC W: ACTING ON REAR WHEEL F:FULLAIR GENERAL INTRODUCTION 1-3 cHaseasao'suainoe | uroeor | ar'suorononm | Hoe Taszio‘swainoe | aroer | ‘ar suorononm | re Models FD, FE and SG avn | 455710) Dan ees eAL 10uNoo ouwitos| 8 exsoirasai'suaines | avosor | arvsuciononm | ry oamean) te saror a weno uy eAL 10uNoo owwisos| #4 noudwosaa acon | usuniovanwvw | 3000 Samana ear a peter 4A ToMINoD owwinuos| OF Pninvwaaal—eSavo) pone Tze = peter 34AL 70UNoD owvatvos| 84 ET onnwians] PSS) ausrownooouvitos| V4 TORTS OREN" 50 ‘waisas | HIDNSTTIVHaAO HO wie me nr colssuines eima swung | & wo ‘Svea saa, aaaLacoaevo ann |a000] TNvaW™ LNYa WAND | z {0L1'hd03 uA ON Tare avr INYTa VRVHOWOA |p Tavs OOo {1.4008 OLNW ON Terasaroers| © Nva¥r INYIONH |, a {11 SOLON ON wun | O28 2 “GEI"O5 WAS HUROS) va uaa Tam yupwt [ 5005} Ag daa eISeY SONA SLs LaNON | ON] CHTSHOLON ONE) BH ne ‘onti] a11 suo1oM ove) one cone fe SOMBAaLzTERNOON! [ON] GLT'sHOLOW Owe] aH soo |e [ewe | 2 zooz | 2 | sone | + yon conti arr'suo1on ows] vue nouvoisaon | % soz | s [ee | x ada ‘awwai] eauniovanwwn | 3000 vornieanaiy | 2 oc coe wusiaany | 2 wwvaa [3005] wwsi [5000] Nouawssa [3009] | | eeonassy| |zoord sve 7334M] [Taaon anions) [yaisis ayvwa'satsas) | 300W'svn) (cSannwnenss ) | [Eaax03%0] "34AL AGOARND BN] [uatnLOv-ne +] [0] [0] {o s] [Lb wl [r) [2 [a] [4] [] [HW [er we) i) SIA ow Oo DU @ © %, @ @ san WM SUNLONULS (NIA) HASINAN NOILVOISILNAGI STOIHSA, 4-4 GENERAL INTRODUCTION Models FD, FE and SG — EXAMPLE — Fig? ‘ST-060B ENGINE MODEL SERIES ENGINE NUMBER Fig. SMTOTS CCHassis NuMBER 3. VEHICLE CERTIFICATION LABEL The Vehicle Certification Label, as shown in Fig. 2, is affixed to the left hand side door of the cab. The name of manufacturer, production year and month, and verifica- tion of items which are in conformity with Federal Motor Vehicle Safety Standards are displayed. ENGINE NUMBER The Engine Number, as shown in Fig. 3 is on the right side of the engine block. CHASSIS NUMBER ‘The Chassis Number is displayed on the left siderail of the frame near the front axle, as shown in Fig. 4. ‘Models JO8C-TP and JO8C-TR ENGINE 3-1-1 3-228E-07 CHAPTER 3 ENGINE Models: JO8C-TP and JO8C-TR TROUBLESHOOTING, SPECIAL TOOLS ENGINE OVERHAUL CRITERIA DISMOUNTING THE ENGINE ASSEMBLY . REMOVAL OF THE ENGINE COMPONENT PARTS CAMSHAFT HOUSING AND CYLINDER HEAD CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING TIMING GEAR PISTON, CRANKSHAFT AND CYLINDER BLOCK LUBRICATING SYSTEM COOLING SYSTEM. FUEL SYSTEM. AIR INTAKE AND EXHAUST SYSTEM ENGINE CONTROL SYSTEM ELECTRICAL PARTS.. AIR COMPRESSOR AND POWER STEERING PUMP INSTALLATION OF THE ENGINE COMPONENT PARTS ENGINE TUNE-UP MOUNTING OF THE ENGINE ASSEMBLY . LIQUID GASKET AND APPLICATION POINTS .. POWER TAKE-OFF (IF FITTED) 34-2 ENGINE Models JO8C-TP and J08C-TR ‘Models JO8C-TP and JO8C-TR ENGINE 3-1-3 ‘Symptom Engine overheating TROUBLESHOOTING (ENGINE) Possit caus —{ Coolant Insufficient coolant Defective thermostat Overflow of coolant due to leakage of ‘exhaust into cooling system Damaged rubber hose Coolant leakage due to deteriorated rubber hose ‘© Coolant leakage from coolant pump ‘© Coolant leakage from rubber hose connection ‘© Coolant leakage from cylinder head gasket | Coolant pump © Bearing seizure ‘© Damaged (corroded) vane Radiator ‘© Clogged with rust and scale ‘© Clogged with iron oxide due to leakage of exhaust into cooling system ‘© Coolant leakage ‘@ Damaged cooling fan ‘© Clogged radiator core due to mud or other debris © Defective radiator cap pressure valve | —{ Abnormal combustion ‘© Incorrect injection timing .. ‘@ Reduced injection pressure .... © Poor fuel © Poor nozzle spray © Unsatisfactory automatic timer... advance angle ‘Add coolant Replace the thermostat Repair Replace rubber hose Replace rubber hose Replace the coolant pump Retighten or replace clamp Replace gasket Replace Replace vane Clean radiator Clean coolant passage and correct exhaust leakage Repair or replace radiator Replace cooling fan Clean radiator .- Replace radiator cap Adjust injection timing Adjust injection pressure Use good quality fuel Adjust or replace nozzle Repair or replace timer 341-4 ENGINE Models JO8C-TP and JO8C-TR ‘Symptom Possible cause Remedy/Prevention Engine overheating FOther problems) ‘© Detective or deteriorated engine oil ....-Change engine oil (© Unsatisfactory operation of oil pump ....FReplace or repair © Insufficient oi sonnel © Brake drag enn nnn ssn AGUS ‘Severe operating conditions| © Lugging the engine ......m:mmnmnnnne Operate engine properly Excessive oil consumption Pistons, eylinder liners and piston rings ‘© Wear of piston rings and cylinder liner... Replace piston rings and cylinder liner ‘© Worn, sticking or broken piston rings. Replace piston rings and cylinder liner ‘© Insufficient tension on piston tings ...-Feplace piston rings and cylinder liner ‘© Unsatisfactory break-in of piston rings.......FReplace piston rings and cylinder liner Change oil as required and replace piston rings and cylinder liner ‘© Incorrectly fitted piston rings (upside down) .. Replace piston rings © Unsuitable oil (viscosity too low) ‘© Gaps of piston rings in line with each other ..Reassemble piston rings | {Valves and vaive guides) ‘© Wom valve stem Replace valve and valve guide © Wom valve guide ..s.nnssnnnnn Replace valve guide © Incorrectly fitted valve stem Seal .....n.nReplace the stem seal (© Excessive lubricant on rocker afM ......-Check clearance of rocker arm and shaft Excess oil feed © Defective oil level gauge - Replace oll level gauge © Oil eVEL 100 HIgh son nnnnnnnnnne/DFAIM @XCRSS oll ‘Models JO8C-TP and JO8C-TR ENGINE 3-1-5 ‘Symptom Remedy/Prevention Excessive oil consumption Oil leakage from miscellaneous parts| Oil eakage from ol seal Replace ol seal Cracks or blowole in cylinder Dock...» Replace cylinder block Oil eakage from connections of ol ines... Tighten connections of ol lines Oil eakage from oil cooler Replace ol cooter Oil eakage from oil pan gasket Replace ol pan gasket Oileakage from O-ring Replace O-ring {Other problems] ‘Overcooled engine Warn 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 oi 4. Oil leaks from the flanges of the exhaust manifold. 5. Lack of power. 6. Excessive blow-by gas. Piston seizure { Pistons, cylinder liners and piston rings | Incorrect clearance between piston... Replace piston, piston rings and cylinder liner and cylinder liner Unsatisfactory installation of piston pin... Replace piston, piston rings, cylinder liner and piston pin as required Broken piston ring ...snnsnnnnnnnsnn Replace piston, piston rings and cylinder liner Difference in expansion due to use of... Replace piston, piston rings wrong piston and cylinder liner 3-4-6 ENGINE Models JO8C-TP and J08C-TR ‘Symptom Possible cause Remedy/Prevention Piston seizure [Coolant] ‘© Reduction in capacity of coolant pump....... Replace the coolant pump (due to vane corrosion) © Leakage of coolant. .-Repair © Insufficient coolant ‘Add coolant © Dirty coolant (Clean and replace coolant © Defective radiator _--Feepair or replace the radiator (coolant leakage, clogging) © Defective rubber hose (leakage) Replace rubber hose © Defective thermostat Replace the thermostat ‘© Leakage of exhaust into cooling system Operation ‘© Abrupt stoppage of engine after running at high speed © Hill climbing using unsuitable gear © Insufficient oll © Dirty oil © Poor quality oil © High oil temperature. © Low oil pressure ‘© Defective oil pump ‘© Reduced performance due to wom oil pump ‘© Suction strainer sucking air. ‘Abnormal combustion © Use of defective fuel © Incorrect injection timing .. © Engine overheating... Repair Operate engine properly Select suitable gear ‘Add oll Change oil Replace with proper engine oil Repair Repair Repair oil pump Replace oil pump Add oil and/or repair strainer .»Change fuel ...Adjust injection timing ...See Symptom: “Engine overheating” ‘Models JO8C-TP and JO8C-TR ENGINE 3-1-7 NOTE: If piston seizure occurs, the problems above will occur. Complaints from the customer are often related to these problems. 1. White smoke is emitted. 2. Lack of power 3. Excessive blow-by gas Symptom Possible cause Remedy/Prevention Lack of power Injection pump ae csseue Plater to “FUEL INJECTION PUMP” Intake © Clogged air cleaner. (Clean element or replace element ‘Overheating ‘See Symptom: “Engine overheating” Fuel and nozzle © Poor nozzle spray ‘Adjust or replace injection nozzle ‘© Nozzle clogged with carbon Clean nozzle ‘© Wear or seizure of nozzle Replace nozzle © Airin fuel system, Repair and bleed air from fuel system © Clogged fuel filter Replace element ‘© Use of poor fuel Use good quality fuel Pistons, cylinder liners and piston rings ‘© Seized or wear of piston Replace the piston, piston rings and liner ‘® Worn or broken piston rings, Replace piston rings, piston piston and cylinder liner and liner 341-8 ENGINE Models JO8C-TP and JO8C-TR ‘Symptom Possible cause Remedy/Prevention Lack of power Other problems Leakage of exhaust ‘© Exhaust brake butterfly valve stuck. in half-open position ‘© Connecting rod bent ‘© Exhaust pipe or muffler crushed (increased back-pressure) © Breakage of turbine oF BIOWEF nnn 1 —| Head gasket | ‘© Fatigued gasket (aging) .. © Damage | Head bolts © Loose bolts. . © Elongated bolts... ‘© Improper tightening torque or... tightening sequence Cylinder block © CrACKING nnn © Surface distortion ssn ‘© Fretting of cylinder liner insertion portion (insufficient projection of cylinder liner) ylinder head © CrAaCKINg oe © Surface distortion ylinder liners © Cracking © Corrosion. © Insufficient project of eylinder liner © Improper installation .aninnnnnnnnnnnnnnne Replace or repair exhaust brake -»-Replace or repair connecting rod ...Replace exhaust pipe or muffler Refer to TURBOCHARGER in CHAPTER 51 Replace gasket Replace gasket Replace gasket Tighten bolts Replace bolts Tighten property Replace cylinder block ..Repair or replace Replace cylinder block ..Replace cylinder head Repair or replace Replace cylinder liner Replace cylinder liner .Rleplace cylinder liner ‘Models JO8C-TP and JO8C-TR ENGINE 3-1-9 ‘Symptom Leakage of exhaust Other problems Incorrect injection timing . Remedy/Prevention Adjust injection timing NOTE: If leakage of the exhaust occurs, the problems above will occur. Complaints from the customer are often related to these problems. 1. Lack of power. 2. The engine overheats. 3. Difficulty starting engine (Electrcal system | “Discharged battery Defective wiring in startr-ciruit Loose or open-circuit battery cable Breakdown of starter Broken glow plug Injection pump Air cleaner! Clogged element Fuel system No fuel in tank Clogged fuel line Air sucked into fuel system through fuel line connections. Clogged fuel fiter Loose connection in high-pressure line Water in fuel Charge battery Repair wiring of starter Tighten battery terminal connections or replace battery cable Replace starter Replace Refer to “FUEL INJECTION PUMP” Clean the element or replace the element Supply fuel Clean fuel line Tighten fuel line connections Replace element Tighten sleeve nut of high pressure line Drain and clean fuel system 34-10 ENGINE Models JO8C-TP and JOBC-TR ‘Symptom Possible cause Remedy/Prevention Difficulty starting engine Nozzles © Seized nozzle... : Replace nozzle (© Broken or fatigued nozzle spring Replace spring Oil system © Oil viscosity too high _.Use proper viscosity oll, or install an oil immersion heater and warm up oil Other problems © Seized piston Replace piston, piston rings, and liner © Seized bearing... . Replace bearing and crankshaft ‘© Reduced compression pressure .. Overhaul engine ‘© Ring gear damaged or worn Replace the ring gear and/or accelerator cable starter pinion. ‘© Improperly adjusted or broken . - Adjust or replace the accelerator cable Rough idling Injection pump Refer to “FUEL INJECTION PUMP” Nozzles Uneven injection pressure Poor nozzle spray Carbon deposit on nozzle tip . Seized needle valve Engine proper ‘© Improper valve clearance © Improper contact of valve seat © Idling speed too low © Coolant temperature too low. ‘© Compression pressure of cylinaers. markedly different from one another Adjust Adjust or replace nozzle ..Remove carbon .Replace nozzle ‘Adjust valve clearance Replace or repair valve and valve seat Adjust idling speed Warm up engine ‘Overhaul engine Models J08C-TP and JO8C-TR ENGINE 3-1-11 ‘Symptom Possible cause Remedy/Prevention Rough idling Other problems ‘© Clogged high pressure injection line ........ Replace line ‘© Leakage due to improper tightening _ Tighten sleeve nut of high pressure injection tine {© Improperly adjusted OF brOKEN ...u.:nnene AGjUSt OF replace accelerator accelerator cable cable © Engine seizure . . Replace pistons, piston rings and liners © Incorrect valve timing Replace camshaft Diesel knock [Tjection pump], Refer to “FUEL INJECTION Nozzles Incorrect injection pressure. Poor nozzle spray Sticking of nozzle Fatigued or broken nozzle spring Fuel system ‘© Use of poor fuel ‘© Fuel leakage into combustion chamber (during engine starting) Other problems © Excessively cooled or heated engine © Insufficient air intake ‘© Insufficient compression pressure ‘© Compression pressure leaks at cylinder head gasket ‘© Improper valve clearance or valve sticking © Tappet sticking PUMP” Adjust Adjust or replace nozzle ‘Check and/or replace Replace spring Use good quality fuel Adjust nozzles Warm up or cool engine Correct «Repair . Replace head gasket ..Adjust or repair Replace tappet and camshaft 34-12 ENGINE Models JO8C-TP and JO8C-TR ‘Symptom Possible cause Remedy/Prevention Unusual engine noise Piston ee Wear of piston pin boss or piston pin Seized, damaged, or wom piston pin bushing Worn pistons or cylinder liners Damaged or seized piston Foreign matter on top surface of the piston Valve mechanism Incorrect valve clearance Valve cotter out of place. Seized valve stem... Broken valve . Damaged rocker arm support Broken valve spring | Bearings seizure Insufficient lubricating oll. Excessive or insufficient tightening of bearing housings Pits and scratches on bearing surface il flm formed on back of bearing Improper installation of bearing Reduction of spread dimension of bearing Distorted bearing housing Excessive oll clearance. Replace piston and/or piston pin Replace piston pin bushing. Replace piston or cylinder liner .-Replace piston and cylinder liner Remove foreign matter and repair or replace piston, cylinder liner, andlor cylinder head Adjust valve clearance Replace valve cotter Replace valve and valve guide Replace valve Replace rocker arm support Replace valve spring Add oll Retighten to specified torque Replace bearing and crankshaft ..Replace bearing Replace bearing Replace bearing Replace or correct bearing housing Replace bearing ‘Models JO8C-TP and JO8C-TR ENGINE 3-1-13, Symptom Unusual engine noise Possit cause Various other parts Exhaust gas leakage from exhaust. Pipe joints Loosen or missing intake manifold flange gasket Intake valve seating is not concentric Intake gas leakage .... Other problems Loose cooling fan mounting bolts or .. fan pulley nut Lack of lubricating oil... (coolant pump, valves, etc.) Wom timing gear Breakage of turbine or blower Remedy/Prevention Retighten joints ..Retighten or replace Replace or correct the valve and valve seat Retighten Tighten the fan and crankshaft pulley . Lubricate Replace the timing gear Refer to TURBOCHARGER in CHAPTER 51 NOTE: The items on this page concern unusual engine noise which is due to causes other than those given for diesel knock. 31-14 ENGINE Models JO8C-TP and JO8C-TR (FUEL INJECTION PUMP) ‘Symptom Possible cause Remedy Engine does not start Fuel not reaching injection pump Fuel lines clogged or damaged Fuel fiter clogged © Airin fuel caused by improper ‘connections of fuel line between fuel tank and feed pump Filter incorporated in inlet Sid@ ....0 of feed pump clogged Faulty feed pump check valve Feed pump piston spring broken Feed pump push rod or tappet sticking || Fuel reaching injection pump ‘© Faulty connection of accelerator cable to pump adjusting lever ‘© Control rack faulty or sticking © Damaged camshatt bearing ...0 . . Plunger wom or sticking... Faulty connection of engine ... stop cable to pump stop lever Nozzle faulty © Fuel leakage caused by loosened... nozzle holder ‘© Low opening pressure of nozzle ‘© Nozzle pressure spring broken ‘© Nozzle needle sticking to nozzle body Pump out of timing Improperly retarded injection timing Incorrect timing caused by Improper. Installation of pump Woodruff key for pump camshaft cut off Improper pre-stroke adjustment Clean or replace fuel lines Clean or replace the filter element Repair connections. Remove foreign material Repair or replace it Replace it Repair or replace it Repair connection Repair it Repair it (Correct or replace it Repair it -Inspect and tighten it Adjust it soReplace it Correct or replace it Correct injection timing Check engine timing and correct it Replace it Correct it to obtain specified Injection timing ‘Models JO8C-TP and JO8C-TR ENGINE 3-1-15, Symptom Engine starts and stops Engine has low power |— Fuel ines clogged ‘— Air in fuel caused by damaged fuel lines or improper connection of fuel lines Pump out of timing © Excessive advanced timing resulting in loud knocking ‘© Excessively retarded timing resulting in black smoke ‘© Defective injection pump overtiow valve © Feed pressure 100 10W .... so ‘© Improper accelerator cable adjustment | Nozzle fauty] @ Fuel leakage from nozzle holder. ‘¢ Bad nozzle spray characteristic © Loosened adjusting screw in nozzle. holder, resuting in low opening pressure ‘© Nozzle pressure spring broken Pump faulty ‘© Fuel leakage from delivery valve holder Defective seat of delivery valve assembly Delivery valve spring broken. Plunger worn Wear of tappet roller ‘Camshaft bearing worn or broken Improper adjustment of governor. {ull oad stopper screw . . . © Large spread in fuel delivery. . . . Remedy Clean or replace fuel lines Repair fuel lines or replace fuel lines and gaskets ‘Check and correct it ‘Check and correct it Repair or replace it Repair the feed pump Adjust it ‘Check and repair nozzle holder Repair or replace it Adjust it Replace it ..Retighten the delivery valve holder itis loosened or replace ‘O-ring ifthe O-ring is detective ..Repair or replace it Replace the spring Replace it Adjust it Replace the roller Replace it Adjust it 344-16 ENGINE Models JO8C-TP and JO8C-TR ‘Symptom Possible cause Remedy Excessive smoke Black smoke Low idle speed irregular Engine always runs at high speed Loud knocking ‘© Excessive fuel delivery caused by incorrect adjustment of full load ‘Adjust fuel delivery on test stand stopper screw © Excessively advanced injection timing. ......Correct it © Large spread in fuel delivery. sos Aust it ‘© Bad nozzle fuel spray characteristics ........Check and correct them White smoke (© Unused after glow System .....nnnmmnnn8@ it ‘© Improperly retarded injection timing ...Advance injection timing © Water in fU0! ...n:mnnsnnnnnnmnnnneCheek and clean fuel ines ‘© Glow plug not operating... snes ChECK glow plug circuit, Refer to ELECTRICAL EQUIPMENT in CHAPTER 20, | — Improper adjustment of throttle control knob ..Correct it |— Bad fuel spray characteristic of nozzles. ..... heck and repair them Incorrect injection timing «nse Correct it Incorrect initial tension setting Of .......Agjust or replace it idling spring or the spring broken, |— Control rack does not move smoothly.........Disassemble pump and repair it |— Large spread in fuel delivery... Adjust it [= Plunger Wom nuns Replace it | — Governor linkage does not move smoothly...Correct it Defective feed pump... ..Disassemble and repair it Accelerator cable sticking ..... shack and correct it Governor linkage sticking .. Disassemble and repair the governor Control rack sticking, Check and correct it Correct it |— Bad fuel nozzle spray pattern Check and correct it atter-dribble High nozzle opening pressure Adjust the opening pressure |_— Incorrect fuel deliveries to Readjust the fuel deliveries some nozzles. Models JO8C-TP and JO8C-TR ENGINE 32-4 SPECIAL TOOLS Prior to starting an engine overhaul, itis necessary to have the following (1) Lifting parts Shape Parts No. Partsname | NoJunit Application 09491 - 1010 | Wire cable 1 | Lifting engine 09433 - 1070 | Eye bolt 2 | iting cylinder head 'SMOJOH8 (2) Related parts of cylinder head Shape Parts No. Parts name | NoJ/unit Application Caulking nozzle seat <. Cra 1 | (Use together with 9800 - 06100) M950 | 7 Caulking nozzle seat (3 SSC CS TOO Stee! Call) y (Use together with 09472-1210) sMa-Joss CE. 09552-1090 smsoet Compression gauge adaptor Measuring compression (for size PF3/8) 3-2-2 ENGINE Models JO8C-TP and JO8C-TR Shape Parts No. Partsname —_—_No//unit Application 09552 - 1060 Press gauge adaptor. 1 Measuring compression 09552 - 1030 suao2e << 09472-2100 | Bar 1 Strike-fitting valve stem seal M3055 09471 - 1520 | Guide 1 Strike-fitting valve guide Sieu0s1 PA 09420 - 1100 | Sliding hammer 1 Removing main idle gear shaft susst31 —— oS Removing sub- and cam idle i Sliding hammer 1 | gear shafts (Remove the for pulling out ‘ adaptor from the top before use) injection nozzle) sussi32 (3) Related parts of valve Shape Parts No. Parts name No/unit Application swoyosa Models JO8C-TP and JO8C-TR ENGINE 32.3, Shape Parts No. Parts name —_| No//unit Application 09470 - 1170 | Valve spring press 1 Removing and installing valve spring Moose (4) Related parts of flywheel Shape Parts No. Partsname —_No/unit Application . Ramoving and installing

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