Hino j05d, j08e Service Manual

For DENSO Authorized

ECD Service Dealer Only

Diesel Injection Pump

SERVICE MANUAL

Common Rail System for HINO

J05D/J08E Type Engine

OPERATION

October, 2003

00400041E

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TABLE OF CONTENTS
1. Product Application -------------------------------------------------------------------------------------	1
1.1 Application -------------------------------------------------------------------------------------------------------------------	1
1.2 System Components Parts Numbers ---------------------------------------------------------------------------------	1
2. Outline ------------------------------------------------------------------------------------------------------	2
2.1 Features of System -------------------------------------------------------------------------------------------------------	2
[1] System Characteristics ------------------------------------------------------------------------------------------------	2
[2] Comparison to the Conventional System -------------------------------------------------------------------------	3
2.2 Outline of System ----------------------------------------------------------------------------------------------------------	4
[1] Composition --------------------------------------------------------------------------------------------------------------	4
[2] Operation -----------------------------------------------------------------------------------------------------------------	4
2.3 Fuel System and Control System --------------------------------------------------------------------------------------	5
[3] Fuel System --------------------------------------------------------------------------------------------------------------	5
[4] Control System ----------------------------------------------------------------------------------------------------------	5
3. Construction and Operation---------------------------------------------------------------------------	6
3.1 Description of Main Components -------------------------------------------------------------------------------------	6
[1] Supply Pump (HP3, HP4) ---------------------------------------------------------------------------------------------	6
[2] Description of Supply Pump Components ------------------------------------------------------------------------	13
[3] Rail --------------------------------------------------------------------------------------------------------------------------	16
[4] Injector (G2 Type) -------------------------------------------------------------------------------------------------------	17
[5] Engine ECU (Electronic Control Unit) ------------------------------------------------------------------------------	22
3.2 Description of Control System Components ------------------------------------------------------------------------	22
[1] Engine Control System Diagram ------------------------------------------------------------------------------------	22
[2] Sensor and Relays -----------------------------------------------------------------------------------------------------	23
3.3 Various Types of Controls -----------------------------------------------------------------------------------------------	29
[1] Fuel Injection Rate Control -------------------------------------------------------------------------------------------	30
[2] Fuel Injection Quantity Control ---------------------------------------------------------------------------------------	31
[3] Fuel Injection Timing Control -----------------------------------------------------------------------------------------	35
3.4 Other Relevant Engine Control -----------------------------------------------------------------------------------------	36
[1] EGR Control --------------------------------------------------------------------------------------------------------------	36
3.5 Engine ECU -----------------------------------------------------------------------------------------------------------------	37
[1] Diagnosis Codes --------------------------------------------------------------------------------------------------------	37
[2] ECU External Wiring Diagram ---------------------------------------------------------------------------------------	44
[3] ECU Connector Diagram ----------------------------------------------------------------------------------------------	45

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1. Product Application

1.1 Application

Vehicle Name	Vehicle Model			Engine Model			Exhaust Volume				Reference
	HINO145, HINO165,				J05D			4.73L
	HINO185									Sales from
Medium Truck
	HINO238, HINO268,				J08E			7.68L		Early ’04
	HINO308, HINO338
1.2 System Components Parts Number
Part Name		Vehicle			DENSO Part			CarManufacturer			Reference
		Name			Number			Part Number
Supply Pump					294050-0011			22730-1311A
Injector					095000-5281			23910-1360A
Rail					095440-0480			22760-1180A
Engine ECU					102758-3010			89560-6540A
		Medium Truck
Accelerator Position Sensor					198800-3160			78010-1200A
		HINO238,
Coolant Temp. Sensor					071560-0110			83420-1250A
		HINO268,
Crankshaft Position Sensor					029600-0570			89410-1280A
		HINO308,
		HINO338
Cylinder Recognition Sensor					949979-1360			89410-1590A
Intake Air Pressure Sensor					079800-5890			89390-1080A
EGR Valve					135000-7091			17350-1220A
Air Flow Meter					197400-2000			22204-21010B			For EGR
											Control
Supply Pump					294000-0251			22730-1321A
Injector					095000-5391			23910-1310A
Rail					095440-0530			22760-1220A
Engine ECU					102758-3010			89560-6540A
Accelerator Position Sensor		Medium Truck			198800-3160			78010-1200A
Coolant Temp. Sensor		HINO145,			071560-0110			83420-1250A
		HINO165,
Crankshaft Position Sensor					029600-0570			89410-1280A
		HINO185
Cylinder Recognition Sensor					949979-1360			89410-1590A
Intake Air Pressure Sensor					079800-5890			89390-1080A
EGR Valve					135000-7071			17350-1210A
Air Flow Meter					197400-2000			22204-21010B			For EGR
											Control

1

2. Outline

2.1 Features of System

The common rail system was developed primarily to cope with exhaust gas regulations for diesel engines, and aimed for 1. further improved fuel economy; 2. noise reduction; and 3. high power output.

[1] System Characteristics

The common rail system uses a type of accumulation chamber called a rail to store pressurized fuel, and injectors that contain electronically controlled solenoid valves to spray the pressurized fuel into the cylinders. Because the engine ECU controls the injection system (including the injection pressure, injection rate, and injection timing), the system is unaffected by the engine speed or load. This ensures a stable injection pressure at all times, particularly in the low engine speed range, and dramatically decreases the amount of black smoke ordinarily emitted by a diesel engine during start-up and acceleration. As a result, exhaust gas emissions are cleaner and reduced, and higher power output is achieved.

(1)Injection Pressure Control

a.Enables high-pressure injection, even in the low engine speed range.

b.Optimizes control to minimize particulate matter and NOx emissions.

(2)Injection Timing Control

a.Optimally controls the timing to suit driving conditions.

(3)Injection Rate Control

a.Pilot injection control sprays a small amount of fuel before the main injection.

	Common Rail System
	Injection Pressure Control				Injection Timing Control		Injection Rate Control
	Optimization, High Pressurization					Optimization	Rate	Pilot Injection
	Common Rail System					Common Rail System	Injection	Main
Injection Pressure								Injection
					Injection Timing			Crankshaft Angle
		Particulate		NOx			Injection Quantity Control
	Conventional							Cylinder Injection
						Conventional		Volume Correction
	Pump					Pump	Speed
	Speed		Injection			Speed
			Pressure
								QD0734E

(4) EGR (Exhaust Gas Recirculation) Control

a. By recirculating the exhaust gas into the intake side of the engine, the combustion temperature is reduced and NOx is decreased.

2

[2] Comparison to the Conventional System
	In-line, VE Pump		Common Rail System
	High-pressure Pipe
	Momentary High Pressure		Rail
			TWV
	Timer	Nozzle	Supply Pump
			Usually High Pressure
	Governor
			Delivery Valve
System	In-line Pump
			Feed Pump SCV (Suction Control Valve)
			Injector
			Fuel Tank
	VE Pump
Injection Quantity Control	Pump (Governor)		Engine ECU, Injector (TWV)*1
Injection Timing Control	Pump (Timer)		Engine ECU, Injector (TWV)*1
Rising Pressure	Pump		Engine ECU, Supply Pump
Distributor	Pump		Engine ECU, Rail
Injection Pressure Control	Dependent upon Speed and Injection Quantity		Engine ECU, Supply Pump (SCV)*2
		*1 TWV: Two Way Valve *2 SCV: Suction Control Valve		QD2341E

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2.2 Outline of System [1] Composition

The common rail system consists primarily of a supply pump, rail, injectors, and engine ECU.

Fuel Temperature Sensor

Vehicle Speed

Accelerator Opening

Intake Air Pressure

Intake Air Temperature Engine ECU

Coolant Temperature

Crankshaft Position

Cylinder Recognition Sensor

	Intake Airflow Rate
	Rail	Pressure	Injector
		Limiter
	Rail Pressure
	Sensor

Fuel Temperature Sensor

Supply Pump	SCV (Suction	Fuel Tank
	Control Valve)

Q000144E

[2] Operation

(1)Supply pump (HP3)

a.The supply pump draws fuel from the fuel tank, and pumps the high pressure fuel to the rail. The quantity of fuel discharged from the supply pump controls the pressure in the rail. The SCV (Suction Control Valve) in the supply pump effects this control in accordance with the command received from the ECU.

(2)Rail

a.The rail is mounted between the supply pump and the injector, and stores the highpressure fuel.

(3)Injector (G2 type)

a.This injector replaces the conventional injection nozzle, and achieves optimal injection by effecting control in accordance with signals from the ECU. Signals from the ECU determine the length of time and the timing in which current is applied to the injector. This in turn, determines the quantity, rate and timing of the fuel that is injected from the injector.

(4)Engine ECU

a.The engine ECU calculates data received from the sensors to comprehensively control the injection quantity, timing and pressure, as well as the EGR (exhaust gas recirculation).

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2.3 Fuel System and Control System [1] Fuel System

This system comprises the route through which diesel fuel flows from the fuel tank to the supply pump, via the rail, and is injected through the injector, as well as the route through which the fuel returns to the tank via the overflow pipe.

[2] Control System

In this system, the engine ECU controls the fuel injection system in accordance with the signals received from various sensors. The components of this system can be broadly divided into the following three types: (1) Sensors; (2) ECU; and (3) Actuators.

(1)Sensors

a.Detect the engine and driving conditions, and convert them into electrical signals.

(2)Engine ECU

a.Performs calculations based on the electrical signals received from the sensors, and sends them to the actuators in order to achieve optimal conditions.

(3)Actuators

a.Operate in accordance with electrical signals received from the ECU. Injection system control is undertaken by electronically controlling the actuators. The injection quantity and timing are determined by controlling the length of time and the timing in which the current is applied to the TWV (Two-Way Valve) in the injector. The injection pressure is determined by controlling the SCV (Suction Control Valve) in the supply pump.

	Sensor							Actuator
		Engine Speed
	Crankshaft Position Sensor NE
								Injector
		Cylinder Recognition						•Injection Quantity Control
	Cylider Recognition Sensor G							•Injection Timing Control
		Load		Engine
	Accelerator Position Sensor			ECU
								Supply Pump (SCV)
	Rail Pressure Sensor							•Injection Pressure Control
								EGR, Engine Warning Light
	Other Sensors and Switches							Q000282E

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3. Construction and Operation

3.1 Description of Main Components [1] Supply Pump (HP3, HP4)

(1)Outline

a.The supply pump consists primarily of the pump body (cam shaft, ring cam, and plungers), SCV (Suction Control Valve), fuel temperature sensor, and feed pump.

b.The two plungers for HP3 or the three plungers for HP4 are positioned vertically on the outer ring cam for compactness.

c.The engine drives the supply pump at a ratio of 1:1. The supply pump has a built-in feed pump (trochoid type), and draws the fuel from the fuel tank, sending it to the plunger chamber.

d.The internal camshaft drives the two plungers, and they pressurize the fuel sent to the plunger chamber and send it to the rail. The quantity of fuel supplied to the rail is controlled by the SCV, using signals from the engine ECU. The SCV is a normally opened type (the intake valve opens during de-energization).

HP3

SCV

Fuel Temperature Sensor

Q000252E

HP4

Fuel Temperature Sensor

SCV

Q000253E

6

				Intake Valve	Intake Pressure
	Injector	Rail	Discharge Valve		Feed Pressure
					High Pressure
				Plunger
					Return Pressure
					Return Spring
		Return
		Fuel Overflow			SVC
					Regulating Valve
				Filter	Feed Pump
			Camshaft		Fuel Inlet
					Intake
	Fuel Tank				Fuel Filter (with Priming Pump)
					QD0704E

7

HP3
	SCV
	Plunger
	Feed Pump
Pump Body
	Fuel Temperature
Ring Cam	Sensor
	Regulating
	Valve
Drive Shaft	Filter
	Plunger
	Q000254E
	8

	HP4
		SCV
	Plunger
	Fuel Temperature	Filter
	Sensor
		Feed Pump
	Ring Cam	Regulating
		Valve
		Pump Body
	Drive Shaft
		Plunger
		Q000255E
		9

(2)Supply Pump Internal Fuel Flow

a. The fuel that is drawn from the fuel tank passes through the route in the supply pump as illustrated, and is fed into the rail.

Supply Pump Interior

Regulating Valve

		Feed Pump				SCV (Suction Control Valve)		Pumping Portion (Plunger)		Rail

Overflow

Intake Valve

Fuel Tank

Q000283E

(3)Construction of Supply Pump (in case of HP3 pump)

a. The eccentric cam is attached to the cam shaft. The eccentric cam is connected to the ring cam.

Cam Shaft

Eccentric Cam	Ring Cam

QD0706E

b.As the cam shaft rotates, the eccentric cam rotates eccentrically, and the ring cam moves up and down while rotating.

Plunger

Eccentric Cam

Ring Cam

Cam Shaft

QD0727E

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c.The plunger and the suction valve are attached to the ring cam. The feed pump is connected to the rear of the cam shaft.

Plunger A

Ring Cam

Feed Pump

Plunger B

QD0728E

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(4)Operation of the Supply Pump

a. As shown in the illustration below (in case of HP3 pump), the rotation of the eccentric cam causes the ring cam to push Plunger A upwards. Due to the spring force, Plunger B is pulled in the opposite direction to Plunger A. As a result, Plunger B draws in fuel, while

Plunger A pumps it to the rail. In the case of the 4-cylinder engine used with the HP3 pump, each plunger pumps fuel in a reciprocal movement during the 360° cam rotation. Conversely, in the case of the 6-cylinder engine used with the HP4 pump, 3 plungers pump fuel in a reciprocal movement for each one rotation of the cam.

Suction Valve

Plunger A

Delivery Valve

Eccentric Cam

Ring Cam

SCV

Plunger B

Plunger A: Complete Compression	Plunger A: Begin Intake
Plunger B: Complete Intake	Plunger B: Begin Compression

Plunger A: Begin Compression

Plunger A: Complete Intake

Plunger B: Begin Intake

Plunger B: Complete Compression

QD0707E

NOTE:

There are 3 plungers for the HP4.

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[2] Description of Supply Pump Components

(1)Feed Pump

a. The trochoid type feed pump, which is integrated in the supply pump, draws fuel from the fuel tank and feeds it to the two plungers via the fuel filter and the SCV (Suction Control

Valve). The feed pump is driven by the drive shaft. With the rotation of the inner rotor, the feed pump draws fuel from its suction port and pumps it out through the discharge port. This is done in accordance with the space that increases and decreases with the movement of the outer and inner rotors.

Quantity Decrease

Quantity Decrease (Fuel Discharge)

Outer Rotor

to Pump Chamber

Inner Rotor

Intake Port

	Discharge	Quantity Increase	Quantity Increase (Fuel Intake)
	Port
from Fuel Tank
			QD0708E

(2)SCV: Suction Control Valve (Normally open type)

a.A linear solenoid type valve has been adopted. The ECU controls the duty ratio (the duration in which current is applied to the SCV), in order to control the quantity of fuel that is supplied to the high-pressure plunger.

b.Because only the quantity of fuel that is required for achieving the target rail pressure is drawn in, the actuating load of the supply pump decreases.

c.When current flows to the SCV, variable electromotive force is created in accordance with the duty ratio, moving the armature to the left side. The armature moves the cylinder to the left side, changing the opening of the fuel passage and thus regulating the fuel quantity.

d.With the SCV OFF, the return spring contracts, completely opening the fuel passage and supplying fuel to the plungers. (Full quantity intake and full quantity discharge)

e.When the SCV is ON, the force of the return spring moves the cylinder to the right, closing the fuel passage (normally opened).

f.By turning the SCV ON/OFF, fuel is supplied in an amount corresponding to the actuation duty ratio, and fuel is discharged by the plungers.

Exterior View of SCV	Cross-section of SCV	SCV
	Return Spring

Pump Body

Cylinder

Q000270E

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