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/ 386
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 |
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Models FD, FE and SG
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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