SMTK-E040HINO DIESEL ENGINEWORKSHOP MANUALJ08E-TM(Shovel)2005 1112345678910111213141516GENERALSTANDARD VALUEENGINE ASSEMBLY/DISASSEMBLYFUEL SYSTEMEMISSION CONTROLELECTRICALINTAKEENGINE MECHANICALEXHAUSTCOOLINGLUBRICATIONSTARTING AND CHARGINGTURBOCHARGERFAILURE DIAGNOSIS FOR EACH ENGINE STATUSENGINE DIAGNOSIS CODEPARTS TO BE PREPAREDGENERAL 111ENGINE1 GENERALGeneraI GeneraI informationWarning................................................................... 1-2How to read this manual ........................................ 1-3Precautions for work ............................................... 1-7Tightening of engine bolts and nuts...................... 1-11Tightening of flare nuts and hoses........................ 1-13Taper thread sealant for piping ............................. 1-14Assembly of joints and gaskets for piping............. 1-15Handling of liquid gasket ....................................... 1-17Failure diagnosis table for each problem .............. 1-18Failure diagnosis procedures................................ 1-19Failure diagnosis using Hino-DX........................... 1-21Connection method of Hino-DX............................ 1-24Chassis number and engine number ................... 1-26GENERAL 12WarningJP30002010102001Observe the following precautions to work safely and to prevent damage to customers' vehicles.This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are notqualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or whoperform service with the way not specified in this manual may not only damage the vehicle, but also put serviceengineers and surrounding people in danger. Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability ofvehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality. tems described in this manual are the procedures to be observed in service and repair. For service and repairaccording to this procedure, be sure to use the special tools designed for each purpose. f a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehiclesmay be impaired. Never use a method or tool not recommended. This manual shows "War ning and "Caution for items that need to be observed so that accidents may not occur during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability ofvehicles. These instructions cannot gi ve war ning for all possible hazar ds. Note that items with " Warning or "Caution are not absolute for safety. GENERAL 13How to read this manuaIJP300020101020021. Scope of repair work(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,assembly disassembly and inspection adjustment" and "Final inspection".(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,assembly disassembly and inspection adjustment" in the second process. Explanation of "Finalinspection" in the third process is omitted here.(3) Although the following work is not described in this manual, it should be performed in actual work.a. Jacking and liftingb. Cleaning and washing of removed parts as requiredc. Visual inspection2. Standard vaIue(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.3. Items to be prepared(1) tems to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the listsection of items to be prepared. tems such as general tools, jack, rigid rack, etc. that are usuallyequipped in general service shop are omitted.4. How to read sections and titIes(1) Sections are classified according to J2008, SAE standard.(2) For areas that show system names like "Engine control system", "nspection", "Adjustment","Replacement", "Overhaul", etc. of components are described.(3) For areas that show part names like "njection pump", "Mounting/removal and disassembly" is described.(4) llustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described inthe illustration. Major names and tightening torque are listed in the table.)! CAUTION The part Iayouts in this manuaI are inserted based on iIIustrations and part numbers of theparts cataIog CD-ROM issued in october, 2005. (Some areas do not show expIoded view.They wiII be additionaIIy issued when the parts cataIog CD is revised.) Be sure to use theparts cataIog for confirmation of iIIustrations and part numbers and for ordering parts.GENERAL 145. How to read troubIeshooting(1) Failure diagnosis in this manual describes Step 2 and Step 3 below :(2) Pre-inspection(1) Question "Step 1"Hear from customers for conditions and environments offaiIures and check the fact.(2) Pre-inspection(3) Reproduction method"Step 2"Perform diagnosis inspection, status inspection,function inspection and basic inspection. Check thefaiIure status. If it is difficuIt to reproduce the probIemwith status inspection, use the reproduction method.(4) TroubIeshooting for eachdiagnosis code(5) TroubIeshooting for eachfaiIure status"Step 3"Summarize inspection resuIts obtained from Step 2.Perform inspection systematicaIIy according totroubIeshooting procedures for each diagnosis code orfaiIure status.(6) Confirmation test "Step 4"Check if faiIure occurs again after repair. If it is difficuIt toreproduce a faiIure, perform the confirmation test underthe conditions and environment of the faiIure.Pre-inspection Pre-inspection is performed in the foIIowing steps :Diagnosis inspection Diagnosis deIetion FaiIure status check (Use the reproductionmethod if not reproduced.) Diagnosis reconfirmation Estimate the faiIure system before the reproduction test. Attach a tester and evaIuateestimated faiIure together with faiIure status. Refer to the troubIeshooting chart forestimated cause of a faiIure. An error code is dispIayed if a faiIure occurs instantaneousIy. If any specific faiIure is notfound, perform troubIeshooting using the reproduction method. FaiIure status checkIf faiIure is reproduced, perform Step 2 Step 3 Step 4.If faiIure is not reproduced, use the reproduction method (simuIation of externaIconditions or check of each wire harness and connector, etc.)GENERAL 156. How to read expIanation detaiIs(1) Part layoutt is the D number for parts to prepare electronic data. t is not required for repair work.ENGlNE MECHANlCAL [J08E] Timing Gear Cover and FIywheeI HousingPart IayoutJP04117090402003*Parts not to be reused.Tightening torqueService procedure OverhauI item11308 Flywheel housing 11390 End plate11309 Oil seal retainer 9828A Front oil seal*11357 Gasket* 9828B Rear oil seal*11357A Gasket*9069H M14 : 171.5N m{1, 750kgf cm} 9419A M16 : 196N m{2, 000kgf cm}9069J M12 : 97N m{990kgf cm} 9419B M16 : 196N m{2, 000kgf cm}SAPH041170900182ExampIePart name codePart cataIog Fig. No.Description ofpart name codeLeft: Part name code (nut)SAPH300020100001GENERAL 167. Definition of termsTerms in this manuaI are defined as foIIows :(1) Directiona. ndividual unitFront/back directionThe power input side is front and the output side is back.Rotating directionWhen viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction isleft rotation.Vertical directionWith a unit mounted on the machine main unit, the upward direction is upper and the downward direction islower.Left/right directionWhen viewed from the rear, the left direction is left and the right direction is right.(2) Standard value Basic dimension excluding tolerance and clearance generated by toleranceswhen two parts are joined(3) Repair limit t is the value requiring repair. Symbol of + or - with the value means increase or decreaseto the standard value.(4) Operation limit t is the value requiring replacement. Symbol of + or - with the value means increase ordecrease to the standard value.(5) Warning t is an item that may result in risk of human life or serious injury by incorrecthandling.(6) Caution t is an item that should not be performed including inhibited work or an item thatrequire attention in working procedures.(7) Reference t is supplementary explanation in work.GENERAL 178. Unit(1) S unit is used in this manual. S unit is the international unit to unify the conventional different internationalunits into one unit per quantity and to promote smooth technical communications.(2) This manual shows both the S unit and conventional units. The conventional units are shown in { }.*1: X means the vaIue when 1 [ConventionaI unit] is converted to the SI unit.It is used as the conversion factor from the conventionaI unit to the SI unit.*2: The conversion vaIue of the torque may vary depending on the unit.Observe the standard vaIues described for each unit.Safety informationPrecautions for workJP300020101010011. GeneraI precautionsTo ensure safety in work and to prevent accidents, observe the foIIowing items :(1) Appearancea. Wear safety goggles.b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.c. Bind long hair at the back.d. Be sure to wear a cap and safety shoes.(2) Safety worka. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or Vbelt) duringoperation of the engine.c. Remove the starter key when the engine is not started.d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near thearea.f. Since the battery fluid is poisonous and corrosive, be careful for handling.g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may occur.h. f a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,resulting in injury.i. To tow a failure machine, refer to "Towing in the "Operation manual" of the machine.SI unitConventionaIunitConversion vaIue*1(1[ConventionaIunit] = X [SI unit])SI unitConventionaIunitConversion vaIue*1(1[ConventionaI unit]= X [SI unit])Force N kgf 1kgf=9.80665NSpringconstantN/mm kgf/mm1kgf/mm=980665N/mmTorque*2N m kgf cm1kgf cm=0.0980665N mVoIume L cc 1cc=1mLPressure Pakgf/cm21kgf/cm2=98.0665kPa=0.0980665MPaEfficiency W PS 1PS=0.735499kWmmHg1mmHg=0.133322kPaCaIorificvaIueW H caI 1kcaI=1.13279W hRotationaIspeedr/minrpm1rpm=1r/min FueIconsumption rateg/W h g/PS h1g/PS h=1.3596g/kW hmin-11rpm=1min-1GENERAL 182. Precautions for service workPay attention to the foIIowing points before service work(1) Preparation before disassemblya. Prepare general tools, special tools and gauges before work.b. To disassemble a complicated area, put a stamp or match mark on the location not functionally affectedto ease assembly. To repair the electric system, disconnect the cable from the minus terminal of thebattery before work.c. Perform inspection according to the procedure in the text before disassembly.(2) nspection during disassemblyEvery time parts are removed, check the area where the parts are assembled and check for deformation,damage, wear or scratch.(3) Arrangement of disassembled partsPlace removed parts neatly in order. Separate parts to be replaced from parts to be reused.(4) Washing of disassembled partsClean and wash parts to be reused well.(5) nspection and measurementnspect and measure parts to be reused as required.(6) Assemblya. Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correctparts in the correct order.b. Be sure to use genuine parts for parts to be replaced.c. Use new packing, gasket, Oring and cotter pin.d. Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areaswhere application of oil is required, and apply specified grease to the oil seal lip before assembly.(7) Check of adjustmentMake adjustments to the service standard values using a gauge or tester.3. Precautions for eIectric system(1) Removal of battery cablea. n an electric system, remove the cable from thebattery minus (-) terminal to prevent burnout due toshort-circuit.b. When the battery cable is removed, the batteryterminal may be damaged. Loosen the nut completelyand never pry it for removal.(2) Handling of electronic partsa. Do not give impact on electronic parts such ascomputer and relay.b. Do not place electronic parts at a high temperature andhumidity area.c. Do not expose electronic parts to water in washing of avehicle.LoosenSAPH300020100002SAPH300020100003GENERAL 19(3) Handling of wire harnessa. Mark clamps and clips to prevent interference of a wireharness with body edge, sharp edge and bolts. Be sureto reassemble it to the original position.b. When parts are assembled, be careful not to pinch awire harness.(4) Handling of connectora. When a connector is removed, hold the connector (asshown by the arrow in the left) and pull it out. Do not pullthe wire harness.b. Unlock the locking connector before pulling.c. nsert the locking connector completely until it clicks.d. To insert a test lead into the connector, insert it from theback of the connector.e. f it is difficult to insert a test lead from the back of theconnector, prepare a harness for inspection.SAPH300020100004SAPH300020100005GENERAL 1104. Precautions for eIectric weIdingInadvertent eIectric weIding on a cab or frame may cause reverse weIding current from the groundingcircuit, resuIting in damage to eIectric and eIectronic parts. Observe the foIIowing items for eIectricweIding.(1) Turn "OFF" the starter switch.(2) Make sure that switches are "OFF".(3) Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.(4) Disconnect connectors of each computer.(5) Remove all fuses. (For locations of fuses, refer to "Electrical Chapter".)(6) Be sure to connect grounding of the electric welding machine near the welding area.Connect grounding from a bolt (plated bolt) or a frame near the welding area.Remove paint of the frame for connection of grounding from the frame.The seal and the bearing etc. that please make sure do not enter between the weld and the groundsection.(7) Other precautionsa. Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that theymay not be exposed to spatter.b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Alsomaintain welding quality.(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the batterydisassembled. When paint is removed from a frame or cab, apply rust preventive coating with the samecolor.(9) After reassembly, check the function if it operates correctly.GeneraI informationGENERAL 111Tightening of engine boIts and nutsJP300020101020031. Tightening torque of generaI standard boIts(1) For bolts with seatingsUnit : N m{kgf cm}! CAUTION 8T boIt is in accordance with 7T boIt.(2) For bolts with washersUnit : N m{kgf cm}! CAUTION 8T boIt is in accordance with 7T boIt.Screw diameter x Pitch 7T 9TM8 x 1.25 (Coarse thread) 28.5{290} 36{370}M10 x 1.25 (Fine thread) 60{610} 74.5{760}M10 x 1.5 (Coarse thread) 55{560} 68.5{700}M12 x 1.25 (Fine thread) 108{1, 100} 136{1, 390}M12 x 1.75 (Coarse thread) 97{990} 125{1, 280}M14 x 1.5 (Fine thread) 171.5{1, 750} 216{2, 210}M14 x 2 (Coarse thread) 154{1, 570} 199{2, 030}Remark BoIt with number "7" on the head BoIt with number "9" on the headScrew diameter x Pitch 4T 7T 9TM6 x 1 (Coarse thread) 6{60} 10{100} 13{130}M8 x 1.25 (Coarse thread) 14{140} 25{250} 31{320}M10 x 1.25 (Fine thread) 29{300} 51{520} 64{650}M10 x 1.5 (Coarse thread) 26{270} 47{480} 59{600}M12 x 1.25 (Fine thread) 54{550} 93{950} 118{1, 200}M12 x 1.75 (Coarse thread) 49{500} 83{850} 108{1, 100}M14 x 1.5 (Fine thread) 83{850} 147{1, 500} 186{1, 900}M14 x 2 (Coarse thread) 74{750} 132{1, 350} 172{1, 750}RemarkBoIt with number "4" on the headProjection boIt Studwith R surface at freeendBoIt with number "7" on the head Stud with Csurface at free endBoIt with number "9" on the headR surface (4T) C surface (7T)SAPH300020100006GENERAL 1122. Precoated boItPrecoated boIt is the boIt with appIication of seaI Iockagent at the thread.(1) When re-application of lock agent is requireda. When precoated bolts are removedb. When precoated bolts are moved due to tighteningcheck (for loosening or tightening)NOTICE Check torque with the Iower Iimit of thetightening torque aIIowabIe vaIue. Ifmovement is found, tighten the boItaccording to the procedure beIow.(2) Re-use method of precoated bolt locka. Clean bolt and screw holes. (Clean screw holes forreplacement.)b. Dry completely by blowing air.c. Apply the specified seal lock agent to the thread of thebolt.3. PIastic region tightening method (angIe method)(1) PrecautionsSome engines are tightened with the plastic regiontightening method.Since it is different from the conventional method, tightenit according to the instruction in the text.(2) Parts tightenedCylinder head bolt, crankshaft main bearing cap bolt,connecting rod bearing cap bolt, etc.! CAUTION Measure the overaII Iength of the boIt beforeassembIy and repIace the boIt if the Iengthexceeds the operation Iimit.AppIy engine oiI to boIt seating and boItthread in assembIy.(3) Tightening method after tightening to seating torqueTightening of 90p , 135p (90p once and 45p once) and180p (90p twice) is available.Seal Lock AgentSAPH300020100007One turn by 90Tighten it 90SAPH300020100008One turn by 90One turn by 45Tighten it 90(First time)Tighten it 45(Second time)SAPH300020100009Two turns by 90Tighten it 90(First time)Tighten it 90(Second time)SAPH300020100010GENERAL 113Tightening of fIare nuts and hosesJP300020101020051. Tightening torque of pipe fIare nutUnit : N m{kgf cm}2. Tightening torque of hosesUnit : N m{kgf cm}3. Lock nut tightening torque of brass jointUnit : N m{kgf cm}Pipe outerdiameter4.76 6.35 8 10 12 15MateriaISteeI pipe 15o5{150o50} 25o5{250o50} 36o5{370o50} 52o7{530o70} 67o7{680o70} 88o8{900o80}Hose outer diameter10.5 fittingHose outer diameter13, 20, 22, fitting atpackingHose outer diameterPF3/8 fittingAir hose21.5o1.5{215o15}41.5o2.5{425o25} OnIy meter gauge10{100}Brake hosePacking51.5o7.5{525o75} Screw nominaIsizeM12 M16 M20 M27Tighteningtorque15o2{150o20} 66o6{670o60} 97o9{990o90} 209o19{2130o190}GENERAL 114Taper thread seaIant for pipingJP30002010102006The taper thread of the air pipe joint has application of sealant[Loctite # 575 (by Japan Loctite)]. Follow the procedures below forconnection or disconnection of pipes.1. For disconnection(1) The sealant ( # Loctite 575) has strong sealing feature.The return torque of the taper joint is increased about 1.5times the initial tightening torque. When the joint isdisconnected, use a long wrench for disconnection(2) When a joint at a poorly accessible area is replaced,remove accessories first and disconnect the joint.2. For connection(1) For application of sealant ( # Loctite 575), wipe thesealing area completely with a rag or thinner. Applysealant directly to about three ridges for quarter roundwith offset of one ridge from the end. Tighten it accordingto the tightening torque in the table below.Remove dirt completely from the mating part (female)before tightening.! CAUTION If your eye or skin comes in contact withseaIant, wash it off immediateIy with water.Tightening torque of taper joint Unit : N m{kgf cm}(2) When a sealing tape is replaced with sealant, remove thetape completely first as in (1).! CAUTION Be carefuI to prevent entry of dirt or foreignmatter in the pipe.(3) f air leak is found after assembly with application ofsealant, air leak cannot be stopped with additionaltightening. Assemble the part again according to (1) and(2).Removal of joint (Example: Use of magnetic valve)Magnetic valveFrame Air pipe (Flare joint)(No application of sealant)Since sealant isapplied to thisarea, removeaccessories withthe joint attachedAir hoseSAPH3000201000161/4 turn Amount of application: 0.1 g/piece3 threads1 threadSAPH300020100017Screwdiameter 1/4 3/8 1/2MateriaISteeI 49o10{500o100} 64o15{650o150}AIuminum,brass25o5{250o50} 34o5{350o50} 44o5{450o50}GENERAL 115AssembIy of joints and gaskets for pipingJP300020101020071. Tightening torque of jointsUnit : N m{kgf cm}2. Joint assembIy procedure and subsequent inspection(1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,gasket, etc.).(2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tightenpipes finally after temporary tightening to prevent leak.(3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.(4) Observe the values above for each tightening torque.*When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosenedor removed, be sure to replace it with a new part. This is not necessary for normal retightening.SeaIing methodGasket seaIing method(AIuminum + Rubber or Copper)MetaI seaIing method(FIare pipe type, nippIe connector type)Tightening screwsizeType A Type BM8 13{130}M10 20{200} 11{110}M12 25{250} 20{200}M14 25{250} 31{320}M16 29{300} 39{400}M18 39{400} 59{600}M20 *39{400} 64{650} 20{200}M24 69{700}M28 *127{1300}GENERAL 1163. ExampIes of joint methods in various pipesGasket seaIing methodMetaI seaIing methodType A(FIare pipe type)Type B(NippIe connector type)Joint boltGasketSealing surface: 4 placesOne piece eye jointwith sleeveGasketFlare pipeConnectorFlare nutJoint boltGasketGasketSealing surface: 5 placesSealing surface: 3 placesNutConnector nippleFlare connectorGasketSealing surface: 5 placesJoint boltSealing surface: 8 placesLock washerNutBracketSealing surface: 1 placeNutConnector nippleSealing surface: 1 placeFlare connectorBox nutSealing surface: 8 placesJoint pipeNut Lock washer3-way jointBracketSealing surface: 3 placesOne piece eye joint without sleeveJoint boltSealing surface: 4 placesJoint boltJoint pipeSealing surface: 6 placesGENERAL 117HandIing of Iiquid gasketJP300020101020081. AppIication of Iiquid gasket and part assembIy procedure(1) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to preventdeposit of oil, moisture, dirt, etc.Be sure to overlap parts at the beginning and at the end of application.(2) Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply theliquid gasket again if offset occurs.(3) Assemble parts within 20 minutes after application of the liquid gasket.f 20 minutes has passed, remove the liquid gasket and apply it again.(4) Start the engine at least 15 minutes or more after assembly of parts.2. RemovaI of parts(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar orclearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into theengine.3. Others(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained ina cartridge, use the application gun.For a tube, desired application width may be obtained from the cut position at the nozzle end.GeneraI information Description of function1 : Approx. 2 mm at the 1st section cut2 : Approx. 5 mm at the 2nd section cutWinding toolTube: 150 gApplication gunCartridge type: 300 gNozzle of tubeGENERAL 118FaiIure diagnosis tabIe for each probIemJP30002010301001Engine mechanicaIJP03Z01020601001Status Cause ActionEngine overheat (cooIant) lnsufficient coolant Replenish coolantFaulty thermostat Replace thermostatWater leak from cooling system CorrectionFaulty coolant pump Repair or replaceFaulty head gasket Replace head gasketEngine overheat(radiator)Clogging of radiator Cleaning of radiatorCorrosion of cooling system Clean and repair cooling systemClogging of radiator core front part Clean radiatorFaulty radiator cap Replace radiator capEngine overheat (compressionpressure)Non-synchronous injection timing Adjust injection timing.Faulty fuel injection pressure Adjust injection pressureFaulty fuel Replace with correct fuelFaulty injector Replace injectorEngine overheat (Iubricationunit)Deterioration of engine oil Replace engine oilFaulty oil pump Replace oil pumplnsufficient engine oil Replenish engine oilLarge engine oiI consumption(piston, cyIinder Iiner and pistonring)Wear of piston ring and cylinderlinerReplace piston ring and cylinderlinerDamage to piston ring Replace piston ring and cylinderlinerFaulty fixing of piston ring Replace piston ring and cylinderlinerFaulty assembly of piston ring Replace piston ring and cylinderlinerFaulty engine oil Replace engine oilFaulty piston ring joint Reassemble piston ringLarge engine oiI consumption(vaIve and vaIve guide)Wear of valve stem Replace valve and valve guideWear of vavle guide Replace valve guideFaulty assembly of valve stem seal Replace stem sealExcessive oil lubrication to rockerarmlnspection of clearance betweenrocker arm and rocker arm shaftLarge engine oiI consumption(others)Faulty oil level gauge Replace with correct level gaugeExcessive filling of engine oil Fill with appropriate amount of oil.Leak of engine oil Repair or replace the part of oilleak.Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop ofenginePiston seizure (Iubrication unit) lnsufficient engine oil Replenish engine oilDeterioration of engine oil Replace engine oillncorrect engine oil Replace with correct engine oil.Low oil pressure lnspection of lubrication unitFaulty oil pump Replace oil pumpPiston seizure Abnormal combustion Refer to overheat section.Piston seizure Cooling unit Refer to overheat section.Causes and actions are described for each item.SAPH300020100031GENERAL 119FaiIure diagnosis proceduresJP300020103010021. DispIay of faiIure code(1) f the system has an error, the failure code is displayed on the multiple display of gauge cluster .2. DeIetion method of past faiIure(1) To delete past failures of the engine ECU, use HNODXon the PC. (Refer to "Hino field support system operationmanual".)3. DeIetion of cIuster gauge past faiIure(1) Turn "ON" the starter switch.(2) When the buzzer stop switch is pressed consecutively 5times in 10 seconds, the failure history mode is displayed.(3) Press work mode selecting switch and the buzzer stopswitch at the same time for 10 seconds or more.(4) When the display shows "No error", deletion iscompleted.(5) Turn "OFF" the starter switch.SAPH300020100032SAPH300020100033SAPH300020100034GENERAL 1204. How to read troubIeshooting for each diagnosis monitor code(1) "Diagnosis code table" and "Troubleshooting for each code" are described for each system that givesoutput of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can bestarted from the code list.ENGlNE DlAGNOSlS CODE [Engine Common] FaiIure of main speed sensor (DTC code P0335/diagnosis monitor code 13)JP03Z010306010041. Set the starter key to "LOCK" and connect the signal checkharness.2. Remove the ECU side connector of the signal check harnessand meausre the resistance between terminal B6 and terminalB7.Standard vaIue : Approx. 125.5 17 (20 dC)NGOK1. Connect the ECU side connector of the signal check harness.After deleting the past failure, output the diagnosis code again.Standard : NormaINGOK1. Remove the connector of the main engine speed sensor andmeasure the resistance between No. 1 and No. 2 terminals atthe sensor.Standard vaIue : Approx. 125.5 17 (20 dC)NGOK1 Measurement of resistance between terminals SAPH03Z010300010[3] Go to measurement of resistance between sensor terminals.2 Check of diagnosis codeSAPH03Z010300011Contact failure of ECU connector, ECU failure,short-circuit of harnessNormal3 Measurement of resistance between terminalsSAPH03Z010300012Failure of main engine speed sensorHarness disconnection or connector failureDetaiIs of workIndicates repIacement of the mainengine revoIution sensor.Check the harness of the reIevant circuit and repair the fauIty area.SAPH300020100035GENERAL 121FaiIure diagnosis using Hino-DXJP30002010301003! CAUTION Hino-DX is used for inspection and adjustmentof the system in addition to faiIure diagnosis.1. Hino-DX(1) With Hino-DX, failure of the common rail fuel injectionsystem can be diagnosed. The interface box (Hino-Bowie) and the special cable are required for connectionto the vehicle.SpeciaI tooI : 380100046 Hino-Bowie380100047 CabIe between vehicIe andHino-BowieFieId support system (CD-ROM forsoftware) Hino Diagnostic eXpIorer(Hino DX) 380100045! CAUTION InstaII the software of the Hino DiagnosticeXpIorer (Hino DX) in the PC. For theinstaIIation method, refer to the instructionmanuaI accompanying the CD.SAPH300020100036GENERAL 1222. List of faiIure diagnosis tooIs3. Connection of signaI check harness(1) To prevent damage to the ECU connector and to improveaccessibility, connect the signal check harness and put atesting rod on the signal check connector of the signalcheck harness for meaurement.a. Disconnect the connector from the ECU.! CAUTION Do not break the Iocking tab of the connector.b. Connect the signal check harness to the machineharness and the ECU.Signal check harness(for common rail fuel injection system)Part No.380100048Part name Part No. ExternaI shape GeneraI description and functionPC(DOS/V standard)

Operating system(OS) : Windows95,Windows98(E5.0 or later),Windows2000(SP3, E5.0 or later),WindowsXP(SP1a, E6.0 or later) CPU and memory : Conditions thatassure operation of the above operatingsystem Display : 800 x 600, 256 colors ormoreHino-Bowie(nterface box)09121 - 1040Cable betweenvehicle and Hino-Bowie (09042 -1190) PC interfaceSignal checkharness09049 - 1080(for common rail fuelinjection system)nterrupting installation between vehicleharness and ECU allows inspection with atester rod while the power is supplied.Vehicle harnessSignal check harnessTest leadSignal check connectorSAPH300020100040GENERAL 123(2) Terminal No.For the signal check harness connector, the ECU terminal number in the text is treated as follows :ECU unitSignal checkharnessECU side Vehicle sideSAPH300020100042GENERAL 124Connection method of Hino-DXJP300020103010041. RemovaI of cover at the rear of the driver's seat(1) Remove maintenance cover A. (Two tabs)(2) Remove the rear cover B mounting bolts M6 (4 places)which are found after removing maintenance cover A andremove the clips at the back of rear cover B.(3) Remove rear cover B.(4) Remove bolts M6 (2 places) at the lower part of rear coverC and clips (2 places) and remove cover C.BAECU EngineCSAPH300020100043GENERAL 1252. Connection of HinoDX(1) Connect the failure diagnosis connector to the PC whichinstalled HinoDX through the interface box.SpeciaI tooI : 380100046 Hino-Bowie (Interface box)380100047 Connecting cabIeCD-ROM HinoDX 380100045(2) Set the starter key to "ON" and start HinoDX.Setup Iayout LayoutEngine ECUFailure diagnosisconnectorSAPH300020100044Failure diagnosis connectorConnect to the failure diagnosisconnector at the vehicle side.Connecting cableHino-BowieSAPH300020100045GENERAL 126Chassis number and engine numberJP300020104010011. Engine type and engine number(1) Engine type and engine number are stamped at the leftcylinder block when viewed from the cooling fan. For orderof parts, information of this number will facilitateprocedures smoothly.Ex. J08E TA10003Stamp position(Example)SAPH300020100046STANDARD VALUE 212ENGINE2 STANDARD VALUESpecification (performance) System drawingEngine Body................................................................ 2-2Standard value........................................................ 2-2Tightening torque.................................................... 2-2FueI System ................................................................ 2-2Tightening torque.................................................... 2-2Emission ControI ........................................................ 2-3Tightening torque.................................................... 2-3Intake ........................................................................... 2-3Tightening torque.................................................... 2-3Engine MechanicaI ..................................................... 2-3Standard value........................................................ 2-3Tightening torque.................................................. 2-11Exhaust...................................................................... 2-12Tightening torque.................................................. 2-12CooIing ...................................................................... 2-12Standard value...................................................... 2-12Lubrication................................................................ 2-12Standard value...................................................... 2-12Tightening torque.................................................. 2-13Starting and Charging.............................................. 2-14Standard value (alternator 60A) ........................... 2-14Tightening torque (alternator 60A) ........................ 2-14Standard value (starter) ........................................ 2-15Tightening torque (starter) .................................... 2-16Turbocharger............................................................. 2-16Standard value...................................................... 2-16Tightening torque.................................................. 2-16STANDARD VALUE 22Engine BodyStandard vaIueJP30002020205001Unit : MPa {kgf/cm2, Ibf/in.2}Tightening torqueJP30002020205002Unit:N m{kgf cm, Ibf ft}FueI SystemTightening torqueJP30002020205003Unit : N m{kgf cm, Ibf ft}Inspection item Standard vaIue Repair Iimit Service Iimit ActionCompression pressure(Engine revoIution per cyIinder: 150 r/min)2.9 - 3.1{30 - 32, 421 -450}

2.3{24, 334}OverhauIDifferencebetweencyIinders0.3{3, 44} orIessTightening area Tightening torque RemarkEngine mounting nut 74{750, 55}Starter B terminaI7.8 - 8.8{80 - 110, 5.8 -6.5}AIternator B terminaI 3.3 - 4.4{33 - 45, 2.4 - 3.2}OiI pan drain cock 41{420, 30}Radiator hose band 4.5 - 5.0{45 - 50, 3.3 - 3.7}FueI fiIter air bIeeding pIug 4.9 - 8.9{50 - 90, 3.6 - 6.6}Tightening area Tightening torque RemarkInjector cIamp 25{250, 18}SuppIy pump - Bearing hoIder case 28.5{290, 21}Bearing hoIder case - Pump drive 28.5{290, 21}SuppIy pump coupIing fIange mounting nut 63.7{650, 47}Injector harness 2.2{22, 1.6}FueI fiIter air bIeeding boIt 1.7 - 2.6{17.3 - 23, 1.2 - 1.9}STANDARD VALUE 23Emission ControITightening torqueJP30002020205004Unit : N m{kgf cm, Ibf ft}IntakeTightening torqueJP30002020205005Unit : N m{kgf cm, Ibf ft}Engine MechanicaIStandard vaIueJP30002020205006Unit : mm {in.}Tightening area Tightening torque RemarkEGR pipe 57o11{582o116, 42o8}EGR vaIve mounting boIt 68.5{700, 51}EGR cooIer mounting boIt 37{377, 27}EGR cooIer - Exhaust manifoId 68.5{700, 51}Tightening area Tightening torque RemarkIntake manifoId mounting boIt 28.5{290, 21}Inspection item Standard vaIue Repair Iimit Service Iimit ActionCompression pressure3.4-3.7MPa{35-38kgf/cm2, 493-237Ibf/in.2}

2.7MPa{28kgf/cm2,392Ibf/in.2}VaIve cIearance (coId)IN 0.30 {0.0118} EX 0.45 {0.0177} CyIinder Iiner protrusion0.01 - 0.08{0.003 - 0.003} CyIinder Iiner fIange width 8{0.314} CyIinder bIock fIange width 8{0.314} CyIinder bIock inner diameterA117 - 117.008{4.6063 - 4.6066} B117.008 - 117.014{4.6066 - 4.6068} C117.014 - 117.022{4.6068 - 4.6072} STANDARD VALUE 24CyIinder Iiner outer diameterA116.982 - 116.99{4.6056 - 4.6059} B116.99 - 116.996{4.6059 - 4.6061} C116.996 - 117.004{4.6061 - 4.6064} CIearance between cyIinder Iiner and cyI-inder bIock0.01 - 0.026{0.0003 -0.0010} CyIinder Iiner inner diameter 112{4.4094} 112.15{4.4154}CyIinderRepIaceIinerPiston outer diameter(Pin hoIe 23mm{0.9 in.} above the Iowerend of the skirt Square direction)111.9o0.008{4.4089o0.0003} Piston cIearance0.048 - 0.112{0.0044- 0.0044} CyIinderLinerRepIacepistonPistonringFree joint cIearanceTopApprox. 10.0{0.3937} SecondApprox. 12.5{0.4921} CyIinder IinerJoint for assembIyCIearanceTop0.3 - 0.40{0.0118 - 0.0157} 1.5{0.0591}RepIacepiston ringSecond0.75 - 0.90{0.0295 - 0.0354} 1.2{0.0472}OiI0.15 - 0.3{0.0059 - 0.1181} 1.2{0.0472}Ring width BdimensionTop 2.5{0.0984} 0.1{0.0039}RepIacepiston ringSecond 2{0.0787} 0.1{0.0039}OiI 4{0.1574} 0.1{0.0039}Inspection item Standard vaIue Repair Iimit Service Iimit ActionSTANDARD VALUE 25PistonPiston ring grooveTop 2.5{0.0984} +0.2{+0.0079}RepIacepistonSecond 2{0.0787} +0.2{+0.0079}OiI 4{0.1574} +0.1{+0.0039}CIearance betweenpiston ring and pis-ton ring grooveTop0.09 - 0.13{0.0035 -0.0051} RepIacepiston ringor piston.Second0.04 - 0.08{0.00016 -0.0031} OiI0.02 - 0.06{0.0008 -0.0024} Piston pin outer diameter 37{1.4567} 0.04{0.0015}RepIacepiston pinPiston boss inner diameter 37{1.4567} +0.05{+0.0020}RepIacepistonCIearance between piston pinand piston boss0.002T -0.025{0.0000 -0.0010}L (T : Tight-ening aIIowance, L :CIearance)

0.05{0.0020}RepIacepiston pinor pistonConnecting rod bushing inner diameter 37{1.4567} +0.1{0.0039}RepIaceconnectingrod bush-ingConnecting rod bushing oiI cIearance0.015 - 0.036{0.0006- 0.0014}

0.08{0.0031}RepIacepiston pinor connect-ing rodbushingInspection item Standard vaIue Repair Iimit Service Iimit ActionSTANDARD VALUE 26Crank-shaftCrank pin outer diameter 65{2.5590} 63.8{2.5118}RepIacethecrankshaft.(Note 1)Thickness of connecting rodbearing2.0{0.0787} Connecting rod oiI cIearance0.031 - 0.082{0.0012 - 0.0032}0.2{0.0079} RepIacebearing forcIearanceof 0.3 ormore (Note2)CrankjournaI outer diameter 80{3.1496} 78.8{3.1024}CrankRepIaceshaft (Note1)Thickness of main bearing 2.5{0.2342} Crankshaft oiI cIearance0.051 - 0.102{0.0020 - 0.0040}0.2{0.0079} RepIace-bearing(Note 2)Center journaI width 36{1.4173} +1.00{+0.039}RepIacecrankshaft.Thickness of thrust bearing 2.5{0.2342} Crankshaft end pIay0.050 - 0.270{0.0020}0.50{0.0020}1.270{0.0500}RepIacethrust bear-ingCrankshaft runout 0.15{0.0059}

Ground tounder-sizeCrank pin width 34{13.386} +0.8{+0.0315}RepIacecrankshaftNote 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.2 ormore. RepIace crankshaft for wear of 1.20 or more.Note 2 : Under-size bearing vaIues are 0.25, 0.50, 0.75 and 1.00.Connecting rod Iarge end width 34{1.3386} 0.8{0.0315}RepIaceconnectingrodConnecting rod end pIay0.20 - 0.52{0.0079 - 0.0205} 1.0{0.0394}RepIaceconnectingrod orcrankshaftInspection item Standard vaIue Repair Iimit Service Iimit ActionSTANDARD VALUE 27CamshaftCamshaft journaI outer diame-ter40{1.5748} 0.15{0.0059}RepIacecamshaftCamshaft bearing inner diame-ter40{1.5748} +0.15{+0.059}BearingRepIace-mentCamshaft bearing oiICIearance0.020 - 0.063{0.0008 - 0.0025} RepIacecamshaftor bearingCam heightIN 50.046{1.9703} 0.08{0.0031}RepIacecamshaftEX 52.739{2.0763} Cam IiftIN 8.046{0.3168} 0.08{0.0031}RepIacecamshaftEX 10.739{0.4228} CamshaftCamshaft journaI width(Rear journaI)33{1.2992} Camshaft end pIay0.100 - 0.178{0.0039- 0.0070} RepIacecamshaftCamshaft runout0.04{0.0016} 0.1{0.039}RepIacecamshaftRocker shaft outer diameter 22{0.8661} 0.08{0.0031}RepIacerocker shaftRocker arm bushing inner diameter 22{0.8661} +0.08{+0.0031}RepIace rockerarm bushingRocker arm oiI cIearance0.030 - 0.101{0.00012 - 0.0040}0.15{0.0059}

VaIve stem outer diameterIN 7{0.2756} RepIacevaIveEX 7{0.2756} VaIve guide inner diameterIN 7{0.2756} RepIacevaIve guideEX 7{0.2756} OiI cIearance between vaIve guideand vaIve stemIN0.023 - 0.058{0.0009 - 0.0020} RepIacevaIve orvaIve guideEX0.050 - 0.083{0.0020 - 0.0033} VaIve sinkIN0.55 - 0.85{0.0217 - 0.0335} 1.1{0.0433} RepIacevaIve andvaIve seatEX1.15 - 1.45{0.0453 - 0.0571} 1.7{0.0669}VaIve seat angIeIN 30p AIIowabIe anIge 30p - 30p 35'CorrectionEX 45p AIIowabIe anIge 45p - 30p 30'VaIve face angIeIN 30p AIIowabIe angIe 29p 30 - 45pEX 45p AIIowabIe angIe 44p 30 - 45pInspection item Standard vaIue Repair Iimit Service Iimit ActionSTANDARD VALUE 28VaIvespringInnerSet Iength 44.8{1.764} Set Ioad129N{13.1kgf} Free Iength64.6{2.5433}

3.0{0.3543}RepIacespringSquareness 2.0{0.0787}RepIacespringOuterSet Iength46.8{1.8252} Set Ioad314N{32.0kgf} Free Iength75.7{2.9803}

3.0{0.3543}RepIacespringSquareness 2.0{0.0787}RepIacespringInspection item Standard vaIue Repair Iimit Service Iimit ActionSTANDARD VALUE 29TiminggearBack-IashCrank - Main idIe0.030 - 0.167{0.0012- 0.0066}

0.30{0.0012}GearrepIace-mentMain idIe - Pump driveidIe0.032 - 0.096{0.0013- 0.0038}

0.10{0.00393}Pump drive idIe -Pump drive0.020 - 0.083{0.0008- 0.0033}

0.10{0.00393}Main idIe - Sub-idIe0.030 - 0.113{0.0012- 0.0044}

0.30{0.0012}Sub-idIe - OiI pump0.030 - 0.113{0.0012- 0.0044}

0.30{0.0012}Sub-idIe - Cam idIe0.050 - 0.218{0.0020- 0.0086}

0.30{0.0012}Cam idIe - Cam0.030 - 0.253{0.0012- 0.0100}

0.30{0.0012}MainidIeShaft outer diameter 57{2.2441} Bushing inner diame-ter57{2.2441} CIearance betweenshaft and bushing0.030 - 0.090{0.0012- 0.0084}

0.20{0.0079}RepIaceshaft orbushingGear width 44{1.7322} Shaft Iength 44{1.7322} End pIay0.114 - 0.160{0.0045- 0.0063}

0.30{0.0012}RepIaceshaft orgearSub-idIeShaft outer diameter 50{1.9685} Bushing inner diame-ter50{1.9685} CIearance betweenshaft and bushing0.025 - 0.075{0.0010- 0.0030}

0.20{0.0079}RepIaceshaft orbushingGear width 22{0.8661} Shaft Iength 22{0.8661} End pIay0.040 - 0.120{0.0016- 0.0047}

0.30{0.0012}RepIaceshaft orgearInspection item Standard vaIue Repair Iimit Service Iimit ActionSTANDARD VALUE 210VaIve timingTiminggearCamidIeShaft outer diameter 34{1.3386} Bushing inner diameter 34{1.3386} CIearance betweenshaft and bushing0.025 - 0.075{0.0002 - 0.0030}

0.20{0.0079}RepIaceshaft orbushingGear width 22{8.6614} Shaft Iength 22{8.6614} End pIay0.040 - 0.120{0.0016 - 0.0047}

0.30{0.0012}RepIacethrustpIate or gearPumpdriveidIeShaft outer diameter 34{1.3386} Bushing inner diameter 34{1.3386} CIearance betweenshaft and bushing0.025 - 0.057{0.0002 - 0.0022}

0.10{0.0039}RepIaceshaft orbushingGear width 28.5{0.9605} Shaft Iength 28.5{0.9605} End pIay0.016 - 0.22{0.0006 - 0.0087} FIatness under cyIinder headLongitudinaI direc-tion 0.06{0.0024}Square direction0.03{0.0012}

0.20{0.0079}Grinding isinhibitedbecausebackIashbetweencam idIe sub-idIegears ischanged.FIatness above cyIinder bIock 0.05{0.0020} 0.20{0.0079}Surface runout of fIywheeI 0.15{0.0060}

Camshaft gear mounting boIt 30.5{1.2010} RepIacementBearing cap boIt(Crankshaft mounting) 108{4.2520} RepIacementConnecting rod boIt 68.0{2.6772} RepIacementHead boIt 126.5{49.8031}RepIacementExhaust vaIve open (before BDC) 59pExhaust vaIve cIose (after BDC) 13pIntake vaIve open (before BTC) 13pIntake vaIve cIose (after BTC) 21pInspection item Standard vaIue Repair Iimit Service Iimit ActionSTANDARD VALUE 211Tightening torqueJP30002020205007Unit : N m{kgf cm, Ibf ft}Tightening area Tightening torque RemarkCrankshaft puIIey mounting boIt 118{1,203, 87}Head cover mounting boIt 28.5{290, 21}Camshaft bearing cap mounting boIt 31{320,23}Union boIt of Ieakage pipe 13.5{135, 10}Injector harness mounting nut 28{290, 21}Camshaft gear mounting boIt 59{600, 44}+90pCamshaft housing mounting boIt 23{230, 17}CyIinder pIug mounting torx boIt 6{60, 4}Rocker arm adjusting screw Iock nut 25{250, 18}Rocker arm support boIt 59{600, 44}Head boIt 59{600, 44}+90p +90pCam idIe gear shaft mounting boIt 108{1,100, 80}Main bearing cap mounting boIt 69{700, 51}+90p +45p Refer to the main text.Connecting rod cap mounting nut 69{700, 51}+90p +45pOiI check vaIve 22{220, 16}Sub-idIe gear shaft mounting boIt 108{1,100, 80}Main idIe gear shaft mounting boIt 172{1,750, 127}FIywheeI mounting boIt 186{1,900, 137}FIywheeI housing mounting boIt196{2,000, 145} M1655{560, 41} M1036{370, 27} M8FIywheeI housing stay - CyIinder bIock 97{990, 72} M12FIywheeI housing stay - FIywheeI housing 171.5{1, 750, 126} M14Rear end pIate torx boIt 55{560, 41}SuppIy pump bearing case mounting boIt 28.5{290, 21}Pump drive idIe gear shaft mounting boIt 108{1,100, 80}STANDARD VALUE 212ExhaustTightening torqueJP30002020205008Unit : N m{kgf cm, Ibf ft}CooIingStandard vaIueJP30002020205009LubricationStandard vaIueJP30002020205010Unit : mm {in.}Tightening area Tightening torque RemarkExhaust manifoId mounting nut 53{540, 40}Exhaust pipe mounting nut 70o14{715o140, 52o10}Inspection itemStandardvaIueRepairIimitServiceIimitActionThermostat vaIve open temperature74.5 - 78.5p C{166.1 -173.3p F} RepIacementThermostat vaIve Iift(Set temperature 95 p C)13mm{0.5118in.} or more RepIacementInspection item Standard vaIueRepairIimitServiceIimitActionHydrauIic aIarm switch operation pressure39kPa{0.4kgf/cm2,5.66Ibf/in.2} STANDARD VALUE 213Tightening torqueJP30002020205011Unit : N m{kgf cm, Ibf ft}OiIpumpOuter diameter of drive gear 54{2.1260} CyIinder bIock sideOiI pump chamber inner diameter54{2.1260} CIearance between drive gear and cyIin-der bIock0.100 - 0.202{0.0039 - 0.0080}

0.30{0.0118}RepIace drivegear or oiI pumpDrive gear width 37.5{1.4764} CyIinder bIock sideDepth of oiI pump chamber37.5{1.4764} Drive gear end pIay0.049 - 0.113{0.00193 - 0.0044}

0.15{0.059}RepIace drivegear or oiI pumpOuter diameter of driven gear shaft 18{0.7087} CyIinder bIock hoIe diameter 18{0.7087} CIearance between drive gear shaft outer diameterand bushing inner diameter at cyIinder bIock side0.040 - 0.099{0.0016 - 0.0039} RepIace drivegear or bushingOuter diameter of driven gear shaft 18{0.7087} CyIinder bIock hoIe diameter 18{0.7087} CIearance between driven gear shaft outerdiameter and cyIinder bIock hoIe diameter0.030 - 0.075{0.0012 - 0.0030} RepIace oiIpumpOuter diameter of driven gear shaft 18{0.7087} Inner diameter of driven gear bushing 18{0.7087} CIearance between driven gear shaft outerdiameter and gear bushing inner diameter0.040 - 0.083{0.016 - 0.0033}

0.15{0.059}RepIace oiIpump or bushingBackIash between drive gear and drivengear0.073 - 0.207{0.0029 - 0.0082}

0.30{0.0118}RepIace oiIpumpTightening area Tightening torque RemarkOiI pan mounting boIt 30{300, 22}OiI strainer 31{320, 23}OiI pan drain cock 41{420, 30}OiI pump mounting boIt 28.5{290, 21}OiI cooIerOiI circuit spring pIugM14 24.5o4.9{250o50, 18o4}M20 24.5o4.9{250o50, 18o4}M22 29.4o4.9{300o50, 22o4}M24 34.3o4.9{350o50, 25o4}CooIant drain pIug 44.1o4.9{450o50, 33o4}OiI cooIer case assembIy mounting boIt 24.5o4.9{250o50, 18o4}Inspection item Standard vaIueRepairIimitServiceIimitActionSTANDARD VALUE 214Starting and ChargingStandard vaIue (aIternator 60A)JP30002020205012Tightening torque (aIternator 60A)JP30002020205013Unit : N m{kgf cm, Ibf ft}Inspection itemStandardvaIueRepair IimitServiceIimitActionResistance between stator coiI terminaIs (for2 phases)0.15 - 0.17 RepIacementResistance between stator coiI core and coiI 1M or more RepIacementResistance of feed coiI 6.4 - 7.0 RepIacementResistance between feed coiI core and coiI 1M or more RepIacementShaft outer diameter ofrotor assembIyFront25mm{0.9843 in.}

24.98mm{0.9835 in.}RepIacementRear17mm{0.6693 in.}

16.98mm{0.6685 in.}Resistance betweendiode and rectifier hoIderForward resis-tance vaIueApprox. 10 RepIacementReverse resis-tance vaIueInfinite Resistance between reg-uIator terminaIs F EForward resis-tance vaIueApprox. 10 RepIacementReverse resis-tance vaIueInfinite Tightening area Tightening torque RemarkE terminaI boIt 3.2 - 4.4{33 - 45, 2 - 3}Fixing boIt at brace 51{520, 38}AIternator mounting through boIt 83{850, 61}Bearing cover mounting boIt 1.9 - 2.5{20 - 25, 1 - 2}PuIIey mounting nut 127 - 157{1, 300 - 1, 600, 94 - 116}Feed coiI mounting boIt 2.9 - 3.9{30 - 39, 2 - 3}Rectifier and reguIator mounting boIt 1.9 - 2.5{20 - 25, 1 - 2}Inside B terminaI mounting nut 4.9 - 5.9{50 - 60, 4 - 4}Outside B terminaI mounting nut 3.2 - 4.4{33 - 45, 2 - 3}Through boIt 7.8 - 9.8{80 - 99, 6 - 7}CoupIer hoIder mounting boIt 1.9 - 2.5{20 - 25, 1 - 2}Cover mounting boIt 3.3 - 4.4{34 - 44, 2 - 3}STANDARD VALUE 215Standard vaIue (starter)JP30002020205014Unit : mm {in.}Inspection itemStandardvaIueRepairIimitService Iimit ActionYokeassembIyResistance between coiIIead wire and yoke 1k or IessRepIace yokeassembIyBrush Iength 18{0.7087} 13{0.5118} or Iess RepIace brushArmatureassembIyResistance between com-mutator and core1M or more 1k or Iess RepIace arma-ture assembIyCommutator outer diameter 36{1.4173} 34{1.1458} or IessShaft outer diameter A 12{0.4724} 11.98{0.4717} or IessShaft outer diameter B 9{0.3643} 8.98{0.3535} or IessUndercut depth0.5 -0.8{0.0197} 0.2{0.0079} or Iess CorrectionHoIderassembIyResistance between hoIderand pIate 1k or IessRepIace hoIderassembIyBrush Iength 18{0.7087} 13{0.5118} or Iess RepIace brushShaftassembIyouterdiameterA 26{1.0236} 25.90{1.0197} or IessRepIace shaftassembIyB 12.1{0.4764} 12.04{4.7401} or IessCIuthc assembIy inner sIeeve outerdiameter25{0.9843} 24.90{0.9803} ormoreRepIacementMetaI bushing inner diameter of pinioncase25{0.9843} 25.2{0.9921} or moreRepIace pinioncaseMetaI bushing inner diameter of centerbracket26{1.02362} 26.2{1.0315}RepIace centerbracketMetaI bushing inner diameter of shaftassembIy9{0.3543} 9.2{0.3622}RepIace shaftassembIyBearing housing inner diameter of rarbracket28{1.1024} 28.1{1.1063} or moreRepIace rearbracketStartmagnetswitchassembIyBetween C terminaI and MterminaI (P coiI)0.12 - 0.15 RepIace startmagnet switchassembIyBetween C terminaI andbody (H coiI)1.08 - 1.32 STANDARD VALUE 216Tightening torque (starter)JP30002020205015Unit : N m{kgf cm, Ibf tt}TurbochargerStandard vaIueJP30002020205016Unit : mm {in.}Tightening torqueJP30002020205017Unit : N m{kgf cm, Ibf tt}Tightening area Tightening torque RemarkStarter mounting nut 171.5{1,750, 126}C Iead wire mounting boIt 2 - 3{19 - 25, 1 - 2}M Iead wire mounting nut 12.3 - 15.2{126 - 154, 9 - 11}Rear bracket mounting through boIt 15.7 - 17.6{160 - 179, 12 - 13}Brush hoIder fixing boIt of rear bracket 3.6 - 4.9{37 - 49, 3 - 4}Start magnet switch assembIy mounting boIt atpinion case3.6 - 4.9{37 - 49, 3 - 4}Battery cabIe mounting nut 16 - 22{165 - 225, 11 - 16}Inspection itemStandardvaIueRepair Iimit Service Iimit ActionTurbine shaft pIay0.040 - 0.085{0.0016 -0.0033} Tightening area Tightening torque RemarkTurbocharger mounting nut 56 {570, 41}PARTS TO BE PREPARED 313ENGINE3 PARTS TO BE PREPAREDSpeciaI tooI (SST) SpeciaI tooIEngine Body................................................................ 3-2Special tool ............................................................. 3-2FueI System ................................................................ 3-2Lubricant, etc. ....................................................... 3-2Engine MechanicaI ..................................................... 3-3Special tool ............................................................. 3-3nstruments ............................................................. 3-6Lubricant, etc. ....................................................... 3-6Lubrication.................................................................. 3-6Special tool ............................................................. 3-6Lubricant, etc. ....................................................... 3-6Starting and Charging................................................ 3-7Special tool ............................................................. 3-7Jig (reference dimensional drawing for manufacture)................................................................................ 3-7nstruments ............................................................. 3-8Lubricant, etc. ....................................................... 3-8Turbocharger............................................................... 3-8Special tool ............................................................. 3-8Engine FaiIure Diagnosis........................................... 3-9Special tool ............................................................. 3-9PARTS TO BE PREPARED 32Engine BodySpeciaI tooIJP30002030901001FueI SystemLubricant, etc.JP30002030901002Shape Part No. Description RemarkSuitable Tool Wire rope For engine lifting380100024 Compression gauge adapter380100025 Compression gauge adapter380100026 Compression gauge adapterName RemarkGuide bolt 380100027 For supply pump positioningPARTS TO BE PREPARED 33Engine MechanicaISpeciaI tooIJP30002030901003Shape Part No. Name Remark380100028 Oil seal pullerFor crankshaft front oil sealremoval380100029 Oil seal pressFor crankshaft front oil sealpress-fitSuitable Tool Eye boltFor assembly/disassemblyof cylinder headSuitable Tool Valve spring pressFor assembly/disassemblyof valve spring retainer380100030 Guide For valve guide press-fit380100031 Bar For nozzle seat clamping380100032 Steel ballFor nozzle seat clamping(together with 094721210)Suitable Tool Valve lapping tool For valve adjustmentPARTS TO BE PREPARED 34380100033 BarFor valve stem sealmountingSuitable Tool Cylinder liner pullerFor removal and inspectionof cylinder linerSuitable Tool Piston ring expanderFor assembly/disassemblyof piston ringSuitable Tool BoltFor mounting of connectingrod small end bushing(together with 094021480or 094021540)Suitable Tool Press sub-assemblyFor assembly/disassemblyof connecting rod small endbushingSuitable Tool Wing nutFor assembly/disassemblyof connecting rod small endbushing (together with094021530)Suitable Tool GuideFor assembly/disassemblyof connecting rod small endbushing (together with094021530)Suitable Tool SpindleFor assembly/disassemblyof connecting rod small endbushingSuitable Tool GuideFor mounting of connectingrod small end bushing(together with 094021540)Shape Part No. Name RemarkPARTS TO BE PREPARED 35Suitable Tool Piston ring holder For piston mountingSuitable Tool GuideFor assembly/disassemblyof flywheel0380100034 Oil seal pullerFor crankshaft rear oil sealremoval380100035Sliding hammerFor main/sub idle gearassembly and cam idle gearshaft removal380100036380100037 Socket wrenchFor assembly/disassemblyof Torx bolt380100038 Oil seal pressFor crankshaft rear oil sealpress-fitSuitable Tool Guide For insertion of cylinder liner0380100039 Tool For cooling jet repair380100040 Check boltFor cooling jet inspectionand adjustmentShape Part No. Name RemarkPARTS TO BE PREPARED 36InstrumentsJP30002030901004Lubricant, etc.JP30002030901005LubricationSpeciaI tooIJP30002030901006Lubricant, etc.JP30002030901007380100041 Tool assemblyFor cooling jet inspectionand adjustmentName RemarkMicrometer For measurement of part outer diameterCylinder gauge For measurement of part inner diameterThickness gauge For measurement of each clearanceDial gauge For measurement of partsName RemarkLiquid gasket (Threebond TB1207B or equivalent :Black)For sealing of partsLiquid gasket (Threebond TB1207D or equivalent :Silver)For sealing of partsLiquid gasket (Threebond TB1211 or equivalent : White) For sealing of partsRed lead Valve adjustmentDye penetrant For inspection of crackShape Part No. Name RemarkSuitable Tool Oil filter wrenchName RemarkLiquid gasket (Threebond TB1207D or equivalent :Silver)For sealing of partsLiquid gasket (Threebond TB1211 or equivalent : White) For sealing of partsShape Part No. Name RemarkPARTS TO BE PREPARED 37Starting and ChargingSpeciaI tooIJP30002030901008AIternatorJig (reference dimensionaI drawing for manufacture)JP30002030901009This is used for assembly of bearing. Reference dimensions are shown in the figures below:Shape Part No. Name Remark380100042 Compression gaugeFor Vbelt tensionadjustment380100043 Belt tension gaugeFor Vbelt tensionadjustmentJig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}For 60A and90A23{20.827}34{1.339}54{2.126}60{2.362}25{0.984}41{1.614}64{2.520}70{2.756}50{1.969}30{1.181}19{0.748}1C{0.039}1C{0.039}50{1.964}50{1.964}10 - 20{0.394 - 0.787}+0.5{0.0196}035{1.378}70{2.756}Jig C Jig D20{0.787}40{1.575}20{0.787}40{1.575}10{0.394} 10{0.394}SAPH300020300034PARTS TO BE PREPARED 38InstrumentsJP30002030901010AIternatorStarterLubricant, etc.JP30002030901011TurbochargerSpeciaI tooIJP30002030901012Name RemarkCircuit tester For measurement of partsMicrometer For measurement of partsRegulator checker (G&M Machinery CD-101D orequivalent)For inspection of regulatorName RemarkCircuit tester For measurement of partsMicrometer For measurement of part outer diameterGrowler tester For inspection of armatureCylinder gauge For measurement of part inner diameterName RemarkKyodo Yushi Multemp AC-N For lubrication of partsNisseki Mitsubishi Pyroknock #2 For lubrication of partsShape Part No. Name Remark380100044 Tool assemblyPARTS TO BE PREPARED 39Engine FaiIure DiagnosisSpeciaI tooIJP30002030901013Shape Part No. Name Remark Personal computer (DOS-V) Operatingsystem(OS):Windows95,Windows98(E5.0 orlater),Windows2000(SP3,E5.0 or later),WindowsXP(SP1a, E6.0or later) CPU and memory:Conditions that assureoperation of the aboveoperating system Display: 800 x 600, 256colors or moreHino-DXFailure diagnosis software(CD-ROM)380100046 Hino-Bowie (nterface box)Used together with thecable between the vehicleand Hino-Bowie 380100047380100048 Signal check harnessThis is installed asinterruption between vehicleharness and the ECU.Tester inspection is allowedin energized status.ENGNE ASSEMBLY/DSASSEMBLY 414ENGINE4 ENGINE ASSEMBLY/DISASSEMBLYService procedure OverhauI itemInspection Before Service ......................................... 4-2Measurement of compression pressure ................. 4-2Engine Body................................................................ 4-3Removal .................................................................. 4-3nstallation............................................................... 4-5Work after installation ............................................. 4-5ENGNE ASSEMBLY/DSASSEMBLY 42Inspection Before ServiceMeasurement of compression pressureJP30002040702001NOTICE Measure the compression pressure beforedisassembIy of the engine and record the resuIt.ReguIar measurement of the compressionpressure can teII the engine status.1. Preparation before measurement(1) Charge the battery completely.(2) Check the valve clearance and adjust it when exceedingthe standard value.(3) Warm the engine and set the water temperature to 80p C{176p F}.(4) Remove the air cleaner.(5) Remove the head cover.(6) Remove all injectors.(7) To prevent spread of engine oil, attach a jig which cuts ahead cover in half. (Cut it so that the camshaft may becovered.2. Measurement(1) Attach a special tool to the nozzle sheet of the cylinderwhere the compression pressure is measured.SpeciaI tooI : 380100026, 380100025, 380100024Compression gauge adapter(2) Turn the starter and measure the compression pressure.! CAUTION Do not operate the starter for 15 seconds ormore. Since the air cIeaner is removed, prevententry of dirt.(3) Measure the compression pressure of each cylindercontinuously.Engine revoIution 150r/min {rpm}(4) f the compression pressure is the service limit or less or ifthe difference between cylinders is over the standardvalue, overhaul the engine.(5) After measurement, reassemble the removed parts.SAPH300020400001Compression pressure:Unit MPa {kgf/cm2,Ibf/in.2}Standard vaIue 2.9 - 3.1 {30 - 32 ,421 - 450}Service Iimit 2.3 {24, 334}Difference betweencyIinders0.3{3, 44} or IessENGNE ASSEMBLY/DSASSEMBLY 43Engine BodyRemovaIJP300020407020021. PreIiminary work before removaI of engine(1) Place the vehicle on a level ground.(2) Block tires with scotch.(3) Remove the battery cable from the battery minus terminal.2. Drain of cooIant and engine oiI(1) Drain coolant from the radiator drain cock and the oilcooler drain plug.NOTICE RemovaI of the fiIIer cap faciIitates quickdrain. Connection of an appropriate hose to the oiIcooIer drain pipe faciIitates drain of cooIantwithout spread.! CAUTION To prevent burn, drain cooIant after thetemperature is sufficientIy Iow. To dispose cooIant, observe the specifiedmethod (waste disposaI) or the method withattention to environment.(2) Drain engine oil from the oil pan drain plug as required.! CAUTION To prevent burn, drain cooIant after thetemperature is sufficientIy Iow. Dispose cooIant according to the specifiedmethod (waste treatment) or with a methodconsidering the environment.3. RemovaI of intake hose, intercooIer hose and exhaustpipe(1) Loosen the clamp and remove the intake hose.(2) Remove nuts and remove the exhaust pipe.! CAUTION CIose the opening of the intake manifoId witha packing tape to prevent entry of dirt insidethe engine.Right side of engineOil cooler drain plugSAPH300020400002Drain cockSAPH300020400003Cylinder headCoverlntake manifoldSAPH300020400004ENGNE ASSEMBLY/DSASSEMBLY 444. Disconnection of fueI hose(1) Remove the fuel hoses (feed side and return side). Wrapthe removed hose with a plastic sheet with its end facingupward to prevent spill of fuel.! CAUTION Wipe spiIIed fueI with a rag.5. Disconnection of water, engine oiI pipes, etc.(1) Disconnect the hose between the radiator and the engine.(2) Disconnect the car heater pipe.(3) Disconnect the oil filter pipe.! CAUTION Wipe off spiIIed water and engine oiI withwaste.6. Engine Iifting(1) Attach a tool to the front of the engine and to the left of theflywheel housing.NOTICE For 3-point Iifting, pIace a wire rope on theboIts as shown by the arrow in the figure.(2) Place a commercially available shackle and a wire rope(3) Keep a little slack of the wire rope.! CAUTION Keep the wire incIination 30p from the verticaIIine.(4) When the wire is completely tense, make sure that thewire is firmly engaged with the engine hanger. Then, liftthe engine slowly.! CAUTION Work carefuIIy so that the engine may notcome in contact with the frame and others.SAPH300020400005CoolingFanFan shroudClipConnectorSAPH300020400006ShackleShackleWithin 30SAPH300020400007lmageSAPH300020400008ENGNE ASSEMBLY/DSASSEMBLY 45InstaIIationJP300020407020031. Connection of fueI hose(1) nsert a fuel hose and fix it with a hose band.Work after instaIIationJP300020407020041. Inspection of engine oiI(1) Make sure that the drain cock is closed.(2) Pour engine oil.Engine oiI amount (L{us gaI})Hino genuine BIue Ribbon ePRO-extraSAE # 10W-30Hino genuine BIue Ribbon ePRO-superSAE # 30! CAUTION Check the amount of oiI with an oiI IeveIgauge. VehicIes with the DPR (DieseI ParticuIateReduction cIeaner) must use the specified(recommended) brand engine oiI to maintainthe function of the DPR for a Iong time.2. Air bIeeding of fueI system(1) Prepare a rag to receive fuel at the end of the drain valve.(2) Loosen the air bleeding plug of the fuel filter.(3) Turn the priming pump to the left and lift and move it frontand back.(4) Move the pump until fuel without bubble comes out fromthe drain valve.(5) Tighten the air bleeding bolt.Tightening torque :1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 Ibf ft}(6) Move the priming pump again 5 to 6 times.(7) Press the priming pump and tighten it fully to the right.! CAUTION After work, wipe off spiIIed fueI. After start ofthe engine, make sure that there is no fueIIeak.Filler capSAPH300020400009OiI pan OiI fiIterApprox. 26{6.87} Approx. 1.7{0.45}Priming pumpAir bleeding boltDrain valveSAPH300020400010FUEL SYSTEM 515ENGINE5 FUEL SYSTEMSetup Iayout LayoutFueI System ................................................................ 5-2Fuel system diagram............................................... 5-2Part layout ............................................................... 5-3Fuel filter drain (on machine main unit)................... 5-4Replacement of fuel filter element(on machine main unit) ........................................... 5-5Replacement of supply pump ................................. 5-6nspection of supply pump ...................................... 5-9Replacement of injector .......................................... 5-9nspection of injector ............................................. 5-11Replacement of common rail ................................ 5-11nspection of common rail ..................................... 5-12FUEL SYSTEM 52FueI SystemFueI system diagramJP30002050402001Fuel tankFuel filterThrough feed pipeLeakage pipelnjectorlnjection pipeOverflow pipeSupply pumpPressure limiterFeed pipeCommon railFlow damperSAPH300020500001FUEL SYSTEM 53Part IayoutJP30002050402002*Parts not to be reused.Tightening torqueService procedure RepIacement procedure item13691 Bearing holder case 23716 njection pipe22610 Coupling 22730 Supply pump22611 Coupling flange 23766 Through feed pipe22760 Common rail assembly 23766A Through feed pipe23083 Through feed pipe 23781 Fuel pipe23711 njection pipe 23783 Fuel pipe23712 njection pipe 23910 njector23713 njection pipe 9645A Oring*23714 njection pipe 9659A Gasket*23715 njection pipe 9851F Oring*22815 28.5N m {290 kgf cm, 21lbf ft} 9068-08250 28.5N m { 290kgf cm, 21lbf ft}22825 63.7N m {650 kgf cm, 47lbf ft} 9068-08400 28.5N m { 290kgf cm, 21lbf ft}900124 108N m {1,100 kgf cm, 80lbf ft} 9068-08450 28.5N m { 290kgf cm, 21lbf ft}900124A 25N m {250 kgf cm, 18lbf ft} 9068-08850 28.5N m { 290kgf cm, 21lbf ft}SAPH300020500002FUEL SYSTEM 54FueI fiIter drain (on machine main unit)JP300020507040011. Prepare a water container under the drain pipe.2. Loosen the fueI fiIter air bIeeding boIt and the drain vaIve.Discharge water at the bottom of the fueI fiIter case.! CAUTION Since discharged water contains fueI,observe the IocaI disposaI procedure fordisposaI.3. CIose the drain vaIve.4. Start the priming pump and bIeed air from the system.! CAUTION Make sure that the fueI fiIter air bIeeding boItis Ioose.5. Tighten the fueI fiIter air bIeeding boIt.Tightening torque :1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 Ibf ft}! CAUTION After work, wipe off spiIIed water or fueI.After start of the engine, make sure that thereis no fueI Ieak.Priming pumpAir bleeding boltDrain valveSAPH300020500003FUEL SYSTEM 55RepIacement of fueI fiIter eIement (onmachine main unit)JP300020507040021. RemovaI of water cup(1) Refer to "Drain of the fuel filter" and discharge water fromthe fuel filter.(2) Remove the water cup of the fuel filter.2. RemovaI of fueI fiIter eIement(1) Remove the fuel filter element.! CAUTION Since the fiIter contains dieseI oiI, prepare atray.3. InstaIIation of fueI fiIter eIement(1) After the O-ring of the fuel filter touches the fuel filterhead, turn the fuel filter element by 3/4 to 1 1/2 andinstall the fuel filter element on the fuel filter head.(2) After the O-ring of the water cup touches the fuel filterelement, turn the water cup by 1/2 to 3/4 and install thewater cup of the fuel filter on the lower part of the fuel filterelement.(3) Mount the water cup of the fuel filter under the fuel filterelement.(4) Tighten the fuel filter drain valve.! CAUTION EIement is not reused.(5) Start the priming pump and bleed air from the system.! CAUTION Make sure that the fueI fiIter air bIeeding boItis Ioose.(6) Tighten the fuel filter air bleeding bolt.Tightening torque :1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 Ibf ft}! CAUTION After work, wipe off spiIIed fueI. After start ofthe engine, make sure that there is no fueIIeak.Fuel filter headO-ring O-ringFuel filter elementWater cupSAPH300020500004FUEL SYSTEM 56RepIacement of suppIy pumpJP300020507040031. Compression upper dead center setting of No.1 cyIinder(1) Turn the crankshaft counterclockwise when viewed fromthe flywheel. Set the timing mark in the flywheel housinginspection window to "1".(2) Remove the inspection window plug in the bearing holdercase of the supply pump. Tighten the guide bolt(380100027) very gently and make sure that the boltseating comes in close contact with the bearing holder.! CAUTION If it is raised, there must be contact otherthan the stopper key for the coupIing fIange.Do not tighten hard.2. RemovaI of suppIy pump(1) Remove the fuel pipe connected to the supply pump.! CAUTION Do not remove pipes A and B.(2) Remove the supply pump together with the supply pumpdrive.(3) Remove the supply pump at the bearing holder case fromthe supply pump drive.1FlywheelFlywheel housingSAPH300020500005ClosecontactRaisedSAPH300020500006Pipe BPipe ASupply pumpSAPH300020500007O-ringSAPH300020500008FUEL SYSTEM 57(4) Fix the coupling flange with a vice to prevent turning andremove the coupling flange.(5) Remove the bearing holder case from the supply pump.3. AssembIy of suppIy pump and bearing hoIder case(1) Fit a new O-ring to the supply pump and install thebearing holder case.Tightening torque : 28.5 N m {290 kgf cm, 21 Ibf ft}(2) Fix the supply pump and install the coupling flange to theshaft. Tighten nuts while fixing with a vice to preventturning.Tightening torque : 63.7 N m {650 kgf cm, 47 Ibf ft}! CAUTION Do not use the guide boIt for stopper key ofthe shaft.4. InstaIIation of suppIy pump(1) Match the casting mark of the supply pump drive with the"0" mark stamped at the front of the coupling.Coupling flangeBearing holder caseShaftNutSAPH300020500009SAPH300020500010Coupling flange Stopper key holeBearing holder caseGuide boltShaftNutSAPH300020500011Casting mark0 mark stampat the frontSAPH300020500012FUEL SYSTEM 58(2) Put the guide bolt 380100027 into the bearing holder caseto come in contact with the stopper key hole of thecoupling flange.! CAUTION Do not tighten the guide boIt by contact notwith the stopper key hoIe of the coupIing ordo not use the stopper key with the non-specified guide boIt. The specified guide boItis designed to prevent contact of the guideboIt end with the deep end of the stopper keyhoIe. (The end cIearance is 2 mm{0.0788in.})(3) Replace the O-ring of the supply pump drive and thesupply pump with new O-rings and attach couplings forassembly. Then, tighten bolts.Tightening torque : 28.5 N m {290 kgf cm, 21 Ibf ft}(4) Replace the O-ring with a new one. nstall the supplypump drive assembled with the supply pump on theflywheel housing.Tightening torque : 28.5 N m {290 kgf cm, 21 Ibf ft}! CAUTION Adjust the gear so that the compression topdead center aIignment of the No.1 cyIindermay not be changed. Be sure to remove the guide boIt in crankingthe engine. After assembIy, be sure to remove the guideboIt and instaII the inspection window pIug.5. Update of suppIy pump Iearning vaIue(1) When the supply pump is replaced, update the learningvalue memorized in the engine ECU with the failurediagnosis tool (HNO field support system) using PC.(Refer to "Hino field support system operation manual".)! CAUTION If Iearning vaIue is not updated, correctcommon raiI pressure is not controIIed,resuIting in engine staII or high common raiIpressure. Therefore, when the suppIy pumpis repIaced, be sure to update the IearningvaIue.Coupling flangeStopper key holeShaftBearing holder caseGuide bolt NutSAPH300020500013Supply pump driveSupply pumpBearing holder caseCouplingSAPH300020500014O-ringSAPH300020500015FUEL SYSTEM 59Inspection of suppIy pumpJP300020507040041. Inspection of suction controI vaIve and fueI temperaturesensor(1) Measure the resistance of the suction control valveterminals and the fuel temperature sensor terminals usinga circuit tester. f it is beyond the standard, remove thesupply pump assembly and request for replacement at theDenso service shop.RepIacement of injectorJP300020507040051. RemovaI of injector(1) Remove the fixing bolt and remove the plate and theinjection pipe oil seal.(2) Remove the nozzle clamp holder and remove the injector.2. InstaIIation of injector(1) Attach a new O-ring to the groove of the cylinder head andinsert the injector.! CAUTION AppIy engine oiI to the O-ring and be carefuIto prevent pinching of the O-ring.(2) nstall the nozzle clamp holder and tack weld the injectortemporarily.! CAUTION Do not fix the nozzIe hoIder untiI the injectionpipe is tack weIded.(3) Put a new injection pipe oil seal on the injector and installthe plate.! CAUTION InstaII the injection pipe oiI seaI to preventundue force to the injection nozzIe. (Offsetposition between the injection pipe oiI seaIand the injection nozzIe may cause oiI Ieak orpoor assembIy of the injection pipe.)Fuel temperature sensorSuction control valveSAPH300020500016Between suction controI vaIve terminaIsStandardvaIue7.65 - 8.15 (at 20p C {68p F})TerminaIs between fueI temperaturesensorsStandardvaIue13.5 - 16.5k (at -20p C{68p F})2.2 - 2.7k (at 20p C{68p F})0.29 - 0.35k (at 80p C{176p F})Fixing boltNozzle clampholderlnjectorO-ringlnjection pipeoil seallnjection pipeSAPH300020500017FUEL SYSTEM 510(4) Assemble the injection pipe temporarily and tighten thefixing bolt of the nozzle clamp holder.Tightening torque : 25 N m {250 kgf cm, 1.8 Ibf ft}3. Entry of injector correction vaIue to the engine ECU (entryusing Hino fieId support system and QR code reader)! CAUTION When the injector is repIaced, it is necessaryto enter the injector correction vaIue (QRcode) described on the new injector to theengine ECU. Incorrect entry of the correctionvaIue may resuIt in fauIty engine.NOTICE AvaiIabIe entry methods of the injectorcorrection vaIue are the PC tooI and the QRcode reader. The work fIow is described beIow. For detaiIedprocedures, refer to the operation manuaI ofthe Hino fieId support system.(1) Read the injector QR code with the scanner of the QRcode reader and prepare the correction data file.(2) Enter the injector correction value directly from the Hinofield support system to the engine ECU.QR codelnjectorSAPH300020500018QR code readerNew injectorHino-BowiePCECU(Special interface)ConnectorSAPH300020500019FUEL SYSTEM 511Inspection of injectorJP300020507040061. Inspection of injector insuIation(1) Remove the injector plastic terminal cap (upper).(2) Measure the insulation resistance between the injectorupper body and one terminal (no polarity) of two terminalsfor the injector harness.(3) Measure the resistance value between two terminalsabove.(4) f the resistance value in (2) and (3) exceeds the standardvalue, replace the injector assembly.2. CIeaning of injector(1) Remove sludge at or around the terminal, if any.! CAUTION In removing sIudge, do not use a cIeaningagent. Wipe it off with a rag. Use of a cIeaningagent may resuIt in eIectric faiIure due topenetration of the agent.RepIacement of common raiIJP300020507040071. RemovaI of common raiI(1) Remove the common rail together with the flow damper,pressure sensor and pressure limiter from the intakemanifold.! CAUTION Remove dirt around parts before removingthe common raiI2. InstaIIation of common raiI(1) nstall the common rail on the intake manifold.Terminal cap (upper)Terminal cap(lower)Upper bodyTerminal(harness tightening area)

lnjector harnessand rubber sealSAPH300020500020Standard vaIue (normaItemperature)1000M or moreStandard vaIue (at 20p C) 0.45 o 0.1Flow damperPressure sensorPressure limiterSAPH300020500021SAPH300020500022FUEL SYSTEM 512Inspection of common raiIJP300020507040081. Inspection of common raiI pressure sensor(1) Measure the resistance value between terminals using acircuit tester. f it exceeds the standard value, replace thecommon rail assembly1 2 3SAPH300020500023Between 1 and 2 Between 2 and 3StandardvaIue(k )At stop ofengine0.5 - 3.0 6.5 - 18.5EMSSON CONTROL 616ENGINE6 EMISSION CONTROLSetup Iayout LayoutEGR.............................................................................. 6-2Part layout ............................................................... 6-2Overhaul of EGR valve and EGR cooler................. 6-3EMSSON CONTROL 62EGRPart IayoutJP30002060402001*Parts not to be reused.Tightening torqueService procedure RepIacement procedure item11104 Coolant pipe 17173 Gasket*11104A Coolant pipe 17308 EGR pipe16305 Coolant pipe 17309 EGR cooler assembly16691 Coolant pipe 17350 EGR valve16691A Coolant pipe 900234A Coolant hose17104A Gasket* 900234B Coolant hose17104B Gasket* 9659A Gasket*9068-10350 68.5 N m{700 kgf cm, 51lbf ft} 9069L 68.5 N m{700 kgf cm, 51lbf ft}(Exhaust manifold)9068-60150 68.5 N m{700 kgf cm, 51lbf ft} 9069L 68.5 N m{700 kgf cm, 51lbf ft} (EGRvalve EGR pipe) (EGR cooler EGRpipe)9069J 37 N m{377 kgf cm, 27lbf ft}SAPH300020600001EMSSON CONTROL 63OverhauI of EGR vaIve and EGR cooIerJP300020607040011. RemovaI of EGR vaIve! CAUTION Since burn may occur, repIace the part aftercooIing. (Leave it standing for 30 minutes ormore after the starter key is turned OFF.)(1) Remove the connector from the EGR solenoid valve.(2) Remove the EGR pipe.(3) Remove the coolant pipe (inlet pipe and outlet pipe)connected to the EGR valve.(4) Remove 6 bolts and 2 nuts and remove the intake air pipetogether with the EGR valve.(5) Fix the intake air pipe with a vice and remove 6 bolts toremove the EGR valve.SAPH300020600002SAPH300020600003SAPH300020600004EMSSON CONTROL 642. InstaIIation of EGR vaIve(1) Replace the EGR valve gasket with a new one and installthe EGR valve on the intake air pipe paying attention tothe directionTightening torque : 68.5 N m {700 kgf cm, 51 Ibf ft}(2) Apply liquid gasket (Threebod TB1207B: Black) to theintake air pipe and connect it to the intake manifold.Tightening torque : 55 N m {560 kgf cm, 41 Ibf ft}(3) Connect each coolant pipe to the EGR valve.(4) Connect the EGR pipe.Tightening torque :57o11 N m {582o116 kgf cm, 42o8 Ibf ft}(5) Connect the connector to the EGR solenoid valve.3. RemovaI of EGR cooIer(1) Remove hoses and pipes from the EGR cooler.(2) Loosen bolts connecting the EGR cooler and the EGRpipe.(3) Remove the EGR pipe.SAPH300020600003SAPH300020600005SAPH300020600006SAPH300020600007EMSSON CONTROL 65(4) Remove the EGR cooler.4. InstaIIation of EGR cooIer(1) Replace the gasket with a new one and tighten the EGRpipe and the EGR cooler temporarily.(2) nstall the EGR cooler.Tightening torque : 37 N m {377 kgf cm, 27 Ibf ft}(3) Tighten the EGR pipe and the EGR cooler with bolts.Tightening torque :57o11 N m {582o116 kgf cm, 42o8 Ibf ft}SAPH300020600008SAPH300020600009SAPH300020600010SAPH300020600006EMSSON CONTROL 66(4) Connect the EGR pipe.Tightening torque : 68.5 N m {700 kgf cm, 51 Ibf ft}(5) Connect hoses and pipes to the EGR cooler.5. Inspection of EGR cooIer(1) Check visually for crack or clogging of the unit gaschannel and the sub-coolant pipe.f a faulty item is found, replace the EGR cooler unit.6. Inspection of EGR (Inspection with Hino-DX)(1) nsect operation of the EGR valve on the vehicle usingHino-DX. (Refer to the Hino field support systemoperation manual.)SAPH300020600011SAPH300020600012ELECTRCAL 717ENGINE7 ELECTRICALSetup Iayout LayoutEIectricaI System........................................................ 7-2Part layout ............................................................... 7-2Layout of components............................................. 7-4nspection of components....................................... 7-6nstallation of component ........................................ 7-8nstallation of starter ............................................... 7-8Removal of alternator.............................................. 7-9nstallation of alternator ........................................ 7-10ELECTRCAL 72EIectricaI SystemPart IayoutJP3000207040200182030 njector harness 89390 Boost pressure sensor83420 Water temperature sender gauge 89410 Engine sub-revolution sensor83530 Oil pressure warning switch 89411 Engine main revolution sensorSAPH300020700001ELECTRCAL 73Tightening torque12511 Alternator bracket 28100 Starter assembly27040 Alternator 900145 V belt9011-64401 83 N m {850 kgf cm, 61 lbf ft} 9241-10107 51 N m {520 kgf cm, 37 lbf ft}9069D 154 N m {1, 570 kgf cm, 114 lbf ft} 9241-14147 154 N m {1,570 kgf cm, 114 lbf ft}SAPH300020700002ELECTRCAL 74Layout of componentsJP30002070402002Boost pressure sensor Engine sub-revolution sensorSuction control valve (SCV) Fuel temperature sensorLeft side viewSAPH300020700003ELECTRCAL 75Service procedure OverhauI itemWater temperature sender gaugeCommon rail pressure sensor Engine main revolution sensorUpper viewSAPH300020700004ELECTRCAL 76Inspection of componentsJP300020707020011. Inspection of oiI pressure warning switch(Laid out on the oiI fiIter)(1) Apply pressure with air or oil and check continuitybetween terminals using a circuit tester. f it is faulty,replace it.2. Inspection of cooIant temperature sender gauge(InstaIIation on thermostat case)(1) Heat the coolant temperature sender gauge using hotwater.(2) Measure the resistance between terminals using a circuittester. f it is faulty, replace the gauge.Between A and CBetween B and bodySAPH300020700005At no Ioad or Iess than 39 kPa{0.4 kgf/cm2,5.6565 Ibf/in.2}With continuityAt 39 kPa {0.4 kgf/cm2,5.6565Ibf/in.2} or moreWithout continuityOil pressure warning switchONOFFWithinToward pressure increase39.2 - 58.8kPa{0.4 - 0.6kgf/cm ,5.7 - 8.5 lbw/in }2 22.9kPa{0.3kgf/cm ,4.7lbw/in }22SAPH300020700006Connector color: DarkCoolant temperature sender gaugeABCSAPH300020700007Temperature(p C{p F})-20{-68}20{68}80{176}110{230}Resistance vaIue( )13.84 -16.332.32 -2.590.31 -0.3260.1399 -0.1435Temperature(p C, p F)75{167}100{212}Resistance vaIue( )79 - 9235.5 -42.5ELECTRCAL 773. Inspection of gIow pIug(1) Measure continuity between the body and the terminalusing a circuit tester. f it is faulty, replace the glow plug.4. Inspection of suction controI vaIve SCV and fueItemperature sensor(1) For inspection and replacement of the suction controlvalve (SCV) and the fuel temperature sensor, refer to thechapter of "J08E Fuel".5. Inspection of common raiI pressure sensor(1) For inspection and replacement of the common railpressure sensor, refer to the chapter of "J08EFuel".6. Inspection of injector(1) For inspection and replacement of the injector, refer tothe chapter of "J08EFuel".SAPH300020700008Standard vaIueResistance vaIue :(NormaI temperature20p C{68p F})2.59 - 3.29Fuel temperature sensorSuction control valveSAPH300020700009SAPH300020700010ELECTRCAL 78InstaIIation of componentJP300020707020021. InstaIIation of engine revoIution sensor(1) Make sure that the sensor has the O-ring. nstall thesensor on the flywheel housing and the cam housing.NOTICE Since this sensor is a fIange type, gap doesnot have to be adjusted.InstaIIation of starterJP300020707020031. InstaII the starter with boIts and nuts.Tightening torque : 154 N m {1,570 kgf cm, 114Ibf ft}Sub-revolution sensorMain revolution sensorO-ringO-ringSAPH300020700011SAPH300020700012ELECTRCAL 79RemovaI of aIternatorJP300020707020041. Remove the through boIt.2. Remove the aIternator adjusting boIt.3. Remove the through boIt whiIe supporting the aIternator,and remove the aIternator.! CAUTION When the through boIt is removed, theaIternator faIIs. The aIternator must be firmIysupported during removaI.SAPH300020700013SAPH300020700013ELECTRCAL 710InstaIIation of aIternatorJP300020707020051. InstaIIation of aIternator(1) Tighten the alternator temporarily using through bolts andnuts.(2) Tighten the adjusting bolt temporarily.2. VbeIt tension adjustment(1) Place a tire lever on the alternator and adjust the V belt(Measuring position: A) within the standard value using aspecial tool. Tighten adjusting bolts and through bolts.SpeciaI tooI : 380100042 Compression gauge380100043 BeIt tension gauge! CAUTION When a tire Iever is pIaced, do not pIace itbeyond the shaded area shown in theaIternator figure.DefIection: 380100042 is used.Tension: 380100043 is used.Tightening torque : Through boIt83 N m {850 kgf cm, 61 Ibf ft}Tightening torque : Adjusting boIt51 N m {520 kgf cm, 38 Ibf ft} Adjusting bolt Fan pulleyAlternator pulleyThrough-bolt CrankshaftpulleySAPH300020SAPH300020700014 Adjusting bolt Fan pulleyAlternator pulleyThrough-bolt CrankshaftpulleyAlternatorSAPH300020700015Standard vaIue (mm{in.})[Reference pressingforce 98 N {10 kgf, 22Ibf}]8 - 10{0.3152 - 0.394}Standard vaIue(N {kgf, Ibf})340 - 440{35 - 45, 76 - 99}NTAKE 818ENGINE8 INTAKESetup Iayout LayoutIntake ManifoId ........................................................... 8-2Part layout ............................................................... 8-2Replacement........................................................... 8-3NTAKE 82Intake ManifoIdPart IayoutJP30002080402001*Parts not to be reused.Tightening torqueService procedure RepIacement procedure item17031 ntake pipe 17113 ntake pipe17111 ntake manifold 17171 Gasket*9068-08000 28.5 N m {290 kgf cm, 21lbf ft} 9240-08087 28 N m {290 kgf cm, 21lbf ft}9068-08550 28.5 N m {290 kgf cm, 21lbf ft}SAPH300020800001NTAKE 83RepIacementJP300020807040011. RemovaI of intake manifoId(1) Remove bolts and nuts and remove the intake manifold.2. InstaIIation of intake manifoId(1) Clean inside of the intake manifold and the cylinder head.(2) Assemble a new gasket.! CAUTION InstaII the gasket so that the protrusion maycome at the rear end stud boIt of the cyIinderhead.(3) nstall the intake manifold and tighten it with bolts andnuts.Tightening torque : 28.5 N m {290 kgf cm, 21 Ibf ft}3. InstaIIation of intake pipe(1) After removing contamination on the contact surface,apply liquid gasket [Threebond TB1207B(black) orequivalent] to the circumference of the contact surface.! CAUTION AppIy it continuousIy. AppIy the Iiquid gasket at the width of 1.5 to2.5 mm {0.0591 to 0.09843 in.} InstaII the oiI cooIer within 20 minutes afterappIication of the Iiquid gasket.(2) nstall the intake pipe with bolts and nuts.ProtrusionSAPH300020800002SAPH300020800003ENGNE MECHANCAL 919ENGINE9 ENGINE MECHANICALSetup Iayout LayoutCyIinder Head ............................................................. 9-2Part layout ............................................................... 9-2Replacement of cylinder head ................................ 9-4Replacement of camshaft housing ......................... 9-6Liquid gasket application procedure for cylinder plug(only when cylinder plug is removed)...................... 9-7Replacement of head cover ...................................