KCM E13C-VV HINO DIESEL ENGINE(General Information Engine Diagnosis) For Wheel Loaders 90Z7 and 92Z7 Shop Manual – PDF DOWNLOAD
FILE DETAILS:
KCM E13C-VV HINO DIESEL ENGINE(General Information Engine Diagnosis) For Wheel Loaders 90Z7 and 92Z7 Shop Manual – PDF DOWNLOAD
SN 90H1-5001 and up
92H1-5001 and up
PN 93213-00652
Language : English
Pages : 626
Downloadable : Yes
File Type : PDF
Pages : 626
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KCM E13C-VV HINO DIESEL ENGINE(General Information Engine Diagnosis) For Wheel Loaders 90Z7 and 92Z7 Shop Manual – PDF DOWNLOAD
SN 90H1-5001 and up
92H1-5001 and up
PN 93213-00652
1 GENERAL 6
Warning 7
How to read this manual 8
Precautions for work 13
Tightening of engine bolts and nuts 17
Tightening of flare nuts and hoses 19
Taper thread sealant for piping 20
Assembly of joints and gaskets for piping 21
Handling of liquid gasket 23
Failure diagnosis table for each problem 24
Failure diagnosis procedures 25
Failure diagnosis using Hino DX 27
Connection method of Hino DX 32
Engine number 33
2 STANDARD VALUE 34
Engine Mounting/Dismounting 35
Fuel System 36
Emission Control 37
Electrical 38
Intake 39
Engine Mechanical 40
Exhaust 46
Cooling 47
Lubrication 48
Starting and Charging 49
Turbocharger 53
3 PARTS TO BE PREPARED 54
Engine Mounting/Dismounting 55
Fuel System 56
Engine Mechanical 57
Exhaust 60
Lubrication 61
Starting and Charging 62
Turbocharger 64
4 ENGINE MOUNTING/DISMOUNTING 66
Overhaul Criteria 67
Engine Mounting/Dismounting 69
Removal 69
Installation 72
Work after installation 72
5 FUEL SYSTEM 76
FUEL SYSTEM 77
Fuel system diagram 77
Part layout 78
FUEL FILTER 84
Fuel filter drain 84
Replacement of the fuel filter element 85
Removal and installation of the fuel filter case 87
SUPPLY PUMP 89
Replacement 89
COMMON RAIL 94
Replacement 94
Inspection 96
INJECTOR 99
Part layout100
Replacement For injectors before October 2017102
Inspection For injectors before October 2017108
Replacement For injectors after October 2017109
Inspection For injectors after October 2017117
6 EMISSION CONTROL118
EGR System119
Part layout119
Overhaul of EGR cooler and EGR valve120
7 ELECTRICAL128
Electrical System129
Part layout129
Layout of components134
Inspection of the components136
Installation of components138
Replacement of the starter140
Replacement of the alternator141
Replacement of the Engine ECU143
Replacement of DPR differential pressure sensor149
8 INTAKE150
Intake Manifold151
Part layout151
Intake manifold replacement152
9 ENGINE MECHANICAL156
Cylinder Head157
Part layout157
Replacement159
Overhaul166
Cylinder Block171
Part layout171
Overhaul172
Timing Gear Cover and Flywheel Housing176
Part layout176
Overhaul179
Main Moving Parts194
Part layout194
Overhaul196
Camshaft and Idle Gear217
Part layout217
Overhaul219
Valve System240
Part layout240
Overhaul242
Valve clearance adjustment251
10 EXHAUST254
Exhaust Manifold255
Part layout255
Replacement256
DPR cleaner259
Part layout259
Inspection260
DPR flow inspection regular situation261
Inspection using the Hino-DX262
Replacement of DPR filter279
11 COOLING282
Cooling system283
Cooling system drawing283
Part layout284
Thermostat case replacement286
Coolant pump replacement288
Case sub assembly, coolant pump replacement290
Inspection of thermostat291
12 LUBRICATION294
Lubrication System295
System drawing295
Part layout296
Replacement of oil cooler297
Replacement of oil pump299
Oil filter case replacement300
Oil Cooler301
Part layout301
Overhaul302
Oil Pump304
Part layout304
Overhaul305
Oil Filter307
Part layout307
Oil filter element replacement308
Oil Pan309
Part layout309
Replacement310
13 STARTING AND CHARGING312
Starter313
Part layout313
Disassembly315
Inspection of components319
Replacement324
Assembly326
Inspection after assembly331
Alternator (60A)332
Part layout332
Circuit drawing333
Disassembly334
Inspection of components338
Assembly341
Inspection after assembly345
14 TURBOCHARGER348
Inspection, disassembly, and assembly for turbocharger vehicles349
Part layout349
Inspection using HinoDX352
Turbine shaft inspection353
Removal359
Installation363
Inspections after installation369
16 MECHANICAL TROUBLESHOOTING372
MECHANICAL TROUBLESHOOTING373
Engine mechanical373
Alternator377
Starter378
Turbocharger379
DPR filter381
17 ENGINE DIAGNOSIS CODE382
Engine ECU384
Precautions384
Engine ECU circuit385
Electrical parts layout386
Connector list390
List of failure diagnosis tools410
Inspection412
System block diagram414
Table of failure code415
Signal check harness419
DPR regeneration429
Check the ECU power supply voltage440
Check the ground441
DTC code P0045 [35]442
DTC code P0049 [35]444
DTC code P0087 [76]445
DTC code P0088 [76]445
DTC code P0088 [69]451
DTC code P0102 [17]452
DTC code P0103 [17]452
DTC code P0108 [25]453
DTC code P0112 [17]457
DTC code P0113 [17]457
DTC code P0117 [11]460
DTC code P0118 [11]460
DTC code P0122 [32]463
DTC code P0123 [32]467
DTC code P0188 [14]471
DTC code P0192 [74]473
DTC code P0193 [74]478
DTC code P0200 [71]483
DTC code P0611 [71]483
DTC code P0605~P0607 [3]483
DTC code P0201~P0206 [61~66]484
DTC code P0217 [6]488
DTC code P0219 [7]489
DTC code P0234 [34]490
DTC code P0237 [25]492
DTC code P0263 [61]496
DTC code P0266 [62]496
DTC code P0269 [63]496
DTC code P0272 [64]496
DTC code P0275 [65]496
DTC code P0278 [66]496
DTC code P0335 [13]498
DTC code P0336 [13]500
DTC code P0340 [12]503
DTC code P0341 [12]504
DTC code P0540 [53]506
DTC code P0545 [27]507
DTC code P0546 [27]510
DTC code P0617 [45]513
DTC code P0628 [72]514
DTC code P0629 [72]518
DTC code P0642 [5]520
DTC code P0643 [5]521
DTC code P0652 [5]522
DTC code P0653 [5]523
DTC code P0686 [51]524
DTC code P06D3 [5]525
DTC code P06D4 [5]527
DTC code P1071, P1072 [26]528
DTC code P1133 [23]530
DTC code P1197 [74]533
DTC code P1198 [74]538
DTC code P119F [74]543
DTC code P1211, P1214 [68]545
DTC code P1212, P1215 [68]547
DTC code P1229 [76]549
DTC code P1266 [76]550
DTC code P1416 [19, 85]551
DTC code P1417, P1418 [19]552
DTC code P1427 [28]554
DTC code P1428 [28]558
DTC code P1458 [81]563
DTC code P1459 [81]565
DTC code P1601 [2]566
DTC code P200C [91]568
DTC code P2032 [27]574
DTC code P2033 [27]578
DTC code P2100, P2103 [31]582
DTC code P2101 [31]584
DTC code P2228, P2229 [15]585
DTC code P244A [91]586
DTC code P244B [92]594
DTC code P2458, P24A2 [93]601
DTC code P2463 [92]608
DTC code P2633 [72]613
DTC code P2634 [72]617
DTC code U0073 [8]619
DTC code U1001 [9]620
DTC code U110A [9]621
DTC code U1122 [8]622
DTC code U1123 [8]623
Warning 7
How to read this manual 8
Precautions for work 13
Tightening of engine bolts and nuts 17
Tightening of flare nuts and hoses 19
Taper thread sealant for piping 20
Assembly of joints and gaskets for piping 21
Handling of liquid gasket 23
Failure diagnosis table for each problem 24
Failure diagnosis procedures 25
Failure diagnosis using Hino DX 27
Connection method of Hino DX 32
Engine number 33
2 STANDARD VALUE 34
Engine Mounting/Dismounting 35
Fuel System 36
Emission Control 37
Electrical 38
Intake 39
Engine Mechanical 40
Exhaust 46
Cooling 47
Lubrication 48
Starting and Charging 49
Turbocharger 53
3 PARTS TO BE PREPARED 54
Engine Mounting/Dismounting 55
Fuel System 56
Engine Mechanical 57
Exhaust 60
Lubrication 61
Starting and Charging 62
Turbocharger 64
4 ENGINE MOUNTING/DISMOUNTING 66
Overhaul Criteria 67
Engine Mounting/Dismounting 69
Removal 69
Installation 72
Work after installation 72
5 FUEL SYSTEM 76
FUEL SYSTEM 77
Fuel system diagram 77
Part layout 78
FUEL FILTER 84
Fuel filter drain 84
Replacement of the fuel filter element 85
Removal and installation of the fuel filter case 87
SUPPLY PUMP 89
Replacement 89
COMMON RAIL 94
Replacement 94
Inspection 96
INJECTOR 99
Part layout100
Replacement For injectors before October 2017102
Inspection For injectors before October 2017108
Replacement For injectors after October 2017109
Inspection For injectors after October 2017117
6 EMISSION CONTROL118
EGR System119
Part layout119
Overhaul of EGR cooler and EGR valve120
7 ELECTRICAL128
Electrical System129
Part layout129
Layout of components134
Inspection of the components136
Installation of components138
Replacement of the starter140
Replacement of the alternator141
Replacement of the Engine ECU143
Replacement of DPR differential pressure sensor149
8 INTAKE150
Intake Manifold151
Part layout151
Intake manifold replacement152
9 ENGINE MECHANICAL156
Cylinder Head157
Part layout157
Replacement159
Overhaul166
Cylinder Block171
Part layout171
Overhaul172
Timing Gear Cover and Flywheel Housing176
Part layout176
Overhaul179
Main Moving Parts194
Part layout194
Overhaul196
Camshaft and Idle Gear217
Part layout217
Overhaul219
Valve System240
Part layout240
Overhaul242
Valve clearance adjustment251
10 EXHAUST254
Exhaust Manifold255
Part layout255
Replacement256
DPR cleaner259
Part layout259
Inspection260
DPR flow inspection regular situation261
Inspection using the Hino-DX262
Replacement of DPR filter279
11 COOLING282
Cooling system283
Cooling system drawing283
Part layout284
Thermostat case replacement286
Coolant pump replacement288
Case sub assembly, coolant pump replacement290
Inspection of thermostat291
12 LUBRICATION294
Lubrication System295
System drawing295
Part layout296
Replacement of oil cooler297
Replacement of oil pump299
Oil filter case replacement300
Oil Cooler301
Part layout301
Overhaul302
Oil Pump304
Part layout304
Overhaul305
Oil Filter307
Part layout307
Oil filter element replacement308
Oil Pan309
Part layout309
Replacement310
13 STARTING AND CHARGING312
Starter313
Part layout313
Disassembly315
Inspection of components319
Replacement324
Assembly326
Inspection after assembly331
Alternator (60A)332
Part layout332
Circuit drawing333
Disassembly334
Inspection of components338
Assembly341
Inspection after assembly345
14 TURBOCHARGER348
Inspection, disassembly, and assembly for turbocharger vehicles349
Part layout349
Inspection using HinoDX352
Turbine shaft inspection353
Removal359
Installation363
Inspections after installation369
16 MECHANICAL TROUBLESHOOTING372
MECHANICAL TROUBLESHOOTING373
Engine mechanical373
Alternator377
Starter378
Turbocharger379
DPR filter381
17 ENGINE DIAGNOSIS CODE382
Engine ECU384
Precautions384
Engine ECU circuit385
Electrical parts layout386
Connector list390
List of failure diagnosis tools410
Inspection412
System block diagram414
Table of failure code415
Signal check harness419
DPR regeneration429
Check the ECU power supply voltage440
Check the ground441
DTC code P0045 [35]442
DTC code P0049 [35]444
DTC code P0087 [76]445
DTC code P0088 [76]445
DTC code P0088 [69]451
DTC code P0102 [17]452
DTC code P0103 [17]452
DTC code P0108 [25]453
DTC code P0112 [17]457
DTC code P0113 [17]457
DTC code P0117 [11]460
DTC code P0118 [11]460
DTC code P0122 [32]463
DTC code P0123 [32]467
DTC code P0188 [14]471
DTC code P0192 [74]473
DTC code P0193 [74]478
DTC code P0200 [71]483
DTC code P0611 [71]483
DTC code P0605~P0607 [3]483
DTC code P0201~P0206 [61~66]484
DTC code P0217 [6]488
DTC code P0219 [7]489
DTC code P0234 [34]490
DTC code P0237 [25]492
DTC code P0263 [61]496
DTC code P0266 [62]496
DTC code P0269 [63]496
DTC code P0272 [64]496
DTC code P0275 [65]496
DTC code P0278 [66]496
DTC code P0335 [13]498
DTC code P0336 [13]500
DTC code P0340 [12]503
DTC code P0341 [12]504
DTC code P0540 [53]506
DTC code P0545 [27]507
DTC code P0546 [27]510
DTC code P0617 [45]513
DTC code P0628 [72]514
DTC code P0629 [72]518
DTC code P0642 [5]520
DTC code P0643 [5]521
DTC code P0652 [5]522
DTC code P0653 [5]523
DTC code P0686 [51]524
DTC code P06D3 [5]525
DTC code P06D4 [5]527
DTC code P1071, P1072 [26]528
DTC code P1133 [23]530
DTC code P1197 [74]533
DTC code P1198 [74]538
DTC code P119F [74]543
DTC code P1211, P1214 [68]545
DTC code P1212, P1215 [68]547
DTC code P1229 [76]549
DTC code P1266 [76]550
DTC code P1416 [19, 85]551
DTC code P1417, P1418 [19]552
DTC code P1427 [28]554
DTC code P1428 [28]558
DTC code P1458 [81]563
DTC code P1459 [81]565
DTC code P1601 [2]566
DTC code P200C [91]568
DTC code P2032 [27]574
DTC code P2033 [27]578
DTC code P2100, P2103 [31]582
DTC code P2101 [31]584
DTC code P2228, P2229 [15]585
DTC code P244A [91]586
DTC code P244B [92]594
DTC code P2458, P24A2 [93]601
DTC code P2463 [92]608
DTC code P2633 [72]613
DTC code P2634 [72]617
DTC code U0073 [8]619
DTC code U1001 [9]620
DTC code U110A [9]621
DTC code U1122 [8]622
DTC code U1123 [8]623
DESCRIPTION:
KCM E13C-VV HINO DIESEL ENGINE(General Information Engine Diagnosis) For Wheel Loaders 90Z7 and 92Z7 Shop Manual – PDF DOWNLOAD
SN 90H1-5001 and up
92H1-5001 and up
PN 93213-00652
Foreword :
- This manual contains special notes, important points, service data and precautions for the removal, installation, disassembly and assembly of major components of the HINO DIESEL ENGINE E13C-VV; Interim Tier 4 compatible engine installed on the KCM 90Z7/92Z7 Wheel Loaders.
- Also, this contains troubleshooting information in accordance with the engine failure status and the generated diagnosis codes.
- To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
- The purpose of this manual is to provide necessary information when handling the product components and inspection for the correct maintenance and repair methods. To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.
- This manual was reproduced with permission from HINO MOTORS LTD.
How to read this manual :
1. Scope of repair work:
(1) Repair work is classified into three large categories of “Diagnosis”, “Mounting/removal, replacement, assemblydisassembly and inspectionadjustment” and “Final inspection”.
(2) This manual describes “Diagnosis” in the first process and “Mounting/removal, replacement, assemblydisassembly and inspectionadjustment” 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 Special Service Tool (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.
G.B 05/02/25