CHAPTER S SERVICE SPECIFICATIONS

Transcription

1 1 page INDEX1 SERVICE SPECIFICATIONS S-1 S-6E-16 CHAPTER S SERVICE SPECIFICATIONS TRUCK CHASSIS SPECIFICATIONS... S - 2 REPAIR SPECIFICATIONS... S - 12 METRIC INFORMATION... S - 26 DECIMAL AND METRIC EQUIVALENTS... S - 27 STANDARD TIGHTENING TORQUE... S - 28 RECOMMENDED LUBRICANTS... S - 29 S

2 S-2 SERVICE SPECIFICATIONS 1 page 1 TRUCK CHASSIS SPECIFICATIONS 2002 HINO FD2J Series WEIGHTS and DIMENSIONS (On standard specifications) Model FD2JGS FD2JJS FD2JKS FD2JMS FD2JPS Wheelbase mm (in.) 3,780 (148.8) 4,280 (168.5) 4,600 (181.1) 5,050 (198.8) 5,530 (217.7) Chassis weight Total kg (lb) 3,630 (8,000) 3,655 (8,055) 3,695 (8,145) 3,760 (8,285) 3,795 (8,360) (On std. spec. without spare tire Front kg (lb) 2,315 (5,100) 2,355 (5,190) 2,375 (5,235) 2,430 (5,355) 2,460 (5,420) and std. tool set) Rear kg (lb) 1,315 (2,900) 1,300 (2,865) 1,320 (2,910) 1,330 (2,930) 1,335 (2,940) Turning radius Tire mm (in.) 6,700 (263.8) 7,500 (295.3) 8,000 (315.0) 8,700 (342.5) 9,400 (370.1) (On std. spec.) Swept mm (in.) 7,450 (293.3) 8,250 (324.8) 8,750 (344.5) 9,450 (372.0) 10,150 (399.6) Tread Front mm (in.) 1,875 (73.8) 1,875 (73.8) 1,875 (73.8) 1,875 (73.8) 1,875 (73.8) Rear mm (in.) 1,750 (68.9) 1,750 (68.9) 1,750 (68.9) 1,750 (68.9) 1,750 (68.9) POWER LINE Power line STD. OPT. OPT. OPT. OPT. Transmission LF06S LF06S LF06S LCT2400 LCT2400 Ratios Ratios Ratios Ratios Ratios 1st nd Transmission 3rd gear ratios 4th th th Rev Rear axle carrier and Gear ratios SH14-1 Series SH14-1 Series SH14-1 Series SH14-1 Series SH14-1 Series Tire 9R /70R19.5 9R R /70R19.5 EQUIPMENT ENGINE Model Piston displacement Capacity of cooling system CLUTCH Clutch disc ass y Clutch cover ass y TRANSMISSION PROPELLER SHAFT Propeller shaft ass y HINO J08C-TP liters (486.0 cu. in.) with LF06S Transmission 21 liters (22.19 US qt) with ALLISON LCT2400 transmission 23 liters (24.30 US qt) SPICER AR350 SPICER AR350 Six-speed over-drive synchromesh 2nd 6th OPT. ALLISON Automatic 5-speed LD0932 series REAR AXLE FRONT AXLE Front axle ass y SERVICE BRAKE Single-Speed LF376 series Reversed Elliot, I beam Air over hydraulic dual circuits system with two leading shoes for front and rear, acting on all wheels Wheel brake ass y Series No.,Front 320 2L series Rear 320 2L series Drum diameter lining width thickness Front mm ( in.) Rear mm ( in.)

3 1 page 1 SERVICE SPECIFICATIONS S-3 PARKING BRAKE For LF06S transmission For ALLISON LCT2400 transmission EXHAUST BRAKE STEERING FRONT SUSPENSION REAR SUSPENSION Mechanical, internal expanding acting on transmission output shaft, mm (8 in.) drum diameter Mechanical, internal expanding acting on transmission output shaft, mm (10.0 in.) drum diameter Electric-pneumatic, with butterfly valve in exhaust pipe Telescopic and tilt steering column Recirculating ball, with hydraulic booster integral type Semi-elliptic leaf springs with double acting shock absorbers Semi-elliptic main and auxiliary leaf springs WHEEL AND TIRE Wheels Wheel type 6-stud disc wheels Tires 9R PR FUEL TANK Capacity 50 US.gal 1 CHASSIS FRAME Ladder type Straight section Width 870 mm (34.3 in.) Tensile strength 55 kg/mm 2 (78,200 lb/sq.in.) CAB All steel, welded construction ELECTRICAL EQUIPMENT Batteries Number per vehicle Two parallel connection, each 12V Capacity 622CCA Alternator Capacity 12V, 105A Starter Capacity 12V, 4.0kW Headlamps Sealed beam type 4-headlamp, white High beam 50W 2 High/Low beam 40W/60W 2 Identification lamps 3.8W 3 (Front) Licence plate lamp 8W 1 Stop/Tail lamps 27W/8W 2 12V Back-up lamps 27W 2 Turn signal and hazard warning lamps Front 27W W 2 Rear 27W 2 Dome lamps 10W 2 Front side marker lamps 5W 2 Clearance lamps (Front) 5W 2

4 S-4 SERVICE SPECIFICATIONS 1 page 1 WEIGHTS and DIMENSIONS (On standard specifications) Model FE2JGS FE2JJS FE2JKS FE2JMS Wheelbase mm (in.) 3,780 (148.8) 4,280 (168.5) 4,600 (181.1) 5,050 (198.8) Chassis weight Total kg (lb) 4,215 (9,290) 4,245 (9,355) 4,260 (9,390) 4,285 (9,445) (On std. spec. without spare tire Front kg (lb) 2,655 (5,850) 2,675 (5,895) 2,685 (5,920) 2,720 (5,995) and std. tool set) Rear kg (lb) 1,560 (3,440) 1,570 (3,460) 1,575 (3,470) 1,565 (3,450) Turning radius Tire mm (in.) 6,500 (255.9) 7,300 (287.4) 7,800 (307.1) 8,500 (334.6) (On std. spec.) Swept mm (in.) 7,250 (285.4) 8,050 (316.9) 8,550 (336.6) 9,250 (364.2) Tread Front mm (in.) 1,885 (74.2) 1,885 (74.2) 1,885 (74.2) 1,885 (74.2) Chassis weight (On std. spec. without spare tire and std. tool set) TRUCK CHASSIS SPECIFICATIONS 2002 HINO FE2J Series Rear mm (in.) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) Model FE2JPS FE2JRS FE2JSS Wheelbase mm (in.) 5,530 (217.7) 5,800 (228.3) 6,220 (244.9) Total kg (lb) 4,335 (9,555) 4,365 (9,620) 4,460 (9,830) Front kg (lb) 2,760 (6,085) 2,770 (6,105) 2,775 (6,115) Rear kg (lb) 1,575 (3,470) 1,595 (3,515) 1,685 (3,715) Turning radius Tire mm (in.) 9,200 (362.2) 9,600 (378.0) 10,200 (401.6) (On std. spec.) Swept mm (in.) 9,950 (391.7) 10,350 (407.5) 10,950 (431.1) Tread Front mm (in.) 1,885 (74.4) 1,885 (74.2) 1,885 (74.2) Rear mm (in.) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) POWER LINE Power line STD. OPT. OPT. Transmission LJ06S LJ06S ALLISON LCT2400 Ratios Ratios Ratios 1st nd Transmission 3rd gear ratios 4th th th Rev Rear axle carrier and Gear ratios SH14-1 Series SH14-1 Series SH14-1 Series EQUIPMENT ENGINE Model Piston displacement Capacity of cooling system HINO J08C-TP liters (486.0 cu. in.) with LJ06S Transmission 21 liters (22.19 US qt) with ALLISON LCT2400 transmission 23 liters (24.30 US qt) CLUTCH Clutch disc ass y Clutch cover ass y TRANSMISSION SPICER AR350 series SPICER AR350 series Six-speed over-drive synchromesh 2nd 6th OPT. ALLISON Automatic 5-speed

5 1 page 1 SERVICE SPECIFICATIONS S-5 PROPELLER SHAFT Propeller shaft ass y LF0932 series REAR SUSPENSION Semi-elliptic main and auxiliary leaf springs REAR AXLE FRONT AXLE Front axle ass y SERVICE BRAKE Single-Speed LF470 series Reversed Elliot, I beam Air over hydraulic dual circuits system with two leading shoes for front and rear, acting on all wheels Wheel brake ass y Series No.,Front 400 2L series Rear 400 2L series Drum diameter lining width thickness Front mm ( in.) Rear mm ( in.) PARKING BRAKE For LJ06S transmission For ALLISON LCT2400 transmission EXHAUST BRAKE STEERING Mechanical, internal expanding acting on transmission output shaft, 254 mm (10.0 in.) drum diameter Electric-pneumatic, with butterfly valve in exhaust pipe Telescopic and tilt steering column Recirculating ball, with hydraulic booster integral type WHEEL AND TIRE Wheels Wheel type 10-stud disc wheels Tires 11R PR FUEL TANK Capacity 50 US.gal 1 CHASSIS FRAME Ladder type Straight section Width 870 mm (34.3 in.) Tensile strength 55 kg/mm 2 (78,200 lb/sq.in.) CAB All steel, welded construction ELECTRICAL EQUIPMENT Batteries Number per vehicle Two parallel connection, each 12V Capacity 622CCA Alternator Capacity 12V, 105A Starter Capacity 12V, 4.0kW Headlamps Sealed beam type 4-headlamp, white High beam 50W 2 High/Low beam 40W/60W 2 Identification lamps 3.8W 3 (Front) Licence plate lamp 8W 1 Stop/Tail lamps 27W/8W 2 12V Back-up lamps 27W 2 Turn signal and hazard warning lamps Front 27W W 2 Rear 27W 2 Dome lamps 10W 2 Front side marker lamps 5W 2 Clearance lamps (Front) 5W 2 FRONT SUSPENSION Semi-elliptic leaf springs with double acting shock absorbers

6 S-6 SERVICE SPECIFICATIONS 1 page 1 WEIGHTS and DIMENSIONS (On standard specifications) Model FF2JKS FF2JMS FF2JPS FF2JRS Wheelbase mm (in.) 4,600 (181.1) 5,050 (198.8) 5,530 (217.7) 5,800 (228.3) Chassis weight Total kg (lb) 4,365 (9,620) 4,390 (9,675) 4,440 (9,785) 4,470 (9,850) (On std. spec. without spare tire Front kg (lb) 2,720 (5,995) 2,755 (6,075) 2,795 (6,160) 2,805 (6,180) and std. tool set) Rear kg (lb) 1,645 (3,625) 1,635 (3,600) 1,645 (3,625) 1,665 (3,670) Turning radius Tire mm (in.) 7,800 (307.1) 8,500 (334.6) 9,200 (362.2) 9,600 (378.0) (On std. spec.) Swept mm (in.) 8,600 (338.6) 9,300 (366.1) 10,000 (393.7) 10,400 (409.4) Tread Front mm (in.) 1,920 (75.6) 1,920 (75.6) 1,920 (75.6) 1,920 (75.6) POWER LINE Power line STD. OPT. OPT. Transmission LJ06S LJ06S ALLISON LCT2000 Ratios Ratios Ratios 1st nd Transmission 3rd gear ratios 4th th th Rev Rear axle carrier and Gear ratios TRUCK CHASSIS SPECIFICATIONS 2002 HINO FF2J Series Rear mm (in.) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) SH16-1 Series SH16-1 Series SH16-1 Series EQUIPMENT ENGINE Model Piston displacement Capacity of cooling system CLUTCH Clutch disc ass y Clutch cover ass y TRANSMISSION PROPELLER SHAFT Propeller shaft ass y HINO J08C-TP liters (486.0 cu. in.) with LJ06S Transmission 21 liters (22.19 US qt) with ALLISON LCT2000 transmission 23 liters (24.30 US qt) SPICER AR350 series SPICER AR350 series Six-speed over-drive synchromesh 2nd 6th OPT. ALLISON Automatic 5-speed LF0932 series REAR AXLE FRONT AXLE Front axle ass y SERVICE BRAKE Single-Speed LF470 series Reversed Elliot, I beam Air over hydraulic dual circuits system with two leading shoes for front and rear, acting on all wheels Wheel brake ass y Series No.,Front 400 2L series Rear 400 2L series Drum diameter lining width thickness Front mm ( in.) Rear mm ( in.)

7 1 page 1 SERVICE SPECIFICATIONS S-7 PARKING BRAKE For LJ06S transmission For ALLISON LCT2000 transmission Mechanical, internal expanding acting on transmission output shaft, 254 mm (10.0 in.) drum diameter FUEL TANK Capacity 50 US.gal 1 CHASSIS FRAME Ladder type Straight section Width 870 mm (34.3 in.) Tensile strength 55 kg/mm 2 (78,200 lb/sq.in.) EXHAUST BRAKE STEERING FRONT SUSPENSION REAR SUSPENSION Electric-pneumatic, with butterfly valve in exhaust pipe Telescopic and tilt steering column Recirculating ball, with hydraulic booster integral type Semi-elliptic leaf springs with double acting shock absorbers Semi-elliptic main and auxiliary leaf springs WHEEL AND TIRE Wheels Wheel type 10-stud disc wheels Tires 11R PR CAB All steel, welded construction ELECTRICAL EQUIPMENT Batteries Number per vehicle Two parallel connection, each 12V Capacity 622CCA Alternator Capacity 12V, 105A Starter Capacity 12V, 4.0kW Headlamps Sealed beam type 4-headlamp, white High beam 50W 2 High/Low beam 40W/60W 2 Identification lamps 3.8W 3 (Front) Licence plate lamp 8W 1 Stop/Tail lamps 27W/8W 2 12V Back-up lamps 27W 2 Turn signal and hazard warning lamps Front 27W W 2 Rear 27W 2 Dome lamps 10W 2 Front side marker lamps 5W 2 Clearance lamps (Front) 5W 2

8 S-8 SERVICE SPECIFICATIONS 1 page 1 TRUCK CHASSIS SPECIFICATIONS 2002 HINO SG2J Series WEIGHTS and DIMENSIONS (On standard specifications) Model SG2JKS SG2JMS SG2JPS SG2JRS SG2JSS Wheelbase mm (in.) 4,600 (181.1) 5,050 (198.8) 5,530 (217.7) 5,800 (228.3) 6,220 (244.9) Chassis weight Total kg (lb) 4,590 (10,115) 4,615 (10,170) 4,680 (10,315) 4,705 (10,370) 4,790 (10,555) (On std. spec. without spare tire Front kg (lb) 2,820 (6,215) 2,855 (6,290) 2,900 (6,390) 2,915 (6,425) 2,910 (6,415) and std. tool set) Rear kg (lb) 1,770 (3,900) 1,760 (3,880) 1,780 (3,925) 1,790 (3,945) 1,880 (4,140) Turning radius Tire mm (in.) 7,800 (307.1) 8,500 (334.6) 9,200 (362.2) 9,600 (378.0) 10,200 (401.6) (On std. spec.) Swept mm (in.) 8,600 (338.6) 9,300 (366.1) 10,000 (393.7) 10,400 (409.4) 11,000 (423.1) Tread Front mm (in.) 1,920 (75.6) 1,920 (75.6) 1,920 (75.6) 1,920 (75.6) 1,920 (75.6) Rear mm (in.) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) POWER LINE Power line STD. OPT. OPT. OPT. Transmission LJ06S LJ06S ALLISON MD3060P ALLISON MD3060P Ratios Ratios Ratios Ratios 1st nd Transmission 3rd gear ratios 4th th th Rev Rear axle carrier and Gear ratios SH16-1 Series SH16-1 Series SH16-1 Series SH16-1 Series EQUIPMENT ENGINE Model Piston displacement Capacity of cooling system CLUTCH Clutch disc ass y Clutch cover ass y TRANSMISSION HINO J08C-TP liters (486.0 cu. in.) with LJ06S Transmission 21 liters (22.19 US qt) with ALLISON MD3060P transmission 23 liters (24.30 US qt) CR380 series CSP380 series Six-speed over-drive synchromesh 2nd 6th OPT. ALLISON Automatic 5-speed REAR AXLE FRONT AXLE Front axle ass y SERVICE BRAKE Single-Speed LF470 series Reversed Elliot, I beam Compressed air, internal expanding, leading-trailing shoes Wheel brake ass y Series No., Front N16-5 series Rear N16-7 series Drum diameter lining width thickness Front mm ( in.) Rear mm ( in.) PROPELLER SHAFT Propeller shaft ass y MC1040 series

9 1 page 1 SERVICE SPECIFICATIONS S-9 PARKING BRAKE EXHAUST BRAKE STEERING FRONT SUSPENSION REAR SUSPENSION Spring brake acting on rear wheel Electric-pneumatic, with butterfly valve in exhaust pipe Telescopic and tilt steering column Recirculating ball, with hydraulic booster integral type Semi-elliptic leaf springs with double acting shock absorbers Semi-elliptic main and auxiliary leaf springs WHEEL AND TIRE Wheels Wheel type 10-stud disc wheels Tires 11R PR FUEL TANK Capacity 50 US.gal 1 CHASSIS FRAME Ladder type Straight section Width 870 mm (34.3 in.) Tensile strength 55 kg/mm 2 (78,200 lb/sq.in.) CAB All steel, welded construction ELECTRICAL EQUIPMENT Batteries Number per vehicle Two parallel connection, each 12V Capacity 622CCA Alternator Capacity 12V, 105A Starter Capacity 12V, 4.0kW Headlamps Sealed beam type 4-headlamp, white High beam 50W 2 High/Low beam 40W/60W 2 Identification lamps 3.8W 3 (Front) Licence plate lamp 8W 1 Stop/Tail lamps 27W/8W 2 12V Back-up lamps 27W 2 Turn signal and hazard warning lamps Front 27W W 2 Rear 27W 2 Dome lamps 10W 2 Front side marker lamps 5W 2 Clearance lamps (Front) 5W 2

10 S-10 SERVICE SPECIFICATIONS 1 page 1 TRUCK CHASSIS SPECIFICATIONS 2002 HINO SG1J Series WEIGHTS and DIMENSIONS (On standard specifications) Model SG1JMS SG1JPS SG1JRS SG1JSS Wheelbase mm (in.) 5,050 (198.8) 5,530 (217.7) 5,800 (228.3) 6,220 (244.9) Chassis weight Total kg (lb) 4,680 (10,315) 4,745 (10,455) 4,770 (10,515) 4,855 (10,770) (On std. spec. without spare tire Front kg (lb) 2,900 (6,390) 2,950 (6,500) 2,960 (6,525) 2,955 (6,515) and std. tool set) Rear kg (lb) 1,780 (3,925) 1,795 (3,955) 1,810 (3,990) 1,900 (4,255) Turning radius Tire mm (in.) 8,500 (334.6) 9,200 (362.2) 9,600 (378.0) 10,200 (401.6) (On std. spec.) Swept mm (in.) 9,300 (366.1) 10,000 (393.7) 10,400 (409.4) 11,000 (423.1) Tread Front mm (in.) 1,920 (75.6) 1,920 (75.6) 1,920 (75.6) 1,920 (75.6) Rear mm (in.) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) POWER LINE Power line STD. OPT. OPT. OPT. OPT. Transmission MF06S MF06S ALLISON MD3060P ALLISON MD3060P FULLER RT8709 Ratios Ratios Ratios Ratios Gear ratios 1st LOW RANGE HIGH RANGE 2nd LO Transmission 3rd st th 2.56 gear ratios 4th nd th th rd th th th th 1.00 Rev Rev Rev Rear axle carrier and Gear ratios SH16-1 Series SH16-1 Series SH16-1 Series SH16-1 Series SH16-1 Series EQUIPMENT ENGINE Model Piston displacement Capacity of cooling system HINO J08C-TR liters (486.0 cu. in.) with MF06S and FULLER RT8709 Transmission 21 liters (22.19 US qt) with ALLISON MD3060P transmission 23 liters (24.30 US qt) PROPELLER SHAFT Propeller shaft ass y REAR AXLE FRONT AXLE Front axle ass y MC1040 series Single-Speed LF470 series Reversed Elliot, I beam CLUTCH Clutch disc ass y Clutch cover ass y TRANSMISSION CR-380 series CSP-380 series Six-speed direct-drive synchromesh 2nd 6th OPT. ALLISON Automatic 5-speed OPT. FULLER nine-speed direct-drive constantmesh SERVICE BRAKE Compressed air, internal expanding, leading-trailing shoes Wheel brake ass y Series No., Front N16-5 series Rear N16-7 series Drum diameter lining width thickness Front mm ( in.) Rear mm ( in.)

11 1 page 1 SERVICE SPECIFICATIONS S-11 PARKING BRAKE EXHAUST BRAKE STEERING FRONT SUSPENSION REAR SUSPENSION Spring brake acting on rear wheel Electric-pneumatic, with butterfly valve in exhaust pipe Telescopic and tilt steering column Recirculating ball, with hydraulic booster integral type Semi-elliptic leaf springs with double acting shock absorbers Semi-elliptic main and auxiliary leaf springs WHEEL AND TIRE Wheels Wheel type 10-stud disc wheels Tires 11R PR FUEL TANK Capacity 50 US.gal 1 CHASSIS FRAME Ladder type Straight section Width 870 mm (34.3 in.) Tensile strength 55 kg/mm 2 (78,200 lb/sq.in.) CAB All steel, welded construction ELECTRICAL EQUIPMENT Batteries Number per vehicle Two parallel connection, each 12V Capacity 622CCA Alternator Capacity 12V, 105A Starter Capacity 12V, 4.0kW Headlamps Sealed beam type 4-headlamp, white High beam 50W 2 High/Low beam 40W/60W 2 Identification lamps 3.8W 3 (Front) Licence plate lamp 8W 1 Stop/Tail lamps 27W/8W 2 12V Back-up lamps 27W 2 Turn signal and hazard warning lamps Front 27W W 2 Rear 27W 2 Dome lamps 10W 2 Front side marker lamps 5W 2 Clearance lamps (Front) 5W 2

12 S-12 SERVICE SPECIFICATIONS 1 page 1 REPAIR SPECIFICATIONS ENGINE Models J08C-TP and J08C-TR SERVICE STANDARD Item Protrusion Depth of block flange 8.0 (0.31) of liner Depth of liner flange 8.0 (0.31) Nominal Assembly standard Repair Service Corrective dimensions or clearance limit limit method (4.60) ( ) (0.0031) Unit: mm (in.) Replace Cylinder block, cylinder liner and piston Piston ring Cylinder block and liner Piston and liner Ring and ring groove Ring gap A ( ) Block inside diameter B ( ) A: ( ) ( ) C ( ) ( ) (4.60) B: ( ) A (0.0003) (0.0007) Liner outside diameter B (0.0001) C: ( ) (0.0003) C ( ) (0.0001) Liner inside diameter (4.4882) Replace liner for 0.15mm (4.4941) (0.0059in) or more 21mm (0.83in) from bottom end (4.4882) ( ) of piston. Vertical to pin hole (4.4850) Replace liner and piston Inside cylinder Top ring ( ) 1.5 (0.0590) Free clearance Approx (0.492) Inside cylinder 1.2 (0.0472) 2nd ring ( ) Replace ring Free clearance Approx (0.570) Oil ring Inside cylinder ( ) 1.2 (0.0472) Top ring Ring thickness (0.1141) 3.0 (0.1181) Groove thickness ( ) (0.0098) 3.2 (0.1259) 2nd ring Ring thickness (0.0748) Replace ring and/or 2.0 (0.0787) Groove thickness ( ) (0.0098) 2.2 (0.0866) piston Oil ring Ring thickness (0.1535) 4.0 (0.1575) Groove thickness ( ) (0.0059) 4.1 (0.1614)

13 1 page 1 SERVICE SPECIFICATIONS S-13 SERVICE STANDARD (Cont'd) Unit: mm (in.) Item Nominal Assembly standard Repair Service Corrective dimensions or clearance limit limit method Piston pin outside diameter 37.0 (1.4567) (1.4551) Replace Piston hole and clearance 0.013T L ( ) T: Tight ( T L) (0.0019) L: Loose 37.0 (1.4567) Con-rod bushing inside (1.4606) Replace con-rod and pin diameter and clearance ( ) (0.0031) Piston Clearance Bend and distortion of the connecting rod Journal Journal outside diameter 80.0 (3.1496) (3.1417) 0.05 (0.0020) for each 100 (3.94) Replace Regrind for uneven wear (3.1024) 0.10mm (0.0039in) or more. Regrind for wear of 0.2mm (0.0079in) or more. Main bearing inside diameter 80.0 (3.1496) 0.3 (0.0118) Replace crank for 1.20mm (0.0472in) or more. Clearance Under size bearing 0.25mm ( ) (0.0079) (0.0098in), 0.50mm(0.0197in) Main bearing cap inside diameter 85.0 (3.3465) 0.06 (0.0024) Bearing cap bolt 108 (4.252) End play ( ) (0.0196) Replace thrust bearing Crankshaft Crank pin Pin outside diameter 65.0 (2.559) (2.5315) Regrind for uneven wear of 0.10mm(0.0039in) or more. Regrind for wear of 0.2mm (0.0079in) or more. Con-rod bearing thickness 2.0 (0.078) Replace crank for 1.20mm (0.0472in) or more. Con-rod bolt 83.5 (3.2874) Clearance Con-rod housing inside diameter End play Crankshaft runout ( ) Replace bearing for clearance of 0.2mm (0.0079in) or more. ( ) (0.0079) Under size bearing 0.25mm (0.0098in), 0.50mm(0.0197in) ( ) (0.0197) 0.15 (0.0059) Roundness 0.06 (0.0024) Replace con-rod Regrind under size Journal outside diameter 40.0 (1.575) (1.569) Replace cam shaft Bearing inside diameter 40.0 (1.575) (1.581) Replace bearing Cam shaft Clearance End play (0.0039) Replace the camshaft ( ) or camshaft bearing ( ) 0.3 (0.0118) Replace cam shaft IN ±0.15 Cam height (1.9711±0.0059) EX ± (0.0197) Replace cam shaft (2.0513±0.0059) Cam shaft runout 0.1 (0.0039) Replace cam shaft Cam shaft gear bolt 51 (2.0078) Replace

14 S-14 SERVICE SPECIFICATIONS 1 page 1 SERVICE STANDARD (Cont'd) Valve system Rocker arm shaft outside diameter 22.0 (0.8661) (0.8630) Replace Bushing inside diameter 22.0 (0.8661) (0.8693) Replace Clearance ( ) (0.0059) Unit: mm (in.) Intake stem outside diameter 7.0 (0.2756) 6.92 (0.2724) Exhaust stem outside diameter 7.0 (0.2756) 6.84 (0.2693) Replace valve Clearance IN 0.10 (0.0039) ( ) Replace the valve or valve guide EX 0.12 (0.0047) ( ) Valve sink from the head bottom surface IN ( ) (0.0433) EX ( ) (0.0630) Valve clearance (cool) IN EX 0.30 (0.0118) 0.45 (0.0177) Setting height 46.8 (1.843) Setting load IN 46.4 kg ( lb) Replace for squareness of 2.0 (0.0787) or more 44.2 kg EX (97.44 lb) Free length 75.7 (2.980) 75.4 (2.968) Replace spring Setting height Setting load IN 44.8 Replace for squareness (1.764) of 2.0 (0.0787) or more 21.7 kg (47.84 lb) EX 20.4 kg (44.97 lb) Free length 64.6 (2.543) 64.3 (2.531) Replace spring Intake valve seat angle ' Repair Intake valve face angle ' - 30 Repair Exhaust valve seat angle ' Repair Exhaust valve face angle ' - 45 Repair Cylinder head bolt 126 (4.9606) Replace Timing gear Backlash Inner spring Outer spring Valve Rocker arm Intake/exhaust valve seat Item Crankshaft gear and main idle gear ( ) (0.0118) Main idle gear and injection pump gear ( ) (0.0118) Injection pump and PS pump gears ( ) (0.0118) Main idle and sub-idle gears Sub-idle and oil pump gears Nominal Assembly standard Repair Service Corrective dimensions or clearance limit limit method ( ) (0.0118) ( ) (0.0118) Replace gear

15 1 page 1 SERVICE SPECIFICATIONS S-15 SERVICE STANDARD (Cont'd) Backlash Item Sub-idle and cam idle gears Cam and cam gears ( ) (0.0118) ( ) (0.0118) Replace gear Unit: mm (in.) Nominal Assembly standard Repair Service Corrective dimensions of clearance limit limit method Main idle shaft Shaft outside diameter Clearance End play (2.2417) ( ) Replace shaft and/or (0.0079) bushing ( ) (0.0079) Replace shaft and/or gear ( ) Timing gear Oil pump Shaft outside diameter Bushing inside diameter Clearance End play (1.967) ( ) (1.970) ( ) Replace shaft and/or bushing ( ) 0.20 (0.0079) ( ) 0.30 (0.0118) Replace shaft and/or gear Shaft outside diameter 34.0 (1.339) (1.337) Replace the shaft Bushing inside diameter 34.0 (1.339) (1.340) Replace the bush Clearance End play Gear width (0.866) Idle shaft length ( ) Clearance between pump inner surface and gear tip ( ) Clearance between gear outer surface and pump bottom surface ( ) Replace shaft and/or ( ) 0.20 (0.0079) bushing 0.30 (0.0118) Replace shaft and/or gear 0.30 (0.0118) Replace gear and/or shaft 0.15 (0.0059) Replace gear Clearance between drive gear Replace cover shaft and case ( ) 0.15 (0.0059) subassembly Clearance between driven gear Replace gear and/or and shaft ( ) 0.15 (0.0059) cover assembly Backlash between the drive gear and the driven gear ( ) 0.30 (0.0118) Replace the oil pump Main unit Sub-idle shaft Cam idle shaft Longitudinal: 0.06 (0.0024) Flatness of cylinder head bottom or less surface Lateral: 0.03 (0.0012) or less Flatness of cylinder block top 0.05 (0.0020) surface or less Nozzle protrusion Flatness of intake and exhaust manifold Flatness of flywheel ( ) 0.04 ( ) or less 0.20 (0.0079) 0.20 (0.0079) 2.75 (0.1082) Replace the oil pump 0.20 (0.0079) Replace the manifold Wear or grind limit of flywheel 1.0 (0.0394) Replace Compression pressure Run at rpm kg/cm 2 28 kg/cm 2 with starter ( lb/sq.in.) (398 lb/sq.in.)

16 S-16 SERVICE SPECIFICATIONS 1 page 1 SERVICE STANDARD (Cont'd) Item Engine oil capacity Alternatorcoolant pump pulley 13.5 L (14.27 US qt) 8-10 ( ) V-belt deflection (about 10kg (22lb) Air conditioner by pressing) compressor- 11 crankshaft (0.434) pulley Coolant capacity 21 L (22.19 US qt) 23 L (24.30 US qt) (with transmission oil cooler only) Unit: mm (in.) Nominal Assembly standard Repair Service Corrective dimensions of clearance limit limit method

17 1 page 1 SERVICE SPECIFICATIONS S-17 TIGHTENING TORQUE Tightening position kg cm lb ft Cylinder head cover fitting bolt Head bolt Main bearing cap bolt Con-rod nut Camshaft gear bolt Front mounting bracket fitting bolt Cooling jet check valve Torsional damper fitting bolt Flywheel bolt Flywheel housing and block fitting bolt Main idle shaft fitting bolt Sub-idle shaft fitting bolt Cam idle shaft fitting bolt Nozzle clamp fitting bolt Injection pump mounting bolt Injection pump coupling flange bolt Injection pump coupling cotter bolt Oil level sensor fitting bolt Oil pan fitting bolt Oil pan drain plug Glow plug Glow plug harness fitting nut Cross head adjusting screw nut Rocker arm adjusting screw nut Rocker support fitting bolt Cam bearing cap fitting bolt Exhaust manifold fitting nut outer Exhaust manifold fitting nut inner Power steering oil pump fitting bolt Power steering pump gear fitting nut Engine side Front Engine mounting fitting nut Chassis side Rear Alternator earth fitting nut Alternator fitting nut (through bolt) Air compressor gear fitting nut Injection pipe (both end nipples) Timing gear plate fitting nut (inner-hexagonal) Alternator B terminal fitting nut Starter B terminal fitting nut Starter C terminal fitting nut Starter fitting nut and bolt Air conditioner compressor fitting bolt V-belt tension pulley lock nut Rear end plate fitting bolt (torx)

18 S-18 SERVICE SPECIFICATIONS 1 page 1 TIGHTENING TORQUE Tightening position kg cm lb ft Intercooler hose clamp 60 4 Oil strainer fitting bolt Oil pump fitting bolt Oil cooler fitting bolt Oil cooler element fitting bolt Oil cooler regulator valve and safety valve Thermostat case mounting bolt M M Coolant pump mounting bolt Fan clutch with cooling fan fitting bolt Propeller shaft on the flange fitting nut Propeller shaft center bearing support mounting nut for model SG only for model SG only for model SG only for model SG only

19 1 page 1 SERVICE SPECIFICATIONS S-19 EXHAUST BRAKE Models J08C-TP and J08C-TR SERVICE STANDARD Unit: mm (in.) Item Assembly standard Repair limit Service limit Corrective method Average gap between cylinder and butterfly valve ( ) Adjust TIGHTENING TORQUE Tightening position kg cm lb ft. Adjusting screw bracket fitting bolt Plate fitting bolt Lever fitting nut Brake cylinder mounting bolt Adjusting screw lock nut Piston fitting nut Control cylinder cap Control cylinder elbow Control cylinder fitting bolt Air hose Butterfly valve fitting bolt 100 8

20 S-20 SERVICE SPECIFICATIONS 1 page 1 ALTERNATOR Models J08C-TP and J08C-TR SERVICE STANDARD Unit: mm (in.) Rotor Stator Field coil Item Assembly standard Repair limit Service limit Corrective method Outer diameter (front) 25.0 (0.9843) (0.9835) Replace Outer diameter (rear) 17.0 (0.6693) (0.6685) Replace Resistance to 0.82 Ω Replace Insulating resistance 1 MΩ or more Replace Resistance 2.1 to 2.5 Ω Replace Insulating resistance 1 MΩ or more Replace TIGHTENING TORQUE Tightening position kg cm lb ft. Retainer plate Pulley nut 1,300-1, Terminal B lower nut Terminal B upper nut Field coil Rectifiers Regulator Through-bolts Rear cover

21 1 page 1 SERVICE SPECIFICATIONS S-21 STARTER Models J08C-TP and J08C-TR SERVICE STANDARD Brush length Commutator Spring installed load Item Assembly standard Repair limit Service limit Corrective method Outer diameter Mica depth (0.827) (0.551) (1.693) (1.654) ( ) Runout 3,500-4,500 g ( oz) Replace Replace 0.05 (0.0020) Replace Unit: mm (in.) Repair or replace TIGHTENING TORQUE Tightening position kg cm lb ft. Two through bolts Terminal C fitting nut

22 S-22 SERVICE SPECIFICATIONS 1 page 1 AIR COMPRESSOR Models J08C-TP and J08C-TR SERVICE STANDARD Piston, piston ring and piston pin Crankshaft and connecting rod Ring gap Piston and piston ring Oil ring Compression ring Piston pin Connecting rod Unit: mm (in.) Item Nominal Assembly standard Repair Service Corrective dimensions of clearance limit limit method 1st, 2nd Compression ring ( ) 1.0 3rd (0.039) ( ) Replace piston ring Oil ring ( ) (0.039) Ring thickness (0.118) (0.1150) Groove width Replace piston and/or (0.118) (0.1209) piston ring Clearance ( ) (0.0031) Ring thickness (0.157) (0.1543) Groove width Replace piston and/or (0.157) (0.1606) piston ring Clearance ( ) (0.0031) Piston pin hole inside 16.0 diameter (0.63) Piston pin outside diameter 16.0 Replace piston and (0.63) piston pin Clearance between piston 0.018T L 0.08 T=Tight pin hole and pin (0.0007T L) (0.0031) L=Loose Connecting rod small end 16.0 inside diameter (0.63) Replace connecting rod Clearance between piston and/or piston pin pin and connecting rod ( ) (0.0028) Connecting rod big end 37.0 inside diameter (1.457) Crank pin outside diameter 34 (1.339) Connecting rod bearing 1.51 dimension (0.0594) Clearance ( ) (0.0039) Drive gear Crankshaft journal side ( ) (1.3773) outside diameter The other side ( ) (1.3778) Connecting rod end play Crankshaft end play 1 cylinder 2 cylinders ( ) (0.019) ( ) (0.0157) ( ) (0.0118) Replace bearing Replace crankshaft Replace connecting rod Replace Replace

23 1 page 1 SERVICE SPECIFICATIONS S-23 SERVICE STANDARD (Cont d) Unit: mm (in.) Item Nominal Assembly standard Repair Service Corrective dimensions of clearance limit limit method Liner, inside diameter 80 (3.15) Cylinder liner 2nd land ( ) (0.0130) Replace piston and/or Piston clearance Skirt cylinder liner ( ) (0.0071) Bearing holder and Crank case side Replace (3.1496) (3.1494) cylinder block inside diameter Bearing holder side (2.8346) (2.8345) Ball bearing inside diameter 35.0 (1.378) Free length 11 9 (0.433) (0.354) Inlet valve Setting 1 Cylinder 9 (0.354) spring length 2 Cylinders 7 (0.276) Preload 1 Cylinder 0.23 (0.507) 0.13 (0.287) kg (lb) 2 Cylinders 0.45 (0.992) 0.36 (0.794) Replace Free length (0.512) (0.453) Discharge valve Setting length 9.5 spring (0.374) Preload kg (lb) (1.019) (0.816) Replace Inlet valve stroke Approx. 2.5 (0.098) Discharge valve stroke Approx. 1.0 (0.04) TIGHTENING TORQUE Tightening position kg cm lb ft. Inlet valve holder 1,000-1, Discharge valve holder 1,000-1, Unloader valve guide 1,000-1, Cylinder head bolt (for 1 cylinder) (for 1 cylinder) (for 2 cylinders) (for 2 cylinders) Cylinder liner bolt Connecting rod bolt Drive gear lock nut 3, Compressor setting bolt Oil pipe flare nut Pressure regulator flare nut Bearing cover bolt

24 S-24 SERVICE SPECIFICATIONS 1 page 1 TURBOCHARGER Models J08C-TP and J08C-TR SERVICE STANDARD Unit: mm (in.) Item Assembly standard Service limit Corrective method Axial (thrust) bearing clearance ( ) 1,125-1,175 mmhg Turbocharger Calibration air pressure Wastgate ( inhg) overhauled performance 0.38 Rod movement (0.015) TIGHTENING TORQUE Tightening position kg cm lb ft. Turbocharger fitting nut

25 1 page 1 SERVICE SPECIFICATIONS S-25 TOTAL ELECTRONICS SYSTEM Models J08C-TP and J08C-TR SERVICE STANDARD Unit: mm (in.) Item Assembly standard Repair limit Service limit Corrective method Engine speed sensor air gap ( ) Adjust TIGHTENING TORQUE Tightening position kg cm lb ft. Injection pump coupling bolt Engine speed sensor

26 S-26 SERVICE SPECIFICATIONS 1 page 1 METRIC INFORMATION METRIC FASTENERS 1. Most threaded fasteners on the Hino Models F and S series are metric. Be careful not to mix them up with threaded fasteners using the inch system. Mismatched or incorrect bolts, nuts and screws can cause damage or malfunction, resulting in personal injury and/or property damage. 2. When bolts, nuts and screws are removed from the vehicle, they should be kept for reuse whenever possible. If they are not re-usable, parts that are equivalent to the original parts in dimensions, strength, and thread pitch must be selected. 3. Most original bolts are marked with identification numbers indicating the strength of the bolts. The markings are shown below. 4. When replacing bolts, be careful to use bolts with the same markings as the original bolts. NOMENCLATURE FOR BOLTS METRIC SYSTEM BOLT STRENGTH IDENTIFICATION BOLT M D T L P T 8 D L D- Nominal Diameter P- Property Class (millimeters) (bolt strength) L- Length (millimeters) T- Thread Pitch (thread width crest to crest millimeters) Metric Bolts Identification class numbers correspond to bolt strength Increasing numbers represent increasing strength.

27 1 page 1 SERVICE SPECIFICATIONS S-27 DECIMAL AND METRIC EQUIVALENTS Fractions Decimal In. Metric mm. Fractions Decimal In. Metric mm. 1/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /

28 STANDARD TIGHTENING TORQUE Bolt tightening torque chart for general purpose Bolt 4 5 Tightening conditions Even tightening area. Bolt nut, coating, naked bolt, lubricant, etc. Optimum conditions. Cast iron or aluminium tightening surface. Washers. Medium conditions. Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions. Unit: kg cm (lb ft) Bolt diameter (mm) ,110 1,040-1,530 1,480-2,170 2,030-2,980 2,560-3,750 ( ) ( ) (7-9) (13-18) (22-32) (36-51) (55-80) (76-110) ( ) ( ) ( ) ,010-1,480 1,390-2,040 1,970-2,900 2,700-3,970 3,410-5,000 ( ) ( ) (9-12) (17-24) (30-42) (47-68) (74-107) ( ) ( ) ( ) ( ) ,180 1,260-1,850 1,740-2,540 2,460-3,620 3,380-4,950 4,260-6,250 ( ) ( ) (11-15) (21-30) (37-53) (59-85) (92-133) ( ) ( ) ( ) ( ) S-28 SERVICE SPECIFICATIONS 6 7 Even tightening area. Bolt nut, coating, naked bolt, lubricant, etc. Optimum conditions. Cast iron or aluminium tightening surface. Washers. Medium conditions. Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions ,120 1,190-1,750 1,640-2,400 2,320-3,410 3,180-4,680 4,020-5,360 ( ) ( ) (10-14) (20-28) (35-50) (56-81) (87-126) ( ) ( ) ( ) ( ) ,020-1,500 1,590-2,320 2,180-3,200 3,100-4,550 4,250-6,210 5,360-7,850 ( ) ( ) (14-19) (27-38) (47-67) (74-108) ( ) ( ) ( ) ( ) ( ) ,165 1,270-1,870 1,990-2,920 2,730-4,000 3,870-5,680 5,310-7,800 6,700-9,850 ( ) ( ) (17-24) (33-48) (58-84) (92-135) ( ) ( ) ( ) ( ) ( ) 1 page Even tightening area. Bolt nut, coating, naked bolt, lubricant, etc. Optimum conditions. Cast iron or aluminium tightening surface. Washers. Medium conditions ,010-1,480 1,730-2,310 2,380-3,170 3,380-4,510 4,630-6,170 5,850-7,790 ( ) ( ) (15-19) (29-41) (51-66) (74-107) ( ) ( ) ( ) ( ) ( ) ,230 1,480-1,970 2,310-3,080 3,170-4,230 4,510-6,010 6,170-8,230 7,790-10,390 ( ) ( ) (19-25) (39-51) (67-88) ( ) ( ) ( ) ( ) ( ) ( ) 11 Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions ,160-1,540 1,850-2,470 2,890-3,850 3,970-5,290 5,640-7,510 7,720-10,2909,740-12,990 ( ) ( ) (25-32) (48-63) (84-111) ( ) ( ) ( ) ( ) ( ) ( ) NOTE: The torque values given in this table should be applied where bolt torque is not specified.

29 1 page 1 SERVICE SPECIFICATIONS S-29 RECOMMENDED LUBRICANTS No. LUBRICANTS P OSITIONS ATMOSPHERIC TEMP. S.A.E No Below 32 F (0 C) 10W ENGINE OIL (A.P.I. CD) (A.P.I. CE) Cylinder Block Injection pump F (23-21 C) Above 50 F (10 C) F (0-39 C) 15W (23-70 F - 21 C) 20 2 TRANSMISSION LUBRICANT (A.P.I.GL-4) (MIL-L-2105) Transmission Above 90 F (32 C) F (32-12 C) or 80 3 TRANSMISSION LUBRICANT Heavy Duty Engine Oil (MIL-L-2104B, C or D) (A.P.I.-SF) (A.P.I.-CD) (Previous A.P.I. designations acceptable) FULLER RT8709 Transmission Above 10 F (12 C) Above 10 F (12 C) Below 10 F (12 C) TRANSMISSION LUBRICANT Mineral gear oil with rust and oxidation inhibitor (A.P.I.-GL-1) Above 10 F (12 C) Below 10 F (12 C) 90 80W 4 AUTOMATIC TRANSMISSION LUBRICANT (ATF DEXRON III) ALLISON Automatic Transmission 5 AXLE LUBRICANT (SP TYPE LUBRICANT) (A.P.I.GL. 5) (MIL-L-2105B) Rear Axle Above 90 F (32 C) F (32-12 C) POWER STEERING FLUID (DEXRON) or (DEXRON II) Integral Power Steering Gear 7 BRAKE AND CLUTCH FLUID (DOT-3) or (DOT-4) Brake and Clutch

30 S-30 SERVICE SPECIFICATIONS 1 page 1 No. LUBRICANTS POSITIONS WHEEL BEARING GREASE Wheel Bearing 8 (MIL-G-10924B/18709A) Propeller Shaft Spider (NLGI No. 2 LITHIUM-SOAP) Propeller Shaft Sliding Spline Clutch Disc Hub Spline HEAT RESISTANCE GREASE T/M Main Drive Shaft Spline 9 (MIL-G-22615/23549/21164) Brake (Adjuster Slit, Anchor Piston) (NLGI No. 2 or No. 3) Slit, Shoe Hold Washer, Shoe Parking Brake (Cam, Anchor Pin, Adjuster) 10 STARTER GREASE (NLGI No. 2 LITHIUM-SOAP) GENERATOR and STARTER 11 BEARING GREASE (NLGI No. 2 LITHIUM-SOAP) Bushing, Clutch, Drive Shaft. Pinion Shaft Lever and Reduction Gear Generator Bearing Starter Bearing CHASSIS GREASE 12 (MIL-G-17740) Chassis Grease Fitting (NLGI No. 1 CALCIUM or LITHIUM-SOAP) No. LUBRICANTS POSITIONS SHELL MOBIL EXXON LITHIUM BASE Drag Link and Mobil Grease 13 DISULFIDE MOLY- Tie Rod Ball Joint Retinax AM Special Beacon Q2 BDENUM GREASE