PDF Shop Manual Kawasaki E13C VV HINO Diesel Engine - 2 MB
This is the comprehensive shop manual for the Kawasaki E13C-VV HINO diesel engine, used in the 90Z7 and 92Z7 wheel loaders.
It provides complete instructions for disassembly, inspection, repair, and reassembly of the engine.
With detailed specifications and step-by-step procedures, this manual is the ultimate resource for any mechanic performing an overhaul or major repair.
Ensure your engine work is done to factory standards for optimal power and longevity.
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93213-00650
E13C-VV (90/92Z7) SHOP MANUAL
February 2012
SHOP MANUAL
HINO DIESEL ENGINE
Engine Diagnosis
General Information
E13C-VV
General Information
Engine Diagnosis
93213-00650
(For Kawasaki Wheel Loaders 90Z7 and 92Z7)
©2012 KCM Corporation. All rights reserved. Printed in Japan (K) Serial No. 90H1-5001 and up
( アメリカ用 ) 92H1-5001 and up
--- Page 3 ---
1–2 GENERAL
Warning
JP30ZLE010102001
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
This manual is prepared for qualified service engineers who are recognized as technical experts. Those who are not
qualified, who are not appropriately trained, who perform service without appropriate tools or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
machines. Be sure to only use genuine Hino replacement parts.
• 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, the safety of service engineers as well as the safety and reliability
of machines may be compromised. Never use a method or tool that is not recommended.
• This manual shows "Warning" and "Caution" for items that need to be observed so that accidents may not occur
during service or repair, or that damage to machine due to improper method may not impair safety and reliability of
machines. These instructions cannot give warning for all possible hazards. Note that items with "Warning" or
"Caution" are not absolute for safety.
--- Page 4 ---
1–12 GENERAL
Tightening of engine bolts and nuts
JP30ZLE010102003
1. Tightening torque of general standard bolts
(1) For bolts with seatings
Unit : Nm{kgfcm, lbfft}
Screw diameter x Pitch 7T 9T
M8 x 1.25 (Coarse thread) 28.5 {290, 21} 36 {370, 27}
M10 x 1.25 (Fine thread) 60 {610, 44} 74.5 {760, 55}
M10 x 1.5 (Coarse thread) 55 {560, 41} 68.5 {700, 51}
M12 x 1.25 (Fine thread) 108 {1100, 80} 136 {1390, 101}
M12 x 1.75 (Coarse thread) 97 {990, 72} 125 {1280, 93}
M14 x 1.5 (Fine thread) 171.5 {1750, 127} 216 {2210, 160}
M14 x 2 (Coarse thread) 154 {1570, 114} 199 {2030, 147}
Remark Bolt with number “7” on the head Bolt with number “9” on the head
! CAUTION • 8T bolt is in accordance with 7T bolt.
(2) For bolts with washers
Unit : Nm{kgfcm, lbfft}
Screw diameter x Pitch 4T 7T 9T
M6 x 1 (Coarse thread) 6 {60, 4} 10 {100, 7} 13 {130, 9}
M8 x 1.25 (Coarse thread) 14 {140, 10} 25 {250, 18} 31 {320, 23}
M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}
M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}
M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1200, 88}
M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1100, 80}
M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1500, 108} 186 {1900, 137}
M14 x 2 (Coarse thread) 74 {750, 54} 132 {1350, 98} 172 {1750, 127}
Bolt with number “4” on
the head Bolt with number ”7” on
Bolt with number “9” on
Remark Projection bolt Stud the head Stud with C
the head
with R surface at free surface at free end
end
! CAUTION • 8T bolt is in accordance with 7T bolt.
R surface (4T) C surface (7T)
SAPH30ZLE0100006
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1–22 GENERAL
Failure diagnosis using HinoDX
JP30ZLE010301003
! CAUTION HinoDX is used for inspection and adjustment
of the system in addition to failure diagnosis.
1. HinoDX
(1) With HinoDX, failure of the common rail fuel injection
system can be diagnosed. The interface box (Hino-Bowie
or DST-i) and the special cable are required for connection
to the unit.
SAPH30ZLE0100028
--- Page 6 ---
2–4 STANDARD VALUE
Emission Control
Tightening torque
JP30ZLE020701005
Unit:Nm{kgfcm, lbfft}
Tightening area Tightening torque Remark
EGR valve mounting bolt 55 {560, 40}
55 {560, 40} Refer to the
EGR cooler mounting bolt
125 {1275, 92} main text.
EGR pipe mounting bolt or nut 72 {730, 53}
EGR pipe - EGR valve 55 {560, 40}
EGR pipe - EGR cooler 125 {1275, 92}
EGR cooler bracket mounting bolt 68 {700, 50}
--- Page 7 ---
2–14 STANDARD VALUE
Cooling
Standard value
JP30ZLE020701011
Inspection item Standard value Action
Thermostat valve opening temperature 80-84qC {176-183qF} Replace
Thermostat valve lift
10 {0.394} or more Replace
(Set temperature 95 qC {203 qF})
Tightening torque
JP30ZLE020701012
Unit:Nm{kgfcm, lbfft}
Tightening area Tightening torque Remark
Thermostat case mounting bolt 55 {560, 40}
Thermostat case cover mounting bolt 55 {560, 40}
Coolant pump mounting bolt 97 {990, 72}
Coolant pump vane assembly mounting bolt 55 {560, 40}
--- Page 8 ---
3–4 PARTS TO BE PREPARED
Engine Mechanical
Special tools
JP30ZLE030901003
Shape Part No. Name Remark
S0942-02060 For crankshaft front oil seal
Puller
(09420-2060) removal
S0940-71200 For crankshaft front oil seal
Press
(09407-1200) mounting
S0947-01120 For assembly/disassembly of
Valve spring press
(09470-1120) Valve spring
S0943-11010
Valve lapping tool For valve adjustment
(09431-1010)
S0947-22190
Valve stem seal press For valve stem seal mounting
(09472-2190)
S0944-21131 For assembly/disassembly of
Piston ring expander
(09442-1131) piston ring
S0942-01442 For cam idle gear shaft (head)
Sliding hammer
(09420-1442) removal
• Main idle gear shaft
S0942-01510
Sliding hammer • For cam idle gear shaft
(09420-1510)
(block) removal
SZ910-24101 For cooling jet inspection and
Check bolt
(9011-24265) adjustment
S0944-41770 For cooling jet inspection and
Gauge
(09444-1770) adjustment
--- Page 9 ---
4–2 ENGINE MOUNTING/DISMOUNTING
Overhaul Criteria
Factors to determine the engine overhaul
JP30ZLE040702001
NOTICE • Measure the compression pressure before
disassembly of the engine and record the
result. Regular measurement of the
compression pressure can tell the engine
status.
1. Preparation before measurement
(1) Charge the battery completely.
(2) Check the valve clearance and adjust it when exceeding
the standard value.
(3) Warm the engine and set the water temperature to 80 qC
{176 qF}.
(4) Remove the air cleaner.
(5) Remove the head cover.
(6) Remove all injectors.
(7) To prevent spread of engine oil, attach a jig which cuts a
head cover in half. (Cut it so that the camshaft may be
covered.
2. Measurement
(1) Install the special tool on the nozzle seat of the cylinder
for which the compression pressure is to be measured.
Use a nozzle clamp and the clamp mounting bolt.
Special tool : Compression gauge adapter
Part No. Parts tightened
Inspection
Special S0950-81060 Insert into the injector
tool
Engine
(09508-1060) mounting part.
SAPH30ZLE0400001
S0955-21030
(09552-1030)
Select the adapter
(3/4-16 UNF)
according to the thread
S0955-21060
size of the air gauge.
(09552-1060)
(W16 threads ridges 18)
(2) Turn the starter and measure the compression pressure.
! CAUTION • Do not operate the starter for more than 15
seconds.
• Since the air cleaner is removed, prevent
entry of dirt.
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5–2 FUEL SYSTEM
FUEL SYSTEM
Fuel system diagram
JP30ZLE050805001
Leakage pipe
Overflow pipe
Pressure limiter
Overflow valve
Injection pipe
Injector
Common rail
Return pipe
Pressure feed pipe Through-feed pipe
Fuel filter
Priming pump
Supply pump
Feed pipe Fuel tank
Feed pipe
Through-feed valve Feed pipe Feed pump
SAPH30ZLE0500001
ç\ê¨ê}
ç\ê¨îzíuê}
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5–12 FUEL SYSTEM
(5) Tighten the fuel filter water drain plug and the joint bolt.
Tightening torque : 6.9r2Nm {70r20kgfcm, 5r1 lbfft}
(Water drain bolt)
(6) Operate the priming pump and bleed the air from the
system.
Priming pump
Air venting bolt
SAPH30ZLE0500014
! CAUTION • Check that the fuel filter air venting plug has
been loosened.
(7) Tighten the fuel filter air venting plug.
Tightening torque : 6.9r2Nm {70r20kgfcm, 5r1 lbfft}
! CAUTION • After completion of the work, wipe up any fuel
which has been spilled and after start of the
engine, again confirm that no fuel is leaking.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.
--- Page 12 ---
5–22 FUEL SYSTEM
3. Injector removal
(1) Remove the injector clamp mounting bolts and remove the
injectors and the injector clamps.
Injector clamp mounting bolt
Injector clamp
Injector
SAPH30ZLE0500028
NOTICE • When pulling is difficult, use a special tool for
pulling.
Special tool : S0942-02010 (09420-2010) Puller
Special tool
Injector
SAPH30ZLE0500029
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5–32 FUEL SYSTEM
Flow damper
1. Inspection of the flow damper
(1) Start the engine and change the engine revolution from
idling to full throttle. Use Hino-DX to check the diagnosis
code of the "flow damper operation".
Refer to the "17 Engine diagnosis code, P0263[61],
P0266[62], P0269[63], P0272[64], P0275[65],
P0278[66]".
(2) If the diagnosis code of the "flow damper operation" is
detected, replace the relevant injector and inspect it
again.
If replace the injector, must be reprogramming.
Refer to the "Injector replacement".
(3) If reproducible after replacing the injector, replace the
common rail.
--- Page 15 ---
7–10 ELECTRICAL
4. Inspection of the coolant temperature switch
105 C 2 C (221 F 3.6 F)
(1) Heat the coolant temperature switch.
OFF ON
NOTICE • The liquid used to inspection can use any of
100 C (212 F) min the glycerin, the silicon oil, the rapeseed oil,
and the anti-freeze.
(2) Measure continuity between the terminals, using a circuit
tester. If it is faulty, replace the coolant temperature
switch.
Measurement item Reference value
105qC r 2qC {221qF r 3.6qF}
Conductivity
Liquid level approx. 2mm or more
(0.08in.)
100qC {212qF}
No conductivity
or less
SAPH30ZLE0700012
5. Inspection of the intake air heater
Intake air heater (1) Measure continuity between terminals and the body and
the terminal using a circuit tester. If it is faulty, replace the
intake air heater.
Inspection item Reference value
Between terminals With continuity
Between the terminal and the
Without continuity
SAPH30ZLE0700013 body
6. Inspection and replacement of the pump control valve
Pump (PCV) and engine speed sensor (Sub)
control valve Engine speed
sensor (sub) (1) If the pump control valve (PCV) and the engine speed
sensor are faulty, remove them from the engine in the
supply pump assembly and request for reinspection at the
Denso service shop.
SAPH30ZLE0700014
--- Page 16 ---
7–20 ELECTRICAL
• Check that there is no dirt on the bosses (4
locations) on the rear of the engine ECU.
• Confirm that the filter (resin housing) on the
rear of the engine ECU is not broken or
Filter contaminated by oil.
(resin housing)
Boss
SAPH30ZLE0700036
Mounting the engine ECU connector
1. Attaching the engine ECU connector
(1) Check that the harness side connector lever is fully open
and place it straight on the engine ECU side connector.
Lever
! CAUTION • At this time, check that the lever is fully open.
SAPH30ZLE0700037
NOTICE • Check that it is inserted along the wrong
fitting prevention keyway.
Wrong fitting prevention keyway
SAPH30ZLE0700038
(2) Press the upper part of the harness side connector and
insert the connector uniformly.
Lever
SAPH30ZLE0700039
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9–2 ENGINE MECHANICAL
Cylinder Head
Part layout
JP30ZLE090402001
SAPH30ZLE0900001
11101 Cylinder head assembly 11213 Head cover gasket*
11115 Cylinder head gasket* 12281 Engine hanger
11181 Cylinder head plate 12281A Engine hanger
11185 Cylinder head bolt 12505 Silent block
11198 Semicircular plug 13719 Valve stem seal
11201 Cylinder head cover 23074A Common rail pressure sensor seal*
*Parts not to be reused.
Tightening torque
11185 Cylinder head - Cylinder block: Z9102 Additional bolt
118Nm {1,200kgfcm, 87 lbfft}+90q+90q 108Nm {1,100kgfcm, 80 lbfft}
SH691-10840 25Nm {250kgfcm, 18 lbfft}
--- Page 18 ---
9–12 ENGINE MECHANICAL
3. Valve guide replacement
(1) Remove the valve stem seal.
(2) Use a brass bar and a press or similar to remove the valve
Valve guide
guide.
SAPH30ZLE0900019
(3) apply engine oil to the outer circumference of the valve
guide.
(4) Press in the valve guide to the cylinder head using a
23.7-24.0 mm
{0.9330-0.9449 in.} press, as shown in the figure.
Press-fitting
Pressing
rod ! CAUTION • At the time of press fitting the valve guide,
take care not to damage the valve stem.
23.7 - 24.0 mm
Standard value
{0.9330-0.9449 in.}
Valve guide
SAPH30ZLE0900020
(5) Install a new valve stem seal.
Refer to the "9 Engine mechanical, Valve system,
overhaul".
--- Page 19 ---
9–22 ENGINE MECHANICAL
SAPH30ZLE0900194
11353A Flywheel housing stay 11353B Flywheel housing stay
Tightening torque
Z9102A 225Nm {2,300kgfcm, 166 lbfft} Z9102B 225Nm {2,300kgfcm, 166 lbfft}
--- Page 20 ---
9–32 ENGINE MECHANICAL
Crankshaft rear oil seal and sleeve replacement
1. Flywheel removal
(1) Remove the flywheel.
Refer to the "9 Engine mechanical, Main Moving
Parts, Flywheel replacement".
2. Crankshaft rear oil seal removal
(1) Remove the rear oil seal with a pliers.
! CAUTION • Do not reuse the oil seal.
3. Crankshaft rear sleeve removal
(1) Place the plate (Special tool) at the crankshaft and tighten
the 2 bolts (Special tool) to the sleeve.
(2) Install the center bolt (Special tool) and tighten it to
remove the oil sleeve.
Special tool
Plate 09223-E0850
Bolt SH111-00635
Center bolt SZ101-12048
Oil seal
Sleeve
Plate (Special tool)
Crankshaft
Sleeve Bolt (Special tool)
Sleeve
Plate (Special tool)
Crankshaft Center bolt (Special tool)
[Before the installation of [After the installation of
the special tools] the special tools]
SAPH30ZLE0900203
--- Page 21 ---
9–42 ENGINE MECHANICAL
2. Disassembly of piston and connecting rod
(1) Use snap ring pliers to remove the retainer ring.
(2) Make match marks, and use a brass bar to remove the
piston pin and separate piston and connecting rod.
Paint mark
Paint mark
SAPH30ZLE0900078
(3) Use the special tool and remove the piston ring.
Special tool
! CAUTION • Handle the piston rings with care as they
break easily.
• Identify and store the piston rings in order of
the cylinder numbers.
• At the time of storage, take care not to mix the
upper and lower surface of the piston rings.
Special tool : S0944-21131 (09442-1131)
SAPH30ZLE0900079
Piston ring expander
3. Assembly of piston and connecting rod
(1) Install the piston so on the connecting rod that the piston
part number stamp and the match mark stamp of the
connecting rod are on opposite sides.
! CAUTION • Confirm that the oil hole offset is as shown in
the figure.
Special tool : S0948-21380 (09482-1380)
Piston pin press
SAPH30ZLE0900080
(2) Use snap ring pliers to install a new retainer ring.