Hino A09c engine service manual

FOREWORD This manual has been prepared to provide information regarding structures, features and repair procedures on Hino Vehi- cles. Applicable for A09C engine When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner’s Manual. All information and specifications in this manual are based upon the latest product information available at the time of print- ing. Hino Motors reserves the right to make changes at any time without prior notice. ■■■■■■■■ 1 MENU

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. CHAPTER MANUAL NO. S5-MA09E02B MODEL A09C STRUCTURES AND FEATURES INTRODUCTION 1 ENGINE 2 INSPECTION AND MAINTENANCE GENERAL INTRODUCTION GN01-001 ENGINE INTRODUCTION EN01-001 ENGINE MECHANICAL EN02-001 AIR INTAKE SYSTEM EN03-001 EXHAUST SYSTEM EN04-001 LUBRICATING SYSTEM EN05-001 COOLING SYSTEM EN06-001 FUEL SYSTEM EN07-001 TURBOCHARGER EN08-001 EMISSION CONTROL EN10-001 ALTERNATOR EN11-001 STARTER EN12-001 AIR COMPRESSOR EN13-001 ENGINE P.T.O. (POWER TAKE-OFF) EN14-001 ENGINE RETARDER EN15-001 ENGINE CONTROL EN16-001 ENGINE CONTROL DN01-001 FUEL CONTROL DN02-001

STRUCTURES AND FEATURES

ENGINE INDEX: STRUCTURES AND FEATURES STRUCTURES All rights reserved. This manual may not be reproduced or copied in whole in part, without the written consent of Hino Motors, Ltd. INTRODUCTION AND FEATURES

INTRODUCTION 1– 1 1 1INTRODUCTION IDENTIFICATION OF VEHICLE MODEL CODE ................................................. 1-2 LIST OF VEHICLE MODEL CODES ........................... 1-2 LIST OF APPLICABLE VEHICLE MODELS........... 1-2 DESIGNATION OF VEHICLE MODEL CODE........ 1-2 INTRODUCTION TO VEHICLE MODEL SERIES ..................................................... 1-3 OBJECTIVE OF DEVELOPMENT ............................... 1-4 SUMMARY ............................................................. 1-4 OUTLINE OF VEHICLE (CHANGE) ................ 1-8 LIST OF VEHICLE (CHANGE) OUTLINE ................... 1-8 LIST OF CHANGE OUTLINE ................................. 1-8 LAWS AND REGULATIONS.......................... 1-13 AUTOMOBILE EMISSION REGULATIONS .............. 1-13 SUMMARY ........................................................... 1-13 APPROACH FOR EMISSION CONTROL ............ 1-13 FAILURE DIAGNOSIS ................................... 1-14 FAILURE DIAGNOSIS WITH COMPUTER (Hino-DX) ................................................................... 1-14 ABOUT Hino-DX ................................................... 1-14 GLOSSARY.................................................... 1-15 DEFINITION OF ABBREVIATION ............................. 1-15 LIST OF ABBREVIATIONS .................................. 1-15

 1–2  2 IDENTIFICATION OF VEHICLE MODEL CODE  LIST OF VEHICLE MODEL CODES LIST OF APPLICABLE VEHICLE MODELS   DESIGNATION OF VEHICLE MODEL CODE    VEHICLE MODEL ENGINE MODEL TRANSMISSION MODEL FM 1A A09C FULLER RTO11909ALL ALLISON 3500RDS CLASSIFICATION OF VEHICLE TYPE F: Cab-over-engine truck CLASSIFICATION OF ENGINE 1A: A09C POSITION OF STEERING WHEEL K : Right-hand steering wheel INDICATION OF VEHICLE BODY CONFIGURATION A: Leaf-suspension type cargo truck M: Mixer truck VEHICLE CLASS AND DRIVE SYSTEM CLASS OF PAYLOAD (TONNAGE) DRIVE SYSTEM 10.0 M 6 x 4 (FOUR-REAR-WHEEL DRIVE) CLASSIFICATION OF WHEEL BASE L: 4,750 to 4,999 mm {187.0 to 196.8 in.} R: 5,750 to 5,999 mm {226.4 to 236.1 in.} W: Over 7,000 mm {275.6 in.} 1A F M R K A G: Air-suspension type cargo truck SHTS01ZZZ0100001

 1–3 INTRODUCTION TO VEHICLE MODEL SERIES  FM MODEL Payload: 10 to 15.75 tons Drive system: 6 x 4 (four-rear-wheel drive) Features of FM model: The FM model is a perfect model for transporting heavy cargos and/or traveling on rough roads, featuring powerful drive performance with four-rear-wheel drive (6 x 4). Hino offers a wide variation of products ranging from dump trucks to long-body trucks. Hino's new light-weight, fuel-efficient in-line six-cylinder diesel engine (A09C) complements Hino's product lineup. Long cargo trucks Mixer trucks Long cargo trucks Mixer trucks FEATURES OF VEHICLE MODEL FEATURES OF VEHICLE MODEL SHTS01ZZZ0100078

 1–4  OBJECTIVE OF DEVELOPMENT SUMMARY  Keyword - More user-friendly, more powerful ! ENGINE New A09C engine in compliance with US04 emission standards SHTS01ZZZ0700001

 1–5 Hino's all-out effort with state-of-art technologies produced this new light-weight, fuel- efficient engine. Hino developed a new high-strength cylinder block and a new basic structure. This development produced a engine that can withstand a high combustion pressure and exert high fuel efficiency and high power output. ENGINE UNIT Introduction of a new efficient EGR cooler and an electronic controlled variable EGR valve in combination with the A09C engine made a great contribution to reduction of NOx emissions. A new electronic variable nozzle turbocharger installed at the turbine inlet precisely controls an air flow and an exhaust pressure (EGR gas flow) and improves the combustion efficiency. ELECTRONIC CONTROLLED COOL EGR SYSTEM ENGINE ECU ENGINE The ultra high injection pressure atomizes the fuel to accelerate mixing with air for higher fuel efficiency. The number of fuel injections, the injection timing and the injection flow are precisely controlled to ensure the combustion controllability in response to driving conditions. ELECTRONIC CONTROLLED HIGH-PRESSURE COMMON RAIL INJECTION SYSTEM ELECTRONIC CONTROLLED VARIABLE NOZZLE TURBOCHARGER NEW A09C ENGINE IN COMPLIANCE WITH US04 EMISSION STANDARDS The engine ECU analyses the changeable operation conditions based on the information obtained from various sensors and controls the intake air flow, EGR gas flow and fuel injection flow for optimum combustion. Other features include high fuel efficiency and dramatic reduction in NOx and PM emissions during rapid acceleration/deceleration. SHTS01ZZZ0700002

 1–6 OUTPUT (PS) kW 300 280 260 240 220 200 180 160 140 120 200 230 260 290 320 350 800 1,000 1,200 1,400 1,600 1,800 2,000 2,200 2,400 Engine Speed r/min TORQUE N m (kgf m) 1,300 1,200 1,100 1,000 900 800 700 600 500 400 100 300 120 100 80 1,079N m/1,100r/min. (110kgf m/1,100r/min.) 235kW/2,100r/min. (320ps/2,100r/min.) The A09C engine outputs a high torque at a low engine speed. This is an advantage in gaining higher fuel efficiency and good drivability at a low engine speed. A09C-TK engine is used for the manual transmission model. A09C-TJ is used for the automatic transmission model. CHARACTERISTICS OF ENGINE A09C-TK ENGINE

Hino A09c engine service manual

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