chapter s service specifications

chapter s service specifications
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
1 page 1
S-2 SERVICE SPECIFICATIONS
TRUCK CHASSIS SPECIFICATIONS
2002
HINO
FD2J Series
● WEIGHTS and DIMENSIONS (On standard specifications)
Model
■ FD2JGS
■ FD2JJS
■ FD2JKS
■ FD2JMS
■ FD2JPS
3,780 (148.8)
4,280 (168.5)
4,600 (181.1)
5,050 (198.8)
5,530 (217.7)
Wheelbase
Chassis weight
Total
(On std. spec.
without spare tire Front
and std. tool set) Rear
mm (in.)
kg (lb)
1,315 (2,900)
1,300 (2,865)
1,320 (2,910)
1,330 (2,930)
1,335 (2,940)
Turning radius
(On std. spec.)
Tire
mm (in.)
6,700 (263.8)
7,500 (295.3)
8,000 (315.0)
8,700 (342.5)
9,400 (370.1)
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)
■ STD.
■ OPT.
■ OPT.
■ OPT.
■ OPT.
LF06S
LF06S
LF06S
LCT2400
LCT2400
Ratios
6.098
3.858
2.340
1.422
1.000
0.761
5.672
Ratios
6.098
3.858
2.340
1.422
1.000
0.761
5.672
Ratios
6.098
3.858
2.340
1.422
1.000
0.761
5.672
Ratios
3.51
1.90
1.44
1.00
0.74
–
5.09
Ratios
3.51
1.90
1.44
1.00
0.74
–
5.09
SH14-1 Series
SH14-1 Series
SH14-1 Series
SH14-1 Series
SH14-1 Series
5.125
4.333
5.428
5.125
4.333
9R22.5-12
245/70R19.5
9R22.5-14
9R22.5-12
245/70R19.5
kg (lb)
3,630 (8,000)
3,655 (8,055)
3,695 (8,145)
3,760 (8,285)
3,795 (8,360)
kg (lb)
2,315 (5,100)
2,355 (5,190)
2,375 (5,235)
2,430 (5,355)
2,460 (5,420)
● POWER LINE
Power line
Transmission
Transmission
gear ratios
1st
2nd
3rd
4th
5th
6th
Rev.
Rear axle carrier and Gear ratios
Tire
● EQUIPMENT
● ENGINE
Model
Piston displacement
Capacity of cooling
system
● CLUTCH
Clutch disc ass’y
Clutch cover ass’y
● TRANSMISSION
Type
● PROPELLER SHAFT
Propeller shaft ass’y
HINO J08C-TP
7.961 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
Type
Single-Speed
● FRONT AXLE
Front axle ass’y
Type
LF376 series
Reversed Elliot, “I”beam
● SERVICE BRAKE
Type
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
320 × 110 × 13 mm
(12.60 × 4.33 × 0.51 in.)
Rear
320 × 125 × 13 mm
(12.60 × 4.92 × 0.51 in.)
1 page 1
SERVICE SPECIFICATIONS S-3
● PARKING BRAKE
For LF06S
transmission
For ALLISON LCT2400
transmission
● EXHAUST BRAKE
Type
● STEERING
Type
● FRONT SUSPENSION
Type
● REAR SUSPENSION
Type
● WHEEL AND TIRE
Wheels
Wheel type
Tires
Mechanical, internal expanding
acting on transmission
output shaft, 203.2 mm
(8 in.) drum diameter
Mechanical, internal expanding
acting on transmission
output shaft, 254.0 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
22.5 × 6.75
6-stud disc wheels
9R22.5-12PR
● FUEL TANK
Capacity
50 US.gal × 1
● CHASSIS FRAME
Ladder type
Width
Tensile strength
Straight “ ” section
870 mm (34.3 in.)
55 kg/mm2 (78,200 lb/sq.in.)
● CAB
Type
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 × 2 + 7.5W × 2
Rear
27W × 2
Dome lamps
10W × 2
Front side marker lamps 5W × 2
Clearance lamps (Front) 5W × 2
1 page 1
S-4 SERVICE SPECIFICATIONS
TRUCK CHASSIS SPECIFICATIONS
2002
HINO
FE2J Series
● WEIGHTS and DIMENSIONS (On standard specifications)
Model
■ FE2JGS
■ FE2JJS
■ FE2JKS
■ FE2JMS
5,050 (198.8)
Wheelbase
Chassis weight
Total
(On std. spec.
without spare tire Front
and std. tool set) Rear
mm (in.)
3,780 (148.8)
4,280 (168.5)
4,600 (181.1)
kg (lb)
4,215 (9,290)
4,245 (9,355)
4,260 (9,390)
4,285 (9,445)
kg (lb)
2,655 (5,850)
2,675 (5,895)
2,685 (5,920)
2,720 (5,995)
kg (lb)
1,560 (3,440)
1,570 (3,460)
1,575 (3,470)
1,565 (3,450)
Turning radius
(On std. spec.)
Tire
mm (in.)
6,500 (255.9)
7,300 (287.4)
7,800 (307.1)
8,500 (334.6)
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)
Rear
mm (in.)
1,800 (70.9)
1,800 (70.9)
1,800 (70.9)
1,800 (70.9)
■ FE2JPS
■ FE2JRS
■ FE2JSS
mm (in.)
5,530 (217.7)
5,800 (228.3)
6,220 (244.9)
kg (lb)
4,335 (9,555)
4,365 (9,620)
4,460 (9,830)
Model
Wheelbase
Chassis weight
Total
(On std. spec.
without spare tire Front
and std. tool set) Rear
Turning radius
(On std. spec.)
Tread
kg (lb)
2,760 (6,085)
2,770 (6,105)
2,775 (6,115)
kg (lb)
1,575 (3,470)
1,595 (3,515)
1,685 (3,715)
Tire
mm (in.)
9,200 (362.2)
9,600 (378.0)
10,200 (401.6)
Swept
mm (in.)
9,950 (391.7)
10,350 (407.5)
10,950 (431.1)
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)
■ STD.
■ OPT.
■ OPT.
● POWER LINE
Power line
Transmission
LJ06S
LJ06S
ALLISON LCT2400
Transmission
gear ratios
Ratios
6.893
4.274
2.607
1.564
1.000
0.770
6.453
Ratios
6.893
4.274
2.607
1.564
1.000
0.770
6.453
Ratios
3.51
1.90
1.44
1.00
0.74
–
5.09
SH14-1 Series
5.125
SH14-1 Series
5.428
SH14-1 Series
5.857
1st
2nd
3rd
4th
5th
6th
Rev.
Rear axle carrier and Gear ratios
● EQUIPMENT
● ENGINE
Model
Piston displacement
Capacity of cooling
system
HINO J08C-TP
7.961 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
Type
SPICER AR350 series
SPICER AR350 series
Six-speed over-drive
synchromesh
2nd—6th
OPT. ALLISON Automatic
5-speed
1 page 1
SERVICE SPECIFICATIONS S-5
● PROPELLER SHAFT
Propeller shaft ass’y
LF0932 series
● REAR AXLE
Type
Single-Speed
● FRONT AXLE
Front axle ass’y
Type
LF470 series
Reversed Elliot, “I”beam
● SERVICE BRAKE
Type
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
400 × 120 × 15 mm
(15.75 × 4.72 × 0.59 in.)
Rear
400 × 155 × 15 mm
(15.75 × 6.10 × 0.59 in.)
● PARKING BRAKE
For LJ06S
transmission
For ALLISON LCT2400
transmission
● EXHAUST BRAKE
Type
● STEERING
Type
● FRONT SUSPENSION
Type
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
Semi-elliptic leaf springs with
double acting shock
absorbers
● REAR SUSPENSION
Type
Semi-elliptic main and auxiliary
leaf springs
● WHEEL AND TIRE
Wheels
Wheel type
Tires
22.5 × 7.50
10-stud disc wheels
11R22.5-14PR
● FUEL TANK
Capacity
50 US.gal × 1
● CHASSIS FRAME
Ladder type
Width
Tensile strength
Straight “ ” section
870 mm (34.3 in.)
55 kg/mm2 (78,200 lb/sq.in.)
● CAB
Type
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 × 2 + 7.5W × 2
Rear
27W × 2
Dome lamps
10W × 2
Front side marker lamps 5W × 2
Clearance lamps (Front) 5W × 2
1 page 1
S-6 SERVICE SPECIFICATIONS
TRUCK CHASSIS SPECIFICATIONS
2002
HINO
FF2J Series
● WEIGHTS and DIMENSIONS (On standard specifications)
Model
■ FF2JKS
■ FF2JMS
■ FF2JPS
■ FF2JRS
4,600 (181.1)
5,050 (198.8)
5,530 (217.7)
5,800 (228.3)
Wheelbase
Chassis weight
Total
(On std. spec.
without spare tire Front
and std. tool set) Rear
mm (in.)
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)
Rear
mm (in.)
1,800 (70.9)
1,800 (70.9)
1,800 (70.9)
1,800 (70.9)
kg (lb)
4,365 (9,620)
4,390 (9,675)
4,440 (9,785)
4,470 (9,850)
kg (lb)
2,720 (5,995)
2,755 (6,075)
2,795 (6,160)
2,805 (6,180)
● POWER LINE
Power line
Transmission
Transmission
gear ratios
1st
2nd
3rd
4th
5th
6th
Rev.
Rear axle carrier and Gear ratios
■ STD.
■ OPT.
■ OPT.
LJ06S
LJ06S
ALLISON LCT2000
Ratios
6.893
4.274
2.607
1.564
1.000
0.770
6.453
Ratios
6.893
4.274
2.607
1.564
1.000
0.770
6.453
Ratios
3.51
1.90
1.49
1.00
0.74
–
5.09
SH16-1 Series
5.428
SH16-1 Series
5.857
SH16-1 Series
5.857
● EQUIPMENT
● ENGINE
Model
Piston displacement
Capacity of cooling
system
● CLUTCH
Clutch disc ass’y
Clutch cover ass’y
● TRANSMISSION
Type
● PROPELLER SHAFT
Propeller shaft ass’y
HINO J08C-TP
7.961 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
Type
Single-Speed
● FRONT AXLE
Front axle ass’y
Type
LF470 series
Reversed Elliot, “I”beam
● SERVICE BRAKE
Type
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
400 × 120 × 15 mm
(15.75 × 4.72 × 0.59 in.)
Rear
400 × 155 × 15 mm
(15.75 × 6.10 × 0.59 in.)
1 page 1
SERVICE SPECIFICATIONS S-7
● PARKING BRAKE
For LJ06S
transmission
For ALLISON LCT2000
transmission
● EXHAUST BRAKE
Type
● STEERING
Type
● FRONT SUSPENSION
Type
● REAR SUSPENSION
Type
● WHEEL AND TIRE
Wheels
Wheel type
Tires
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
Semi-elliptic leaf springs with
double acting shock
absorbers
Semi-elliptic main and auxiliary
leaf springs
22.5 × 7.50
10-stud disc wheels
11R22.5-14PR
● FUEL TANK
Capacity
50 US.gal × 1
● CHASSIS FRAME
Ladder type
Width
Tensile strength
Straight “ ” section
870 mm (34.3 in.)
55 kg/mm2 (78,200 lb/sq.in.)
● CAB
Type
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 × 2 + 7.5W × 2
Rear
27W × 2
Dome lamps
10W × 2
Front side marker lamps 5W × 2
Clearance lamps (Front) 5W × 2
1 page 1
S-8 SERVICE SPECIFICATIONS
TRUCK CHASSIS SPECIFICATIONS
2002
HINO
SG2J Series
● WEIGHTS and DIMENSIONS (On standard specifications)
Model
■ SG2JKS
■ SG2JMS
■ SG2JPS
■ SG2JRS
■ SG2JSS
4,600 (181.1)
5,050 (198.8)
5,530 (217.7)
5,800 (228.3)
6,220 (244.9)
Wheelbase
Chassis weight
Total
(On std. spec.
without spare tire Front
and std. tool set) Rear
mm (in.)
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)
kg (lb)
4,590 (10,115)
4,615 (10,170)
4,680 (10,315)
4,705 (10,370)
4,790 (10,555)
kg (lb)
2,820 (6,215)
2,855 (6,290)
2,900 (6,390)
2,915 (6,425)
2,910 (6,415)
● POWER LINE
■ STD.
■ OPT.
LJ06S
LJ06S
Ratios
6.893
4.274
2.607
1.564
1.000
0.770
6.453
Ratios
6.893
4.274
2.607
1.564
1.000
0.770
6.453
Ratios
3.49
1.86
1.41
1.00
0.75
–
5.03
Ratios
3.49
1.86
1.41
1.00
0.75
–
5.03
SH16-1 Series
5.428
SH16-1 Series
5.857
SH16-1 Series
5.428
SH16-1 Series
5.857
Power line
Transmission
Transmission
gear ratios
1st
2nd
3rd
4th
5th
6th
Rev.
Rear axle carrier and Gear ratios
■ OPT.
■ OPT.
ALLISON MD3060P ALLISON MD3060P
● EQUIPMENT
● ENGINE
Model
Piston displacement
Capacity of cooling
system
● CLUTCH
Clutch disc ass’y
Clutch cover ass’y
● TRANSMISSION
Type
● PROPELLER SHAFT
Propeller shaft ass’y
HINO J08C-TP
7.961 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
MC1040 series
● REAR AXLE
Type
Single-Speed
● FRONT AXLE
Front axle ass’y
Type
LF470 series
Reversed Elliot, “I”beam
● SERVICE BRAKE
Type
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
406.4 × 127 × 15.5 mm
(16 × 5.0 × 0.61 in.)
Rear
406.4 × 178 × 15.5 mm
(16 × 7.0 × 0.61 in.)
1 page 1
SERVICE SPECIFICATIONS S-9
● PARKING BRAKE
Type
● EXHAUST BRAKE
Type
● STEERING
Type
● FRONT SUSPENSION
Type
● REAR SUSPENSION
Type
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
Tires
22.5 × 7.50
10-stud disc wheels
11R22.5-14PR
● FUEL TANK
Capacity
50 US.gal × 1
● CHASSIS FRAME
Ladder type
Width
Tensile strength
Straight “ “ section
870 mm (34.3 in.)
55 kg/mm2 (78,200 lb/sq.in.)
● CAB
Type
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 × 2 + 7.5W × 2
Rear
27W × 2
Dome lamps
10W × 2
Front side marker lamps 5W × 2
Clearance lamps (Front) 5W × 2
1 page 1
S-10 SERVICE SPECIFICATIONS
TRUCK CHASSIS SPECIFICATIONS
2002
HINO
SG1J Series
● WEIGHTS and DIMENSIONS (On standard specifications)
Model
■ SG1JMS
■ SG1JPS
■ SG1JRS
■ SG1JSS
5,050 (198.8)
5,530 (217.7)
5,800 (228.3)
6,220 (244.9)
Wheelbase
Chassis weight
Total
(On std. spec.
without spare tire Front
and std. tool set) Rear
mm (in.)
kg (lb)
1,780 (3,925)
1,795 (3,955)
1,810 (3,990)
1,900 (4,255)
Turning radius
(On std. spec.)
Tire
mm (in.)
8,500 (334.6)
9,200 (362.2)
9,600 (378.0)
10,200 (401.6)
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)
kg (lb)
4,680 (10,315)
4,745 (10,455)
4,770 (10,515)
4,855 (10,770)
kg (lb)
2,900 (6,390)
2,950 (6,500)
2,960 (6,525)
2,955 (6,515)
● POWER LINE
Power line
■ STD.
■ OPT.
Transmission
MF06S
MF06S
Ratios
7.395
4.758
3.076
1.936
1.341
1.000
7.142
Ratios
7.395
4.758
3.076
1.936
1.341
1.000
7.142
Transmission
gear ratios
1st
2nd
3rd
4th
5th
6th
Rev.
Rear axle carrier and Gear ratios
■ OPT.
■ OPT.
ALLISON MD3060P ALLISON MD3060P
Ratios
3.49
1.86
1.41
1.00
0.75
–
5.03
Ratios
3.49
1.86
1.41
1.00
0.75
–
5.03
■ OPT.
FULLER RT8709
Gear ratios
LOW RANGE HIGH
LO 13.29
1st
9.16 5th
2nd 6.53 6th
3rd
4.80 7th
4th
3.57 8th
Rev. 13.89 Rev.
SH16-1 Series SH16-1 Series SH16-1 Series SH16-1 Series
4.100
4.625
5.428
5.857
RANGE
2.56
1.83
1.34
1.00
3.89
SH16-1 Series
4.100
● EQUIPMENT
● ENGINE
Model
Piston displacement
Capacity of cooling
system
● CLUTCH
Clutch disc ass’y
Clutch cover ass’y
● TRANSMISSION
Type
HINO J08C-TR
7.961 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)
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
● PROPELLER SHAFT
Propeller shaft ass’y
MC1040 series
● REAR AXLE
Type
Single-Speed
● FRONT AXLE
Front axle ass’y
Type
LF470 series
Reversed Elliot, “I”beam
● SERVICE BRAKE
Type
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
406.4 × 127 × 15.5 mm
(16 × 5.0 × 0.61 in.)
Rear
406.4 × 178 × 15.5 mm
(16 × 7.0 × 0.61 in.)
1 page 1
SERVICE SPECIFICATIONS S-11
● PARKING BRAKE
Type
● EXHAUST BRAKE
Type
● STEERING
Type
● FRONT SUSPENSION
Type
● REAR SUSPENSION
Type
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
Tires
22.5 × 7.50
10-stud disc wheels
11R22.5-14PR
● FUEL TANK
Capacity
50 US.gal × 1
● CHASSIS FRAME
Ladder type
Width
Tensile strength
Straight “ “ section
870 mm (34.3 in.)
55 kg/mm2 (78,200 lb/sq.in.)
● CAB
Type
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 × 2 + 7.5W × 2
Rear
27W × 2
Dome lamps
10W × 2
Front side marker lamps 5W × 2
Clearance lamps (Front) 5W × 2
1 page 1
S-12 SERVICE SPECIFICATIONS
REPAIR SPECIFICATIONS
ENGINE
Models J08C-TP and J08C-TR
SERVICE STANDARD
Unit: mm (in.)
Nominal Assembly standard Repair
dimensions
or clearance
limit
Item
Protrusion Depth of block flange
of liner
Depth of liner flange
8.0 (0.31)
0.01 - 0.08
(0.0004 - 0.0031)
Service
limit
Corrective
method
0.08
(0.0031)
Replace
114.15 (4.4941)
Replace liner for 0.15mm
(0.0059in) or more
8.0 (0.31)
117.0 (4.60)
Block inside diameter
Cylinder block and liner
Cylinder block, cylinder liner and piston
A
B
+0.014
(+0.0005)
+0.008
(+0.0003)
C
+0.022
(+0.0008)
+0.014
(+0.0005)
117.0 (4.60)
Liner outside diameter
A
–0.010
(–0.0003)
–0.018
(–0.0007)
B
–0.004
(–0.0001)
–0.010
(–0.0003)
Piston and liner
C
Liner inside diameter
Ring gap
2nd ring
Ring and ring groove
Oil ring
114.0 (4.4882)
Oil ring
C: 0.01 - 0.026
(0.0003 - 0.0010)
0.056 - 0.088
(0.0022 - 0.0034)
0.3 - 0.4
(0.0119 - 0.0157)
Free clearance
Approx. 12.5 (0.492)
Inside cylinder
0.3 - 0.45
(0.0119 - 0.0177)
Free clearance
Approx. 14.5 (0.570)
Inside cylinder
0.3 - 0.45
(0.0119 - 0.0177)
Groove thickness
Groove thickness
1.5 (0.0590)
1.2 (0.0472)
Replace ring
1.2 (0.0472)
2.9 (0.1141)
0.06 - 0.10
(0.0024 - 0.0039)
0.25
(0.0098)
0.04 - 0.08
(0.0016 - 0.0031)
0.25
(0.0098)
1.9 (0.0748)
Replace ring and/or
2.0 (0.0787)
2.2 (0.0866)
piston
0.15
(0.0059)
3.9 (0.1535)
Ring thickness
Groove thickness
113.92 (4.4850) Replace liner and piston
3.0 (0.1181)
Ring thickness
2nd ring
B: 0.012 - 0.024
(0.0004 - 0.0009)
Inside cylinder
Ring thickness
Top ring
A: 0.01 - 0.026
(0.0003 - 0.0010)
+0.004
(+0.0001)
–0.004
(–0.0001)
21mm (0.83in) from bottom end 114.0 (4.4882)
of piston. Vertical to pin hole.
Top ring
Piston ring
+0.008
(+0.0003)
0
4.0 (0.1575)
0.02 - 0.06
(0.0008 - 0.0023)
3.2 (0.1259)
4.1 (0.1614)
1 page 1
SERVICE SPECIFICATIONS S-13
SERVICE STANDARD (Cont'd)
Nominal Assembly standard Repair
Service
Corrective
dimensions
or clearance
limit
limit
method
37.0 (1.4567)
36.96 (1.4551) Replace
Item
Clearance
Piston pin outside diameter
Piston
Unit: mm (in.)
Piston hole and clearance
37.0 (1.4567)
Con-rod bushing inside
diameter and clearance
–0.013T - 0.014L
0.05 +0.05 (+0.0019) T: Tight
(–0.00051T - 0.00055L) (0.0019)
L: Loose
0.015 - 0.036
(0.0006 - 0.0014)
0.08
37.1 (1.4606)
(0.0031)
0.05 (0.0020)
for each
100 (3.94)
Bend and distortion of the
connecting rod
Journal outside diameter
Journal
Main bearing inside diameter 80.0 (3.1496)
0.051 - 0.102
(0.0020 - 0.0040)
0.2
(0.0079)
Main bearing cap inside diameter 85.0 (3.3465)
108 (4.252)
0.050 - 0.219
(0.0020 - 0.0086)
End play
Crankshaft
Pin outside diameter
65.0 (2.559)
Con-rod bearing thickness
2.0 (0.078)
0.50
(0.0196)
Replace thrust bearing
64.30 (2.5315)
Con-rod bolt
Crank pin
Under size bearing 0.25mm
(0.0098in), 0.50mm(0.0197in)
0.06 (0.0024)
Bearing cap bolt
Regrind for uneven wear of
0.10mm(0.0039in) or more.
Regrind for wear of 0.2mm
(0.0079in) or more.
Replace crank for 1.20mm
(0.0472in) or more.
83.5 (3.2874)
0.031 - 0.082
(0.0012 - 0.0032)
Clearance
Roundness
0.06 (0.0024)
0.20 - 0.53
(0.0079 - 0.0208)
End play
Replace bearing for clearance
of 0.2mm (0.0079in) or more.
Under size bearing 0.25mm
(0.0098in), 0.50mm(0.0197in).
0.2
(0.0079)
68.985 - 69
(2.7149 2.7165)
Con-rod housing inside
diameter
Crankshaft runout
Cam shaft
Replace
Regrind for uneven wear
79.80 78.80 (3.1024) 0.10mm (0.0039in) or more.
(3.1417)
Regrind for wear of 0.2mm
(0.0079in) or more.
0.3 (0.0118) Replace crank for 1.20mm
(0.0472in) or more.
80.0 (3.1496)
Clearance
Replace con-rod and pin
0.5
(0.0197)
Replace con-rod
0.15
(0.0059)
Regrind under size
Journal outside diameter
40.0 (1.575)
39.85 (1.569)
Replace cam shaft
Bearing inside diameter
40.0 (1.575)
40.15 (1.581)
Replace bearing
Clearance
0.020 - 0.063
(0.0008 - 0.0024)
0.1 (0.0039)
Replace the camshaft
or camshaft bearing
End play
0.10 - 0.178
(0.0040 - 0.0070)
0.3 (0.0118)
Replace cam shaft
IN
Cam height
50.0667±0.15
(1.9711±0.0059)
EX 52.1038±0.15
(2.0513±0.0059)
–0.50 (–0.0197) Replace cam shaft
Cam shaft runout
0.1 (0.0039)
Replace cam shaft
Cam shaft gear bolt
51 (2.0078)
Replace
1 page 1
S-14 SERVICE SPECIFICATIONS
SERVICE STANDARD (Cont'd)
Nominal Assembly standard Repair
dimensions
or clearance
limit
Rocker arm
Item
Rocker arm shaft outside
diameter
22.0 (0.8661)
Bushing inside diameter
22.0 (0.8661)
Clearance
6.92 (0.2724)
7.0 (0.2756)
6.84 (0.2693)
IN
0.023 - 0.058
(0.0010 - 0.0022)
0.10 (0.0039)
EX
0.037 - 0.067
(0.0015 - 0.0026)
0.12 (0.0047)
IN
0.55 - 0.85
(0.0217 - 0.0334)
1.1
(0.0433)
EX
1.05 - 1.35
(0.0414 - 0.0531)
1.6
(0.0630)
0.30
(0.0118)
EX
0.45
(0.0177)
Setting height
Outer spring
Valve system
IN
Valve clearance (cool)
IN
46.4 kg
(102.23 lb)
EX
44.2 kg
(97.44 lb)
Setting load
75.7 (2.980)
Inner spring
75.4 (2.968)
44.8
(1.764)
Setting height
IN
21.7 kg
(47.84 lb)
EX
20.4 kg
(44.97 lb)
Setting load
Free length
Replace spring
Replace for squareness
of 2.0 (0.0787) or more
64.6 (2.543)
64.3 (2.531)
Replace spring
Intake valve seat angle
30˚
30˚ - 30˚35'
Repair
Intake valve face angle
30˚
29˚30' - 30˚
Repair
Exhaust valve seat angle
45˚
45˚ - 45˚30'
Repair
Exhaust valve face angle
45˚
44˚30' - 45˚
Cylinder head bolt
Backlash
Replace the valve or
valve guide
Replace for squareness
of 2.0 (0.0787) or more
46.8 (1.843)
Free length
Intake/exhaust
valve seat
22.08 (0.8693) Replace
0.15
(0.0059)
7.0 (0.2756)
Clearance
Timing gear
Corrective
method
Replace valve
Exhaust stem outside
diameter
Valve sink from the head
bottom surface
Service
limit
21.92 (0.8630) Replace
0.03 - 0.101
(0.0012 - 0.0039)
Intake stem outside
diameter
Valve
Unit: mm (in.)
Repair
126 (4.9606)
Crankshaft gear and main
idle gear
0.030 - 0.132
(0.0012 - 0.0051)
0.30
(0.0118)
Main idle gear and injection
pump gear
0.030 - 0.218
(0.0012 - 0.0085)
0.30
(0.0118)
Injection pump and PS pump
gears
0.030 - 0.183
(0.0012 - 0.0072)
0.30
(0.0118)
Main idle and sub-idle gears
0.030 - 0.162
(0.0012 - 0.0063)
0.30
(0.0118)
Sub-idle and oil pump gears
0.030 - 0.131
(0.0012 - 0.0051)
0.30
(0.0118)
Replace
Replace gear
1 page 1
SERVICE SPECIFICATIONS S-15
SERVICE STANDARD (Cont'd)
Unit: mm (in.)
Nominal
Assembly standard Repair
dimensions
of clearance
limit
0.050 - 0.218
Sub-idle and cam idle gears
(0.0020 - 0.0085)
Oil pump
Sub-idle shaft
Cam idle shaft
Timing gear
Main idle shaft
Backlash
Item
Cam and cam gears
Shaft outside diameter
57.0 –0.03
–0.06
–0.0012
)
(2.2441 –0.0024
Corrective
method
Replace gear
0.30
(0.0118)
56.94 (2.2417)
Clearance
0.030 - 0.090
(0.0012 - 0.0035)
0.2 (0.0079)
Replace shaft and/or
bushing
End play
0.114 - 0.160
(0.0045 - 0.0062)
0.20 (0.0079)
Replace shaft and/or gear
Shaft outside diameter
–0.025
50.0 –0.05
(1.969 –0.0010
–0.0020)
49.95 (1.967)
Bushing inside diameter
+0.03
50.0 +0
+0.0012
(1.969 +0 )
50.03 (1.970)
Replace shaft and/or
bushing
Clearance
0.025 - 0.075
(0.0010 - 0.0029)
0.20 (0.0079)
End play
0.040 - 0.095
(0.0016 - 0.0037)
0.30 (0.0118)
Replace shaft and/or gear
33.95 (1.337)
Replace the shaft
Shaft outside diameter
34.0 (1.339)
Bushing inside diameter
34.0 (1.339)
34.025 (1.340)
Replace the bush
0.025 - 0.075
(0.0010 - 0.0029)
0.20 (0.0079)
Replace shaft and/or
bushing
0.040 - 0.095
(0.0016 - 0.0037)
0.30 (0.0118)
Replace shaft and/or gear
Clearance between pump inner
surface and gear tip
0.100 - 0.202
(0.0039 - 0.0079)
0.30 (0.0118)
Replace gear and/or shaft
Clearance between gear outer
surface and pump bottom surface
0.049 - 0.113
(0.0019 - 0.0044)
0.15 (0.0059)
Replace gear
Clearance between drive gear
shaft and case
0.040 - 0.085
(0.0015 - 0.0033)
0.15 (0.0059)
Replace cover
subassembly
Clearance between driven gear
and shaft
0.040 - 0.083
(0.0016 - 0.0032)
0.15 (0.0059)
Replace gear and/or
cover assembly
0.073 - 0.207
(0.0029 - 0.0081)
0.30 (0.0118)
Replace the oil pump
Longitudinal:
0.06 (0.0024)
or less
Lateral:
0.03 (0.0012)
or less
0.20 (0.0079)
0.05 (0.0020)
or less
0.20 (0.0079)
2.25 - 2.75
(0.0886 - 0.1082)
2.75 (0.1082)
Replace the oil pump
0.20 (0.0079)
Replace the manifold
1.0 (0.0394)
Replace
Clearance
Gear width
End play
Idle shaft length
Backlash between the drive gear
and the driven gear
Main unit
0.030 - 0.253
(0.0012 - 0.0099)
Service
limit
0.30
(0.0118)
Flatness of cylinder head bottom
surface
Flatness of cylinder block top
surface
Nozzle protrusion
22.0 (0.866)
Flatness of intake and exhaust
manifold
Flatness of flywheel
0.04 (0.00157) or less
Wear or grind limit of flywheel
2
Compression pressure
Run at 180 - 220 rpm
35 - 38 kg/cm
with starter
(498 - 540 lb/sq.in.)
2
28 kg/cm
(398 lb/sq.in.)
1 page 1
S-16 SERVICE SPECIFICATIONS
SERVICE STANDARD (Cont'd)
Unit: mm (in.)
Item
Nominal
dimensions
Engine oil capacity
13.5 L
(14.27 US qt)
V-belt deflection
(about 10kg (22lb)
by pressing)
Coolant capacity
Assembly standard Repair
of clearance
limit
Alternatorcoolant pump
pulley
8 - 10
(0.317 - 0.394)
Air conditioner
compressorcrankshaft
pulley
11
(0.434)
21 L
(22.19 US qt)
23 L
(24.30 US qt)
(with
transmission
oil cooler only)
Service
limit
Corrective
method
1 page 1
SERVICE SPECIFICATIONS S-17
TIGHTENING TORQUE
Tightening position
kg·cm
Cylinder head cover fitting bolt
Head bolt
lb·ft
250
18
600 + 90˚ + 90˚
43 + 90° + 90°
Main bearing cap bolt
700 + 90˚ + 45˚
51 + 90° + 45°
Con-rod nut
700 + 90˚ + 45˚
51 + 90° + 45°
600 + 90˚
43 + 90°
1100
80
Camshaft gear bolt
Front mounting bracket fitting bolt
Cooling jet check valve
220
16
Torsional damper fitting bolt
1200
87
Flywheel bolt
1900
137
Flywheel housing and block fitting bolt
2000
144
Main idle shaft fitting bolt
1750
127
Sub-idle shaft fitting bolt
1100
80
Cam idle shaft fitting bolt
1100
80
Nozzle clamp fitting bolt
250
18
Injection pump mounting bolt
950
68
Injection pump coupling flange bolt
950
69
Injection pump coupling cotter bolt
950
69
Oil level sensor fitting bolt
120
9
Oil pan fitting bolt
300
22
Oil pan drain plug
420
30
Glow plug
250
18
Glow plug harness fitting nut
15
1.1
Cross head adjusting screw nut
250
18
Rocker arm adjusting screw nut
250
18
Rocker support fitting bolt
480
35
Cam bearing cap fitting bolt
320
23
Exhaust manifold fitting nut outer
620
45
Exhaust manifold fitting nut inner
540
39
Power steering oil pump fitting bolt
480
35
Power steering pump gear fitting nut
Engine mounting fitting nut
Front
850
61
Engine side
1.200
87
Chassis side
750
54
Rear
Alternator earth fitting nut
750
54
40
2.9
Alternator fitting nut (through bolt)
850
61
Air compressor gear fitting nut
3600
260
Injection pipe (both end nipples)
400
29
Timing gear plate fitting nut (inner-hexagonal)
250
18
Alternator B terminal fitting nut
70
5.1
Starter B terminal fitting nut
200
14
Starter C terminal fitting nut
22
1.6
Starter fitting nut and bolt
1570
113
Air conditioner compressor fitting bolt
300
21
V-belt tension pulley lock nut
420
30
Rear end plate fitting bolt (torx)
560
41
1 page 1
S-18 SERVICE SPECIFICATIONS
TIGHTENING TORQUE
Tightening position
kg·cm
lb·ft
Intercooler hose clamp
60
4
Oil strainer fitting bolt
320
23
Oil pump fitting bolt
290
21
Oil cooler fitting bolt
290
21
200 - 300
15 - 21
250 - 350
18 - 25
290
21
Oil cooler element fitting bolt
Oil cooler regulator valve and safety valve
Thermostat case mounting bolt
M8
M10
Coolant pump mounting bolt
560
41
290
21
Fan clutch with cooling fan fitting bolt
560
Propeller shaft on the flange fitting nut
650 - 870
1.300 - 1.600 for model SG only
47 - 62
94 - 115 for model SG only
41
Propeller shaft center bearing support mounting nut
380 - 500
650 - 870 for model SG only
28 - 36
47 - 62 for model SG only
1 page 1
SERVICE SPECIFICATIONS S-19
EXHAUST BRAKE
Models J08C-TP and J08C-TR
SERVICE STANDARD
Unit: mm (in.)
Item
Assembly standard
Average gap between cylinder and butterfly valve
0.4 - 0.55
(0.016 - 0.021)
Repair limit Service limit Corrective method
Adjust
TIGHTENING TORQUE
Tightening position
kg·cm
lb·ft.
Adjusting screw bracket fitting bolt
160 - 220
12 - 15
Plate fitting bolt
160 - 220
12 - 15
Lever fitting nut
100 - 160
8 - 11
Brake cylinder mounting bolt
650 - 750
47 - 54
Adjusting screw lock nut
100 - 160
8 - 11
60 - 80
4.4 - 5.7
450 - 550
33 - 39
Piston fitting nut
Control cylinder cap
Control cylinder elbow
500 - 600
37 - 43
Control cylinder fitting bolt
300 - 350
22 - 25
Air hose
200 - 230
15 - 16
100
8
Butterfly valve fitting bolt
1 page 1
S-20 SERVICE SPECIFICATIONS
ALTERNATOR
Models J08C-TP and J08C-TR
SERVICE STANDARD
Item
Rotor
Repair limit Service limit Corrective method
Outer diameter (front)
25.0 (0.9843)
–
24.98 (0.9835)
Replace
17.0 (0.6693)
–
16.98 (0.6685)
Replace
Insulating resistance
Resistance
Field coil
Assembly standard
Outer diameter (rear)
Resistance
Stator
Unit: mm (in.)
Insulating resistance
0.068 to 0.82 Ω
–
–
Replace
1 MΩ or more
–
–
Replace
2.1 to 2.5 Ω
–
–
Replace
1 MΩ or more
–
–
Replace
TIGHTENING TORQUE
Tightening position
Retainer plate
Pulley nut
kg·cm
lb·ft.
19 - 25
1.4 - 1.8
1,300 - 1,600
95 - 115
Terminal B lower nut
33 - 45
2.4 - 3.2
Terminal B upper nut
60 - 80
4.4 - 5.7
Field coil
19 - 25
1.4 - 1.8
Rectifiers
30 - 50
2.2 - 3.6
Regulator
19 - 25
1.4 - 1.8
Through-bolts
66 - 95
4.8 - 6.8
Rear cover
19 - 25
1.4 - 1.8
1 page 1
SERVICE SPECIFICATIONS S-21
STARTER
Models J08C-TP and J08C-TR
SERVICE STANDARD
Unit: mm (in.)
Item
Assembly standard
Brush length
Outer diameter
Commutator
Mica depth
Runout
Spring installed load
Repair limit Service limit Corrective method
21.0
(0.827)
–
14.0
(0.551)
Replace
43.0
(1.693)
–
42.0
(1.654)
Replace
0.7 - 0.9
(0.028 - 0.035)
–
–
–
–
–
0.05
(0.0020)
Repair or replace
3,500 - 4,500 g
(123.5 - 158.7 oz)
–
–
Replace
TIGHTENING TORQUE
kg·cm
lb·ft.
Two through bolts
Tightening position
110 - 180
8.0 - 13
Terminal C fitting nut
180 - 250
13 - 18
1 page 1
S-22 SERVICE SPECIFICATIONS
AIR COMPRESSOR
Models J08C-TP and J08C-TR
SERVICE STANDARD
Unit: mm (in.)
Nominal
Assembly standard
dimensions
of clearance
1st, 2nd 0.3 - 0.5
(0.012 - 0.019)
–
3rd
0.1 - 0.3
(0.004 - 0.011)
Ring gap
Item
Compression ring
Replace piston ring
1.0
(0.039)
Ring thickness
3.0
(0.118)
–
–
2.92
(0.1150)
Groove width
3.0
(0.118)
–
–
3.07
(0.1209)
–
0.02 - 0.055
(0.0008 - 0.0021)
–
0.08
(0.0031)
Ring thickness
4.0
(0.157)
–
–
3.92
(0.1543)
Groove width
4.0
(0.157)
–
–
4.08
(0.1606)
–
0.010 - 0.045
(0.0004 - 0.0018)
–
0.080
(0.0031)
Piston pin hole inside
diameter
16.0
(0.63)
–
–
–
Piston pin outside diameter
16.0
(0.63)
–
–
–
Clearance between piston
pin hole and pin
–
0.018T - 0.010L
(0.0007T - 0.0004L)
–
0.08
(0.0031)
Connecting rod small end
inside diameter
16.0
(0.63)
–
–
–
–
0.020 - 0.040
(0.0008 - 0.0016)
–
0.07
(0.0028)
Connecting rod big end
inside diameter
37.0
(1.457)
–
–
–
–
Crank pin outside diameter
34
(1.339)
–
–
–
–
Connecting rod bearing
dimension
1.51
(0.0594)
–
–
–
–
–
0.02 - 0.09
(0.0008 - 0.0035)
–
0.10
(0.0039)
–
–
34.985
(1.3773)
–
–
34.997
(1.3778)
–
0.2 - 0.4
(0.008 - 0.015)
–
0.5
(0.019)
Replace connecting rod
1 cylinder
–
0 - 0.3
(0 - 0.012)
–
0.4
(0.0157)
Replace
2 cylinders
–
0 - 0.22
(0 - 0.0086)
–
0.3
(0.0118)
Replace
Compression ring
Oil ring
Piston and piston ring
1.0
(0.039)
–
Clearance
Clearance between piston
pin and connecting rod
Connecting rod
–
Corrective
method
0.2 - 0.8
(0.008 - 0.031)
Clearance
Piston pin
Piston, piston ring and piston pin
Service
limit
–
Oil ring
Crankshaft and connecting rod
Repair
limit
Clearance
Drive gear
34.99 - 35.0
(1.3776 - 1.3779)
Crankshaft journal side
outside diameter
The other side 35.002 - 35.013
(1.3781 - 1.3784)
Connecting rod end play
Crankshaft end play
Replace piston and/or
piston ring
Replace piston and/or
piston ring
Replace piston and
piston pin
T=Tight
L=Loose
Replace connecting rod
and/or piston pin
Replace bearing
Replace crankshaft
1 page 1
SERVICE SPECIFICATIONS S-23
SERVICE STANDARD (Cont’d)
Cylinder liner
Item
Liner, inside diameter
Unit: mm (in.)
Nominal Assembly standard
dimensions
of clearance
80
–
(3.15)
Repair
limit
Service
limit
–
–
–
0.33
(0.0130)
Corrective
method
–
–
0.25 - 0.30
(0.0098 - 0.0118)
–
0.07 - 0.13
(0.0028 - 0.0051)
–
0.18
(0.0071)
Bearing holder and Crank case side
cylinder block
Bearing holder
inside diameter
side
80.0
(3.1496)
–
–
79.996
(3.1494)
72.0
(2.8346)
–
–
71.996
(2.8345)
Ball bearing inside diameter
35.0
(1.378)
–
–
–
–
11
(0.433)
–
–
9
(0.354)
–
–
–
–
–
–
–
2nd land
Piston clearance
Skirt
Free length
Inlet valve
spring
Setting
length
1 Cylinder
9 (0.354)
2 Cylinders
7 (0.276)
Preload 1 Cylinder
kg (lb)
2 Cylinders
0.23 (0.507)
0.45 (0.992)
0.13 (0.287)
0.36 (0.794)
Replace piston and/or
cylinder liner
Replace
Replace
Free length
13
(0.512)
–
–
11.5
(0.453)
–
Setting length
9.5
(0.374)
–
–
–
–
Preload kg (lb)
0.46
(1.019)
–
–
0.37
(0.816)
Inlet valve stroke
–
Approx. 2.5
(0.098)
–
–
–
Discharge valve stroke
–
Approx. 1.0
(0.04)
–
–
–
Discharge valve
spring
Replace
TIGHTENING TORQUE
Tightening position
kg·cm
lb·ft.
Inlet valve holder
1,000 - 1,200
73 - 86
Discharge valve holder
1,000 - 1,200
73 - 86
Unloader valve guide
1,000 - 1,200
73 - 86
Cylinder head bolt
250 - 300 (for 1 cylinder)
400 - 500 (for 2 cylinders)
18 - 21 (for 1 cylinder)
30 - 36 (for 2 cylinders)
Cylinder liner bolt
250 - 300
18 - 21
Connecting rod bolt
230 - 260
17 - 18
Drive gear lock nut
3,600
260
Compressor setting bolt
450 - 500
33 - 36
Oil pipe flare nut
200 - 220
14.5 - 15.9
Pressure regulator flare nut
400 - 500
29 - 36
Bearing cover bolt
140 - 180
11 - 13
1 page 1
S-24 SERVICE SPECIFICATIONS
TURBOCHARGER
Models J08C-TP and J08C-TR
SERVICE STANDARD
Item
Axial (thrust) bearing clearance
Calibration air pressure
Wastgate
performance
Rod movement
Unit: mm (in.)
Assembly standard
Service limit
–
0.025 - 0.08
(0.0010 - 0.0031)
1,125 - 1,175 mmHg
(44.3 - 46.2 inHg)
–
0.38
(0.015)
–
Corrective method
Turbocharger
overhauled
TIGHTENING TORQUE
Tightening position
Turbocharger fitting nut
kg·cm
lb·ft.
570
41
1 page 1
SERVICE SPECIFICATIONS S-25
TOTAL ELECTRONICS SYSTEM
Models J08C-TP and J08C-TR
SERVICE STANDARD
Item
Engine speed sensor air gap
Unit: mm (in.)
Assembly standard
Repair limit Service limit Corrective method
1.0 - 1.5
(0.04 - 0.05)
–
–
Adjust
TIGHTENING TORQUE
Tightening position
Injection pump coupling bolt
Engine speed sensor
kg·cm
lb·ft.
950
68
450 - 550
33 - 39
1 page 1
S-26 SERVICE SPECIFICATIONS
METRIC INFORMATION
METRIC FASTENERS
1.
2.
3.
4.
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.
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.
Most original bolts are marked with identification numbers indicating the strength of the
bolts. The markings are shown below.
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 M12-1.75 × 25
↑ ↑
↑
D T
L
P
T
D
8
6
7
8
9
10
11
L
D- Nominal Diameter
(millimeters)
L- Length (millimeters)
P- Property Class
(bolt strength)
T- Thread Pitch (thread
width crest to crest
millimeters)
Metric Bolts – Identification class numbers correspond to bolt strength – Increasing numbers represent increasing strength.
1 page 1
SERVICE SPECIFICATIONS S-27
DECIMAL AND METRIC EQUIVALENTS
Fractions
Decimal In.
Metric mm.
Fractions
Decimal In.
Metric mm.
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2
0.015625
0.03125
0.046875
0.0625
0.078125
0.09375
0.109375
0.125
0.140625
0.15625
0.171875
0.1875
0.203125
0.21875
0.234375
0.250
0.265625
0.28125
0.296875
0.3125
0.328125
0.34375
0.359375
0.375
0.390625
0.40625
0.421875
0.4375
0.453125
0.46875
0.484375
0.500
0.397
0.794
1.191
1.588
1.984
2.381
2.778
3.175
3.572
3.969
4.366
4.763
5.159
5.556
5.953
6.35
6.747
7.144
7.54
7.938
8.334
8.731
9.128
9.525
9.922
10.319
10.716
11.113
11.509
11.906
12.303
12.7
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
0.515625
0.53125
0.546875
0.5625
0.578125
0.59375
0.609375
0.625
0.640625
0.65625
0.671875
0.6875
0.703125
0.71875
0.734375
0.750
0.765625
0.78125
0.796875
0.8125
0.828125
0.84375
0.859375
0.875
0.890625
0.90625
0.921875
0.9375
0.953125
0.96875
0.984375
1.00
13.097
13.494
13.891
14.288
14.684
15.081
15.478
15.875
16.272
16.669
17.066
17.463
17.859
18.256
18.653
19.05
19.447
19.844
20.241
20.638
21.034
21.431
21.828
22.225
22.622
23.019
23.416
23.813
24.209
24.606
25.003
25.4
Bolt tightening torque chart – for general purpose
Bolt
Bolt
diameter
(mm)
Unit: kg·cm (lb·ft)
4
6
8
10
12
14
Even tightening area. Bolt nut, coating,
naked bolt, lubricant, etc. Optimum
conditions.
10 - 15
(0.8 - 1.0)
36 - 53
(2.7 - 3.8)
88 - 128
(7 - 9)
174 - 255
(13 - 18)
304 - 445
(22 - 32)
486 - 712
(36 - 51)
758 - 1,110 1,040 - 1,530 1,480 - 2,170 2,030 - 2,980 2,560 - 3,750
(55 - 80)
(76 - 110)
(108 - 156)
(147 - 215)
(186 - 271)
Cast iron or aluminium tightening surface.
Washers.
Medium conditions.
14 - 20
(1.1 - 1.4)
48 - 71
(3.5 - 5.1)
117 - 172
(9 - 12)
232 - 340
(17 - 24)
405 - 592
(30 - 42)
647 - 950
(47 - 68)
1,010 - 1,480 1,390 - 2,040 1,970 - 2,900 2,700 - 3,970 3,410 - 5,000
(74 - 107)
(101 - 147)
(143 - 209)
(196 - 287)
(247 - 361)
Tightening area having black coarse
surface. Rusty. Naked bolt or lubricant
unavailable. Poor tightening conditions.
17 - 25
(1.3 - 1.8)
60 - 88
(4.4 - 6.3)
146 - 214
(11 - 15)
290 - 425
(21 - 30)
506 - 742
(37 - 53)
809 - 1,180
(59 - 85)
1,260 - 1,850 1,740 - 2,540 2,460 - 3,620 3,380 - 4,950 4,260 - 6,250
(92 - 133)
(129 - 183)
(178 - 261)
(245 - 358)
(309 - 452)
Even tightening area. Bolt nut, coating,
naked bolt, lubricant, etc.
Optimum conditions.
16 - 24
(1.2 - 1.7)
58 - 83
(4.2 - 6.0)
138 - 201
(10 - 14)
273 - 400
(20 - 28)
477 - 700
(35 - 50)
764 - 1,120
(56 - 81)
1,190 - 1,750 1,640 - 2,400 2,320 - 3,410 3,180 - 4,680 4,020 - 5,360
(87 - 126)
(119 - 173)
(168 - 246)
(231 - 338)
(291 - 387)
Cast iron or aluminium tightening surface.
Washers.
Medium conditions.
22 - 32
(1.6 - 2.3)
75 - 110
(5.5 - 7.9)
183 - 270
(14 - 19)
364 - 533
(27 - 38)
636 - 932
(47 - 67)
1,020 - 1,500 1,590 - 2,320 2,180 - 3,200 3,100 - 4,550 4,250 - 6,210 5,360 - 7,850
(74 - 108)
(116 - 168)
(158 - 231)
(225 - 329)
(308 - 449)
(388 - 567)
Tightening area having black coarse
surface. Rusty. Naked bolt or lubricant
unavailable. Poor tightening conditions.
27 - 40
(2.0 - 2.8)
94 - 138
(6.8 - 9.9)
229 - 336
(17 - 24)
455 - 667
(33 - 48)
795 - 1,165
(58 - 84)
1,270 - 1,870 1,990 - 2,920 2,730 - 4,000 3,870 - 5,680 5,310 - 7,800 6,700 - 9,850
(92 - 135)
(144 - 211)
(198 - 289)
(280 - 410)
(385 - 564)
(485 - 712)
Even tightening area. Bolt nut, coating,
naked bolt, lubricant, etc.
Optimum conditions.
24 - 32
(1.8 - 2.3)
82 - 110
(6.0 - 7.9)
200 - 267
(15 - 19)
397 - 574
(29 - 41)
694 - 925
(51 - 66)
1,010 - 1,480 1,730 - 2,310 2,380 - 3,170 3,380 - 4,510 4,630 - 6,170 5,850 - 7,790
(74 - 107)
(126 - 167)
(173 - 229)
(244 - 326)
(335 - 446)
(424 - 563)
Cast iron or aluminium tightening surface.
Washers.
Medium conditions.
32 - 42
(2.4 - 3.0)
110 - 146
(8.0 - 10.5)
267 - 356
(19 - 25)
529 - 706
(39 - 51)
925 - 1,230
(67 - 88)
1,480 - 1,970 2,310 - 3,080 3,170 - 4,230 4,510 - 6,010 6,170 - 8,230 7,790 - 10,390
(108 - 142)
(168 - 222)
(230 - 305)
(327 - 434)
(447 - 595)
(564 - 751)
Tightening area having black coarse
surface. Rusty. Naked bolt or lubricant
unavailable. Poor tightening conditions.
40 - 53
(2.9 - 3.8)
137 - 183
(10.0 - 13.2)
334 - 445
(25 - 32)
662 - 882
(48 - 63)
Tightening
conditions
16
18
20
22
24
4
S-28 SERVICE SPECIFICATIONS
STANDARD TIGHTENING TORQUE
5
7
8
9
10
11
1,160 - 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
(84 - 111)
(134 - 178)
(210 - 278)
(288 - 382)
(408 - 543)
(559 - 744)
(705 - 939)
NOTE: The torque values given in this table should be applied where bolt torque is not specified.
1 page 1
6
1 page 1
SERVICE SPECIFICATIONS S-29
RECOMMENDED LUBRICANTS
No.
1
2
3
LUBRICANTS
ENGINE OIL
(A.P.I. CD)
(A.P.I. CE)
TRANSMISSION
LUBRICANT
(A.P.I.GL-4)
(MIL-L-2105)
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)
POSITIONS
Cylinder Block
Injection pump
ATMOSPHERIC TEMP.
S.A.E No
Below
32° F (0° C)
10W - 30
–10° - 70° F
(–23° - 21° C)
15W - 40
Above
50° F (10° C)
40
32° - 100° F
(0° - 39° C)
30
–10° - 70° F
(–23° - 21° C)
20
Above
90° F (32° C)
140
90° - 10° F
(32° - –12° C)
90 or 80
Above
10° F (–12° C)
50
Above
10° F (–12° C)
40
Below
10° F (–12° C)
30
Above
10° F (–12° C)
90
Below
10° F (–12° C)
80W
Above
90° F (32° C)
140
90° - 10° F
(32° - –12° C)
90
Transmission
FULLER
RT8709
Transmission
TRANSMISSION
LUBRICANT
Mineral gear oil with rust and
oxidation inhibitor (A.P.I.-GL-1)
4
AUTOMATIC
TRANSMISSION
LUBRICANT
(ATF DEXRON III)
5
AXLE LUBRICANT
(SP TYPE LUBRICANT)
(A.P.I.GL. 5)
(MIL-L-2105B)
Rear Axle
6
POWER STEERING
FLUID
(DEXRON) or
(DEXRON II)
Integral
Power Steering Gear
7
BRAKE AND
CLUTCH FLUID
(DOT-3) or (DOT-4)
Brake and Clutch
ALLISON
Automatic
Transmission
1 page 1
S-30 SERVICE SPECIFICATIONS
No.
LUBRICANTS
POSITIONS
8
WHEEL BEARING GREASE
(MIL-G-10924B/18709A)
(NLGI No. 2 LITHIUM-SOAP)
Wheel Bearing
Propeller Shaft Spider
Propeller Shaft Sliding Spline
9
HEAT RESISTANCE GREASE
(MIL-G-22615/23549/21164)
(NLGI No. 2 or No. 3)
Clutch Disc Hub Spline
T/M Main Drive Shaft Spline
Brake (Adjuster Slit, Anchor Piston)
Slit, Shoe Hold Washer, Shoe
Parking Brake (Cam, Anchor Pin, Adjuster)
10
STARTER GREASE
(NLGI No. 2 LITHIUM-SOAP)
Bushing, Clutch, Drive Shaft.
Pinion Shaft Lever and Reduction
Gear
11
GENERATOR and STARTER
BEARING GREASE
(NLGI No. 2 LITHIUM-SOAP)
Generator Bearing
Starter Bearing
12
CHASSIS GREASE
(MIL-G-17740)
(NLGI No. 1 CALCIUM or LITHIUM-SOAP)
Chassis Grease Fitting
No.
LUBRICANTS
POSITIONS
13
LITHIUM BASE
DISULFIDE MOLYBDENUM GREASE
Drag Link and
Tie Rod Ball Joint
SHELL
MOBIL
EXXON
Retinax AM
Mobil Grease
Special
Beacon Q2
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising