FOREWORD

This workshop manual has been prepared to provide'information regarding repair procedures on Hino Trucks.

Applicabie for J08E-TA, TB engine

When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner's Manual.

All information and specifications in this manual are based upon the latest product information available at the time of printing. Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.

Hino Motors Sales U.S.A. , Inc.

S5-UJ08E02A

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular truck.

S5UJ08E02A

INDEX: ENGINE GROUP 1/2

GENERAL INTRODUCTION

ENGINE INTRODUCTION

ENGINE MECHANICAL

EXHAUST SYSTEM

LUBRICATING SYSTEM

AIR INTAXE SYSTEM

WORKSHOP MANUAL

COOLING SYSTEM

FUEL SYSTEM TURBOCHARGER

FUEL INJECTION PUMP

EMISSION CONTROL

ALTERNATOR

STARTER

AIR COMPRESSOR

ENGINE PTO

(POWER TAKE-OFF)

ENGINE RETARDER

ENGINE CONTROL

INDEX: ENGINE GROUP 2/2

ENGINE CONTROL

FUEL CONTROL

BRAKE CONTROL

OTHERS

GENERAL INTRODUCTION (ENGINE) GN01—1

GENERAL INTRODUCTION (ENGINE)

GENERAL INTRODUCTION (ENGINE) ...GN01-2

GENERAL PRECAUTIONS. GN01-2

HOW TO USE THIS WORKSHOP MANUAL. GN01-5

IDENTIFICATION INFORMATION. GN01-7 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS GN01-7

DISMOUNTING AND MOUNTING GN01-8

GNO1—2 GENERAL INTRODUCTION {ENGINE)

GENERAL INTRODUCTION (ENGINE)

GENERAL PRECAUTIONS

EN0D106010100001

Some recommended and standard maintenance services for your engine are included in this section. When perform- ing maintenance on your engine, be careful not to get injured by using improper work procedures. Improper or incomplete work can cause a malfunction of the engine, which may result in personal injury and/or property damage. If you have any questions about performing maintenance, please consult your Hino dealer.

WARNING

When working on your engine, observe the following general precautions to prevent death, personal injury and/or property damage, in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICE in each chapter.

• Always wear safety glasses or goggles to protect your eyes.

• Remove rings, watches, ties, loose hanging jewelery and loose clothing before starting work on the vehicle.

• Bind long hair securely behind the head.

• When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and block the wheels.

• Always stop the engine and turn off the starter switch, unless the operation requires the engine running. Removing the key from the switch is recommended.

• To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radia- tor, muffler, exhaust pipe and tait pipe.

• Do not smoke while working on the vehicle, since fuel arid gas from battery are flammable.

• Take utmost care when working on the battery. It contains corrosive sulfuric acid.

• Large electric current flows through the battery cable and starter cable. Be careful not to cause a short, which can result in personal injury and/or property damage.

• Read carefully and observe the instructions placed on the jack before using it.

• Use safety stands to support the vehicle whenever you need to work under it. h is dangerous to work under a vehicle supported only by a jack.

• If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly

  applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.

• Run the engine only in a well-ventilated area to avoid inhalins of carbon monoxide.

• Keep yourself, your clothing and your toola 8WBy from moving parts such as the cooling fan and V-belt when the engine is running.

• Be careful not to damage lines and hoses by stepping or holding on them.

• Be careful not to leave any tool in the engine compartment Tools may be hit by moving parts, which can cause personal injury.

  DEFINITION OF SAFETY TERMS

  
  

  DANGER	Indicates an extremly hazardous situation if proper procedures are not followed and could result in death or seriouG injury.
  WARNING	Indicates a potential hazardous situation if proper procedures are not followed and could result in death or serious injury.
  CAUTION	Indicates a hazardous situation if proper procedures are not followed and could result in seriouG injury or damage to parts/equipment.
  NOTICE	indicates the need to follow proper procedures and to pay attention to precautions so that efficient service is provided.
  HINT	Provides additional infomation to help you to perform the repair efficiently.

  GENERAL INTRODUCTION (ENGINE)

  GN01—S

  
  

  TOWING

  • When being towed, always place the gear shih lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No. 1 crossmember when attaching the towing chain. Newr lift or tow the vehicle if the chain is in direct contact with the bumper.

{l)

(2)

(3)

(4)

(5)

(6)

(7)

(B)

2.

(1)

{2)

Towing procedures

Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and entry of dirt or foreign macer.

Use a heavy duty cable or rope when towing the vehicle. Fastan the cable securely to the towing hook on the frame. The hook should be used only if the towed vehicle is not loaded.

The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and vertical directions from the straight ahead, level direction. Avoid using the hook in a way that sub- ject it to jerk, as in towing a vehicle trapped in a gutter.

Keep the gear shift lever in "Neutral'.

Make sure that the starter switch is kept in the "ON" position.

Make sure that the engine of the towed vehicle Is kept running. If the engine is off, no compressed air/ no vacuum will be available for the bra This is dangerous, as the brake system does not function if the engine is not running.

In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to turn, making it impos- sible to control the vehicle.

Note that the engine brake and exhaust brake cannot be applied, if the propatler shaft is removed.

Make a slow start to minimize shock. Towing speed should be less than 30 km/h (18 mile/h).

If the engine of the towed vehicle ia defective, make sure that the

vehide is towed only by a tow truck designed for that purpose.

Front end towing (with from wheels raised off the ground)

When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of axle lubricant or the entry of dirt or for- eign matter.

The above-mentioned precautions should be observed for vehicles equipped with either automatic or manual transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with lubricant if neoessary.

Rear end towing

When being towed with the rear wheels raised ofi the ground, fasten and secure the steering wheel in a straight ahead pos"rtion.

GN01—4 GENERAL INTRODUCTION (ENGINE)

CLEAN AIR ACT

1. Fleury-duty enjgine rebuilding practices.

   
   

   • The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and are applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reassembly, and also may include the removal of the engine from the vehide and other acts associated w"ith rebuilding an engine. Any devi- ation from the provisions contained in this section is a prohibited am under section 203{a) (3) of the Clean Air Act (42 U.S.C. 7522(a) (3)).

1. When rebuilding an engine, portions of an engine, or an engine sys- tem, there must be a reasonable technical basis for knowing that the resultant engine is equivalent, from an emissions standpoint, to a cer- tified configuration (i.e., tolerances, catibrations, specifications) and the model year(s) of the resulting engine configuration must be identi- fied. A reasonable basis would exist if:

   1. Parts ineialled, whether the parls are new, used, or rebuilt, are such that a person familiar with the design and function of motor vehicle engines would reasonably believe that the parts perform the same function with respect to emissions control as the original parts; and

   2. Any parameter adjustment or design element change is made only:

      • In accordance with the oriBinal engine manufacturer's instruc-

        tions; or

      • Where data or other reasonable technical basis exists that such parameter adjustment or design element change, when per- formed on the engine or similar engines, is not expected to adversely affect in-use emissions.

2. When an engine is being rebuilt and remains installed or is reinsBJied in the same vehicle, "a muot be rebuilt to a configuration of the same or later model year as the original engine. When an engine is being replaced, the replacement engine must be an engine of (or rebuilt to) a configuration of the same or later model year as the original engine.

3. At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or reset without diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are installed to satisfy requirements in § 86.004- 25 or for other reasons and regardless of form or interface. Diagnostic systems must be free of all such codes when the rebuilt engine is returned to service. Such signals may not be rendered inoperative during the rebuilding process.

4. When conducting a rebuild without removing the engine from the vehi- cle, or during the installation of a rebuilt engine, all critical emissions- retated components listed in § 86.004-25(2) not mherwise addressed by paragraphs (1) through (3) of this section must be checked and deaned, adjusted, repaired, or replaced as necessary, following man- ufacturer recommended practices.

   GENERAL INTRODUCTION (ENGINE) GN01—5

   
   

   
   

   
   

   SLIDING HAMMER

   DESCRIPTION

   09420-1442

   F'ART NUMBER

   SAPHO01 100006

5. Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The records shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the engine and emissions-related control components including a listing of parts and components used, engine parameter adjustments, emissions-related codes or signals responded to and reset, and work performed under paragraph (4) of this section.

   1. Parties may keep records in whatever format or system they choose as long as the records are understandable to an EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an understandable format when requested.

   2. Parties are not required to keep records of information that is not reasonably available through normal business practices including information on activities not conducted by themselves or informa- tion that they cannot reasonably access.

   3. Parties may keep records of their rebuilding practices for an engine family rather than on each individual engine rebuilt in cases where those rebuild pramices are followed routinely.

   4. Records must be kept for a minimum of Mo years after the engine is rebuilt.

HOW TO USE THIS WORKSHOP MANUAL 

This workshop manual is designed as a guide for servicing the vehicles. An INDEX is provided on the first page of each chapter.

TROUBLESHOOTING is dealt with in each chapter.

When beginning operations, refer to the TROUBLESHOOTING section for a guide to appropriate diagnoses.

SPECIAL TOOLS are dealt with in each chapter.

When ordering a special tool, confirm the part number with the applicable parts catalog.

• REPAIR PROCEDURES

  Repair procedures when self-explanatory, such as simple installation and removal of paM, have been omitted. Illustrations, such as the one below, have been provided to make such simple procedures clear. Only essential procedures requiring specific directions have been deah w'ah explic'itly.

  GNO1—6

  GENERAL INTRODUCTION (ENGfNE)

  
  

  TIMING GEAR AND CAMSHAFT

  EXAMPLE:

  
  

  
  

  1	Gasket		Main idle geer
  2	Rear end plate		Crankshaft gear
  3	Camshaft gear	IO	Air compressor drive gear
  	Cam idle gear		Power steering pump drive gear
  5	Idle gear thrust plate	72	Pin
  6	Sub••idle gear	t3	Idle gear shaft
  7	Oil pump gear	14	Idle gear

  Tightening torque Unit: N m (kgf-cm, lbf-ft}

  A*	T- 108 {1,100, 79}	C* T= 172 (1,750, 125}
  B*	T= 108 {1,100, 79}	D T= 55 {560, 39} Application of lock sealant

  ”=AppIy oil to the threads and seat surface before tightening.

  In some cases, illustrations may be of parts which differ in some nonessen- tial way from the parts found on your particular vehicle. In such cases, the principle or procedure being illustrated applies regardless of such nones- sential differences.

  • DEFINfTlON OF TERMS

    This engine rotates counterclockwise viewed from the flywheel side.

    GENERAL INTRODUCTION (ENGINE)

    
    

    IDENTIFICATION INFORMATION

    GNO1—7

    • ENGINE SERIAL NUMBERS.

Please quote these numbers when ordering spare parts or reporting technical matter to receive prompt service attention.

The engine serial number is engraved on the engine cylinder block.

SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS

1. FLANGE BOLT Unit: Num (kgf-cm, lbf ft)

   
   

   Class		9T
   Representation Diameter x Pitch
   	28.5 (290, 21.0)	36 (370, 26.B)
   M10 x 1.25	60 (610, 44.1}	74.5 {760, 55.0}
   M10 x 1.5	55 (560, TO.5}	68.5 {700, 50.6)
   M12 x 1.25	108 {1,100, 79.6)	136 (1,380, 100.5}
   M12 x 1.75	97 (990, 71.B)	125 {1,2B0, 82.6)
   M14 x 1.5	171.5 t1,75O, t26.6)	116 (2,210, 159.8)
   M14 x 2	154 (1,570, 113.6}	190 \‘2,030, 146.8)

2. BOLT Wi1"H WASI4ER Un"8: Num {kgf cm, Ibf-ft}

Claea	4T		9T
Representation Diameter x P)tch
M6 x	6 (60, 4.3)	10 {100, 7.2}	13 (13O, 9.4)
l¥l8 x 1.25	14 {140, 10.1)	25 {250, 18.1)
MLO x 1.15		51 (520, 37.6)	64 (650, 47.0)
M10 x 1.5	26 (270, 19.5}	47 {480, 34.7}	59 (600, 43.4}
M12 x 1.25	M (550, 39.8}	93 {950, 68.7)	118 (1,200, 86.8)
M12 x 1.75	49 (500, 36.2}	B3 {8B0, 61.ff}	108 (t,100, 79.6}
M14 x 1.5	83 (850, 61.5)	147 (1,500, 108.5)	186 (1,900, 137.4)
M14 x 2	74 {750, 54.2)	132 {1,350, 97.6)	172 (t,750, 12e.6}

GN01—8

GENERAL INTRODUCTION (ENGINE)

DISMOUNTING AND MOUNTING

PROCEDURE FOR INSTALLING JOINTS AND GAS-

KETS OF ENGINE PIPING

1. Gasket seal type (aluminum + rubber, asbestos or copper).

   
   

   Location of gasket seal
   JOINT BOLT JOINT GASKET	JOINT BOLT GASKET	JOINT BOLT GASKET
   JOINT BOL GASKET	GASKET

   Tightening torque chart

   
   

   Clamping screw size (Diameter) mm (in.}	Tightening torque N-m {kgf cm, Ibf-ft)
   8 (0.315)	IS t130, ej
   10 (0.394}	20 {20O, 14}
   12 {0.472)	25 (250, 18)
   14 {0.551)	25 (150, 18}
   16 (0.830)	29 (300, 22)
   18 {0.709}	39 (400, 29)
   20 {0.787}	•39 {400, 29)
   24 (0.945)	69 {700, 51}
   2B (1.102)	t27 (1,500, 94)

   GENERAL INTRODUCTION (ENGINE) GN01—9

   
   

2. hgetal seal type (Flare connector type).

Location of metal seal
CONNECTOR FLARE NUT	BRACKET 3-WAY JOIN NUT LOCK WASHER	BRACKET FLARE NUT NUT LOCK WASHER

Tightening torque chart

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