SB-17-024 – Fuel Injectors Test Workshop Manual Addition – HINO

SEOCONTENT-START

SERVICE MANUAL INFORMATION
SB-17-024 FUEL INJECTORS TEST WORKSHOP
MANUAL ADDITION
GROUP: SERVICE MANUAL UPDATE
BULLETIN NO: SB-17-024
DATE: 8-22-2017
SUBJECT VEHICLES: All Hino Trucks.
The following is to inform you of the above caption. This service data
should be attached to the relevant pages of the workshop manuals for
maintenance and to use for servicing.
OVERVIEW:
Troubleshooting Inspection procedure of the “new Injector test in the DPR
malfunctions” were addition.
NOTE: For any warranty claims with injector replacement to be paid after
October 1st 2017, this injector test will need to be performed.
BEFORE YOU BEGIN:
– Read and understand all instructions and procedures before you begin
the work.
– Read and follow all WARNINGS and NOTICES set forth in this
publication. These alerts help to avoid damage to components, serious
personal injury, or both.
– Park the vehicle on a flat, level and solid surface.
– Place the gear shift lever in “Neutral” or “Park”.
– Apply the parking brake firmly and confirm parking brake activation.
– Turn off the engine and remove the key from the ignition switch.
– Always wear safety glasses or goggles to protect your eyes.
– Place wheel chocks in front of and behind all the wheels to prevent the
vehicle from moving.
WARNING: To prevent a fire, avoid smoking and
open flames near the vehicle while performing this procedure.
FUEL INJECTOR TEST KIT :
PART NUMBER QUANTITY
HDT-650591 1
VEHICLE PREPARATION
1. Park the vehicle on a flat, level and solid surface.
2. Confirm the engine is stopped, the ignition switch is in the off (LOCK)
position, and the key is removed.
3. Apply the parking brake.
4. Chock all of the wheels.
FUEL INJECTOR TEST KIT SETUP:

CONNECTING TOOLS PROCEDURE:
Important: The engine must be at 158°F (70°C) – Truck in P or N with the
parking brake on, all symptoms repaired and all accessories must be off
(exhaust brake, PTO, air condition, audio system, wipers; do not operate
steering wheel or actuate the air brake while test is taking place).
Important: Hose connections must be clamped, using clamps provided in
the kit.
Important: Customers main fuel tank should have no less than ¼ tank of
fuel or air may not purge.
Important: Once the air is purged with using steps 4 thru 8 below, if the
fuel system is opened for any reason (with exception of connecting the
return hose), purge cycle will need to be performed again following
steps 4 thru 8.
NOTICE: If the fuel hoses cannot be connected according to Plan A, use
Plan B as an alternative. Refer to the table at the end of the procedure
“Location of the connecting fuel lines”.
Conventional Fuel Hose Connections
1. Remove the fuel hose from the trucks fuel filter inlet (driver’s side engine
compartment). Connect the single 7’ foot fuel hose from the straight barbed
fitting (top of valve assembly), to the fuel filter inlet on the truck (no adaptor
needed).
2. Connect the other 7’ foot fuel hose that is connected to the 90° barb
fitting from the valve, to the fuel hose removed from the fuel filter inlet (use
3/8”-3/8” barbed adaptor to complete the connection).
3. Connect the 2.5’ foot fuel hose (barbed fitting with valve) to
the fuel feed from the injector test bottle.
CEO Fuel Hose Connections
1. Remove the fuel hose from the trucks fuel filter inlet; separate the fuel
line on the drivers side directly behind the cab near the transmission bell
housing. Connect the single 7’ foot fuel hose from the straight barbed
fitting (use short 1/2” fuel hose with 3/8” barb to complete connection).
2. Connect the other 7’ foot fuel hose that is connected to 90° barb fitting
from the valve to the rubber fuel hose removed from the fuel inlet behind
the cab (use 3/8”-1/2” barbed adaptor to complete connection).
3. Connect the 2.5’ foot fuel hose (barbed fitting with valve), connect this to
the fuel feed from the injector test bottle.
Conventional/COE
Important: 12’ foot return fuel hose from injector test bottle
is not connected at this time
4. Connect the fuel lines as shown. Fill the fuel injector test bottle with
600cc of diesel fuel. Have the fuel valve turned to supply from tank.
5. Open DXII Diagnosis > Engine ECU > Inspection Menu > Injector
Inspection > Click Start > All-Cylinder Inspection
6. With the fuel valve directed from the main tank open, start the truck
and allow it to idle. Monitor the clear fuel hose(s) to remove air (shaking
clear fuel hose slightly may be necessary to remove air from fuel hose).
7. Once air is removed from the clear fuel hose from the main fuel tank,
rotate the lever valve to draw fuel from the injector test bottle. Keep
running from the injector test bottle until 2.5’ foot clear fuel hose between
injector test bottle and valve has purged air. Use approximately 200cc of
fuel from injector test bottle.
Once air is removed from this fuel hose, rotate valve so fuel is now
drawing from main fuel tank.
8. Click Start Inspection.
9. Run the truck from the main fuel tank, use 180 second purge cycle in
DXII (beginning of the injector test procedure), allowing all of the air to be
purged from the fuel system, while fuel is returning to the trucks main fuel
tank.
10. After the purge cycles completes (180 seconds), click Cancel. Turn the
truck off, pause for a moment and then attempt to start the truck. If the
truck restarts easily, turn ignition off again and connect clear return fuel
hose. If truck does not easily restart (due to air in the lines) run another 180
second purge cycle by clicking on Start inspection before connecting return
hose.
Important: Do not choose a different location for the return hose
connection.
Conventional – make the connection on the frame rail under the cab on
driver’s side, slide the hose on the metal fuel return pipe.
COE: make the connection on the driver’s side frame rail, directly behind
the cab and connect the hose to the metal fuel return pipe.
11. Once connections are secure, start the truck and while truck is running
at idle, valve still select for drawing fuel from main fuel tank, allow
return fuel and air to enter injector test bottle.
Once air is purged from the return fuel line, fill the injector test bottle just
past 900cc (regulate fuel level with valve). Once full, turn the valve to
draw from the injector test bottle; prepare for the injector test procedure.
12. While the truck is still running, start 180 second purge cycle again in
DXII Start Inspection, then perform injector test as outlined. Use the valve
to regulate fuel in the injector test bottle; when the main fuel tank is being
used as a fuel source, return raises fuel level in the injector test bottle (use
caution never to overfill the injector test bottle), measurement and
purge cycle should begin with no less than 800cc of diesel fuel in the
injector test bottle.
13. If you can see the metal tubes in the bottle through the fuel then a
sufficient amount of air has been removed. If you cannot see the metal
tubes through the fuel then more air needs to be removed by running
additional purge cycles.
14. Once injector test bottle is at proper level, turn valve to run truck
from injector test bottle. Click Start inspection.
15. Allow 180 second purge cycle to complete then click OK.
16. Monitor the injector test bottle until it reaches a line graduation that can
be used as a start point. Once this is reached, click Measurement Start.
Document the start of the measurement, subtract 300cc from the selected
number and this will be the point where measurements ends.
17. Once the fuel injector test bottle decreases by 300cc, click
Measurement End. For example if you started at 900cc click
Measurement end at 600cc.
18. Once Judgment is provided and there are no abnormalities detected,
click End Inspection.
19. Once the DX session is complete, be sure to click New Diagnosis in the
upper right to end the DX session and upload the report with test results for
your records.
INDIVIDUAL INJECTORS TESTING
1. Refill the bottle using valve just above the 900cc mark on the bottle.
Click Inspecting #1 cylinder when the fuel is at 900cc.
2. When the fuel level in the bottle has gone down 300cc, click on
Measurement end.
3. Refill the bottle using valve just above the 900cc mark on the bottle.
Click Inspecting #2 cylinder when the fuel is at 900cc. At this point you
would continue testing for each of the remaining fuel injectors.
4. After checking the last injector, click on inspection result display.
5. Record and replace any injectors that have failed the test which are
denoted with NG. ONLY replace the injector(s) that are NG. If only one
injector failed the test, ONLY replace the one failed injector.
NOTICE
• Be sure to reconnect each hose to avoid fuel leaks.
• After completing the test, confirm that fuel does not leak from any of
the hoses.
• Confirm the determination result for judgment.
• Determination value of the each cylinder inspection will only be
used by the specialized agency.