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GENERAL INTRODUCTIN l-1
Gl-1
GI-S194E-03
CHAPTER GI
ENEAL ODUT
GENERA
ENERAL
L PREC
PRECAAUTION
UTIONS
S .....
......
......
......
.•.....
•......
....•..
...•.....
... Gl-
Gl-2
2
HW TO USE THIS WORKSHOP MANUAL ......•....... Gl-3
IDENTIFICATION INFORMATION ..........•...•....... Gl-4
SPECIFICA
PECIFICATTIONS ••..•
••..•.•.••...•
.•.••...•••.....•
••.....•...•.•••.•
.•.•••.•••.... Gl-5
STANDARD
STANDARD TIGHT
TIGHTNI
NING
NG TOR
TORQ
Q U
U ......
............•
......•..
........
...... Gl-
Gl-11
11
RECO
RECOMMEND
MMENDED
ED LBR
LBRIC
ICANTS
ANTS ....
.......•...
...•....•
.••.••
•.•••.•
•.•..•
..• Gl12
Gl12
Gl-2 GENERAL INTRODUCTION
GENERAL PRECAUTIONS
Some recmmnded and standard maintenanc seces r yur ngine ar mentined in this sctn.
When peormng maintenance n yur engne b careful nt to t njured by imprper wrk·
Iproper r incompete wrk can caus a mafunctin of the engn wich ay rest in prsna inu and/r rpy
damage
WARNING
, v v
NOTE ARNNG
M
B x
o A
o Rv , ,
B
o T v ,
x ,
,
, x
o D
T
v
o L B
A
A
,
,
q
q
Rv
R
-v
-v
v
x
x
o K , v V
B v T v
GENERAL INTRODUCTION Gl-3
HOW TO USE THIS ORKSHOP MANUAL.
Ths workshop manual s desgned
desg ned as a gude for servcng ve
hcle.
An INDEX s provde on the fst age of each chater
TROUBLESHOOTING
TROUBLESHOO TING s ealt with each chater
When begnnng opeatons, efer to the sectos on for a
gue to aproprate dagnoses
SPECIA TOOLS are dealt wth n each chapter.
SLIDING HAMMER-DESCIPTO When orderng a specal tool confrm the pas number wh
the applcable pas catalog
09420-144 PAS UBE
Repar procedures when the self-exlanato such as smple
nstallaton an
an removal of as have been omtte. Illustra
tons such as the one below have been provded to make such
smple proceures
proceures clear Only essental oc
oceures
eures requrng
drectons have been dealt wth explctly
TIMING GEAR AND CAMSHAFT
EXAMPL:
1. Thst bearing 5. Buing 9. Crankaf ear 13 ront end pla ket
13 Fron
2. Camaf gear 6. Idler ear thst plate 10 Injecon pump drive ear 14. Front end pla
3 Oil pump drive ear 7 Straiht 11 Idr ear thst pla
4 Idler gear 8 Idler gear shaf 12 Camaf
In some cases llustratons may be of parts whch der n
some nonessental way from the pars foun on your parcu
lar vehcle In such cases however the prncpale or proce
ure beng llstrate apples regarless of such nonessental
ferences.
Gl- GEERAL INTRODUCTIO
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBERS
Please quote these numbers when ordeing spae pats or
epotng technca matter a they w gve you pomp serce
aenton.
Te engne sea numbe s engaed o the engne cner
bok
GENERAL INTRODUCTION Gl-5
H INO H07D SPECIFIC TIONS
H INO H07D T SPECIFIC TIONS
DIESEL ENGINE FOR INDUSTRIAL USE
7.412 ite, 4-c y cl,
cl,
6c y l
l watrcoold
H 07D H 07DT
ePERFORMANC
PERFORMANCE
E (STD. spcs.)
GENERAL USE (SAE J1349 Goss) GENERATOR USE (SAE 349 Gross)
tand-by Powe Prime Powe
Min. fuel
Output, Output, ax. trque
consumption Output at Output at Outpu
Outputt at Output at
ntermttent ratng ntnuu ratng N-m {bfft}
gkWh {bPh} 1500 r/mn 1800 r/m 1500 rmn 1800 rmn
kW {HP} at r/mn kW {H} at rmn at r/mn
at rmin kW {HP} kW {HP} kW {P} kW {P}
115 {154} at 2,700 100 {134} at 2700 465 {343} at 1,600 220 {0362} at 1600 77 {103} 91 {122} 70 {94} 83 {111}
Ambient conditions: SAE
Intake air teperature 2s0 c
Baroetric pressure 00 kPa
Water vapour pressure 10 kPa
eENGINE ESCRIPTION
Type Diesel, 4-cycle, 6cy., inie, overhead vave, watercooled
2. Combustio syste Direct injectio tpe
3 Cylider
Bore x Stroke 10 x 30 {433 x 52 in}
4. Pisto displaceet 7.42 liters {4523 cu.in}
cu .in}
5 Copressio ratio 19.7
6. Directio of rotatio Coutercockwise viewed fro flywhee
Diesions (L x W x H) Approx. 1,65 x 70 x 868 m
{45.9 X 291 X 342 i}
8. Dryweght Apprx. 510 k
kg
g {,124 lb}
eFEAURES
1. Cy
Cyli
lid
der
er bloc
block
k Mono bock cast iron with repaceable dy ier
2 Cyli
Cylind
nder
er he
head
ad Sigle piece cast iron
3 Crankshaft ductiohardened, die forged special stee with couter
weights
4 Pi
Pist
sto
o a
ad
d ri
rigs
gs Heatresistace aluiniu aloy
Two compressio rigs, chroe plated
Oe oi ring, chroe pated with oil expader
5. Cashaf duction hardeed carbon steel
6 Valves Heat resistace steel
Gl-6 GENERAL INTRODUCTION
e STANDARD EQUIPMENT
1. Flywheel housing HNO own (SAE No 2 type)
2. Flywheel HN own (SAE 1 1/2 in type
3.. Fuel injection pump type
3 BOSCH "A type
4. Governor
4. Centrifugal, all speed control type
5. Fuel injection nozzle type BOSCH hole type
6 Fuel filter Paper element ype
7 Water separator
8. Coolin system orced-circulation by olute pump
9. Lubricating system ull forced pressure feed by gear pump
10. Oil filter Paper element type (Full flow & Bypass flow)
11 Intake manifold nlet position at rear
12 Exhaust manifold with
flange plate Upward exhust
13 Generator lternator with integral regulator
24V, 20A
14 Staer 24V, 45 kW
15 Safe relay
16 Connectors of electrical
equipments
e OPTIONAL EQUIPMENT
1. Cool
Cooling
ing fan
fan (suctio
(suction
n or blow
blowou
out}
t}
2 Min switch
3. Ber switch
4. Btte relay
5 St
St
er
er swit
switch
ch wit
withh ey
ey
6 Ammeter
7. Fuse bo
8 Engine shut off solenoid
9. Emerency relay
10. Coolant temperature switch
11 Coolant temperture uge sender
12. Coolan
Coolantt tem
temper
pertu
ture
re ga
gauge
uge
13.
13. Oi
Oill p
pre
ress
ssur
ure
e swit
switch
ch
14. Oil pressure ue sender
15 Oil pressure gauge
16. Glow plu
17. Glow plu indictor
18 Tachometer with hourmeter
19. Tchometer cable
2 Muler
21 Air cleaner
22
22 Air c cle
len
ner
er c
cp
p
23
23 Rdt
Rdtoror with
with oo
ool
ln
n fn
fn shro
shroud
ud
FRON SIDE VIEW
SM1-083
LE SDE VIEW
NOTE: 1) Thes spcficato are subjc to chang who oc.
2 Thee spcfcato are o expor modls
3 Al speccao o h poducs are wt oa mauatu alowance ad tolrance
4 Th eoac adad dawngs a or stadard speccaton
Gl-8 GENRAL INTRODUCTION
SPECIFICATION
DIESEL ENGINE FOR INDUSTRIAL UE
H IN O H 0 7 C H 0 7 C T H 0 7 C -T
6.728 liters, 4-cycle
SPECIFICATIONS
6cyl watercooled
turbocharged
e PERFOMNCE (STD sps.)
GENERAL USE (SAE J1349 Gross) GENERATOR USE (SAE J1349 Gos
Stand-by Powe Prime Powe
Output, Mn. fuel
Ott, Max. torque
itermttent ratg cosmto Outut at Output at Output at Outpu a
ontnou ratg N-m bft}
kW {HP} at r/m g/kWh {b/HP} 500 m 800 r/m 1500 m 1800 r/m
kW P} at r/m at r/m
at r/m kW {HP} kWP kWP} kW P}
479 a 2800 8
817
17 a 800 60 443 a 1600 8 0358 a 1600 9 3} 6155} 831 05
054
4
Ambint conditio: A
Itak air tmratur 2s0 c
Baromtrc
Watr rur
vaour rur 100ka
10 ka
e EGE DESCRPTO
1 y il, 4-ycl 6cyl ili
ili
ovrhad valv
val v watrcoold
watrcoold
turbochard
2. ombution ytm irct ijtion ty
3 ylindr
Bor x trok 110 x 11 mm {433 x 45 in}
4 . iton dilacmn
dilacmntt 62 lit 4106 cuin}
5. omrion ratio 185
xct H0AA HKA HKA 15
6 i
ir
rct
ctio
io
of
of rrot
otat
atio
io
ountrclockwi viwd rom lywhl
7 imnio L x W x H Arox 1165 x 70 x 68 mm
59 X 291 X 32 in
8 right Arox 55 kg 1200 lb}
eEUES
1 yli
yli
d
drr bl
bloc
ockk ono block cat iron with rlacabl dry linr
2 yli
li
d
drr ha
hadd ingl ic cat iron
3 ran
ankkha
a Iductionhardnd di ord cal tl with countr
wight
4 i
ito
ton
n ad
ad ri
ri
Hatritanc
Hatritanc aluminim alloy
hr comrion rin chrom latd
lat d
oil rig chrom latd with coil xandr
5 amha Iduction hardnd carbon tl
6 Valv Hat ritanc tl
GENERAL INTRODUCTON Gl-9
e STANDARD EQUIPMENT
1. Flywheel housing HNO own (SAE No. 2 type)
2. Flywhee HNO w (SA 11 1/2 in type)
3. Fue injection pump BOSH • pe
u
4. Governor Ceifugal, al speed cotro ype
5. ue injection ozze BSH o pe
6. ue filter Paper ele�t tye
7. Water separator
8. Cooling system Force-circulation by voute pump
9. Lubricting system Ful force pressure fee by ger pump
10. Oil filte P_e elemet type (ull flw & Bypass fow))
11. Intake manifod nlet osition at fron
12. Exhaust manifod with
flnge plate Rearward exhaust
13 Generator Alterator with integrl regulator
24V 20A
20A
14. Starter 24V 45 kW
15. Sfey rey
16. Connectors of eectrica
equipment
e OPTIONAL EQPMENT
1. Cooling fan (suction or blowout)
2 Ma
Maiin switch
3. Btery switch
4. Baery relay
5 Starter switch with key
6 Ammeter
7. use bo
8. Engine shut o solenoid
9. Emergency relay
10. Coolant temperture switch
11.
12. Coolant
Coolant temperature gauge sener
temperture guge
13. Oil pressure switch
14 Oil pressure gauge sender
15. Oil pressure guge
16. Glow plug
17. Glow plug indictor
18. Tchometer with hourmeter
19. Tachometer cble
20. ufle
1. Air clener
22.
22. Ai
Airr cle
clen
ner
er cap
cap
23. Raitor with cooling fn shrou
61-0 GENERAL INTRODUCIN
FRON SIDE VIEW
SM1-084
LE SIDE VIEW
NOTE: 1) These specifcaton
specifcaton ae subject to chage wthout notce.
2) These
These specf
specfct
ctons
ons are fo
fo expo
expott models
3) Al specifcatos of the podcts ae wth oma maufactu
maufactu
aowaces ad toerances.
4) The pefomace
pefomace ad dawgs ae fo stadad specfcato
specfcaton
n
TOKYO, JAPAN
J HINO MOTRS, LTD.
Unit: N-m
TIGHTENNG TORQUE OF STANDAD BOLT
diBolImam)mtr
t I �i/ l m
odnt-
-
caton TTghteni I
ghteniionsng
condi
I 4 6 8 10 I 12 14 16 18 20 22 24
Evn
coat ntigghten
� I Optmum condtions. naked ngbolara.t, lubriBolctantnut,tc I 0o90150 } I 32 454 )9 883-_1928 ) 03428 0 29328423 425 3} 466 619. }{ 5 , }01 .960- 00300 0 510842 2282, 30 -2229 58023 2 80662361
1
14
1
5
36
5
3
6 5
555 5
5
555 0
6 47
8
7
7 2
82
82 7434
7 8
108
10
10
5
0
04
4
5
5
4 4
4 0 70
70
199
0 0
8 2 5
5
560
60 37
750
50
4
(✓ 1 1120 6 4341- 48-n 8 ('3234 3 394032-5982008 }{ . 6 016 10 01- 07 03}6 39202--2 2 0} 39230-23 220 2289 3}9{26416 328902}3 4241-4-- 490 30}
3 2 3 5 55 80 56
56 147
Cat
suac ronWashrs.
or aluminum tightning
Mdum condtons.
1 9 6 96 1 16 6 4 5 5 63 4
45
5 93 99 0
05
5 4
45
51 13 0
00
0 5 9 4 8 3 0
4 { 0
5 47
47 95 1 1 48
48 3 0
04
4 1 70
70 0
00
0 7
700
00 7 4 0 5
0 ghten
coar ng area
boPoort ortiglsurf
hav
briacceantng condi
uhteni
ng black
Rusty.
unavaitiolNakd
ansbl. {162 25 }5 {58690B62} {44362- 2049 2 829 4425 063 }{ · 151}12 _1 -2,5 }2165 _3,56 0} , _ 8,5 ", 606, 90 I
1
1
2
4
8
5 5
8
0
4
30
6
5
37
4
742
79 3
34
4
809
47
59
8
1 180
180
85
35
7
2
260
60
2
1
18
850
133
81
81
50
1 1
70
70
17
740
40
47
2
4
49
18
9 08
08
4
40
0
14
4 0
7
0
09
6
9
2
200
0
33
380
80
9
45
4
49
950
50
3 8
42
47
47
77
309
361
4
2
255
1
Evn tightenngbolarea.t lubriBolctntnuetc. 5.327-1-12.3}5 54654926-6.31o3} 31.3510- 5 } {262 3--2--3092 63775s 63 }{ 656- }I1, 9- 266I66260920 9 3, }5 I 2 13'620-2,361 2.36-6 53,6 } .29 - 5 27603 �
z
coati
Optimngumnakd
m
Opti conditions
1 8 1 4 19 7 78 4 8 8 64 7 93 09 83 16 1 0 3 53 7 52 3 40 31 8 458 95 394 3 25 6 :
16 24
8 8 8 20 7 47 0
00
0 7 11
120
20 1 0 1 5 4 24
400
00 3 4 0 3 180
180 4 80
80
I 40 0 53
l
22166-3213} {365-109 } 195222 260} 3 36205 2326 62 692 9 10 lQP 9 5196 ,6 9}{2,599 23 081} 3 420- 2962} 62590-6 6, }{236 --5695 }
17 4 4 0 5 81 87 1 1 7 8 24 1 3 8 2 1 3 r
a ron Washrs.
or alumnum tightning z
Msua.
-
� Medi edium cond ons 3
3 7 1
0
78
78 7
83
83 7
47 5 7
4
5 38
38
3
36
6 93
3 00
03
0
3
020
20
1 70
15
500
00
15
15
9
93
3 228
23
330
30
37
180
180
313
32 0
0
3 1100
00
44
45
550
50
0 4
I 4 30
7 08
08 9
20
20
99
9 5 5
5 3 0
4 7 82
82
0
:
0
{226. 3 82 9962 -93 3 {2 269-2332695 { 6536 64} 7 52 {, 723 5 96--22 6 {26,9828 2,9o2 26 3958 ,6 01 { 557566, 657 . 7796 52
55 7 4 9 7 8 7 4 1 8 1 2 5 3 4
49
9 8 67
67 0
ghteni
coar
ghtenisuaceng are hav ng blNakd
ack
C
Rusy
-
boPoor ortgluhteni
brinntg cond unavaitiloansble
5 9 2 1 5 4 3 44 3 65 79 114 4 12 55 183 38
38 19 8 3
35
5 7 3 3 2 557 520 74
74 7 91 0
05
5 9 9
95
5
4 138 9
95
5 1 1
166 2 8 0 19 0
27 0 4 5 29
920
20 2
30
30 3 0 5 80
80 5 31
31 8
800
00 7
700
00 85
85
0 2 8 9 7 3 48 58 84 9 1 5 4 21 89
89 0 410 38 4 485 1
z
Evnntgghteni
coati nakd
Optmum condtions.
ngbolreat lubriBolctant,nutetc 26 1} I H 620 .9 92062226} 97 5 }9 I 6 956 6 }9 1, 1691626-226 76 7 2 . }3 47 2562 46. 560 56 5 6 -76679}
23
4
3
32
3
I
05
8
10
110
8
0 6
1 8
39
4
574
62
I
80
4
90 7
925
90
1 01
01
05
5 4
45
5 13
13
9
980
80 17
730
30
6 2
3
310
10
5 233
23
380
80
0 30 8
31 0
3
33
380
80
44
4
27
27
10
10
5
4
0
05
3
5
30
0 170
170
0 73
73
58
850
50
9 9
93
3
I 2 2} {1 1 111 6} {626-2 56 { . 616. } .6 6 , 92 61 . 0 0 ,153 } ,527- 9. 6 - 5 6,.96-,539
1 23 7 5 9 29 41 1 6 4 1 3 2 9 4
44
4 3 33 44 2
244 5 3
(� I uac. a ronWahrs. or alumnum tghtening
Medum condions
31
144 0 79 43
31
1 2
9
9 34 9
91
1 5 8
888 92
233 90 2 12 2 1 5 4 9
93
3 19
19 5
544 3 2 04 3 10 88
88 4 4 82
82 442 28
28 5 37
37 05
05 08
08 807 08
08 7 3 4 1 018
018 9
3 42 0 14 3 529 70 925 12 4
480
80 23 0 3 08
08 {3· 70
70 42 0 4 0 60 0 1 82
233 9
90
0 1 0
e ghten 9-51 17--79 332 32 6 6932-8-8632 9 , 6 1 2 1 2.2 2292 , 3923: 295 36 56 7\575OSC,Z {97- 79 J
0 80 05 9 39 5 8 108 142 6 222 23 30 3 434 447 59 5 4 1
coao suac
sung ac
area Ruy.having blNaked ack
b oo thtenng condtions.
u bi nt unava l a bl
39
93
2
3
0
5
a.l
9
10
3 1 3
13 2
4 2 76
3
34
4
5
43 6
445
633 4
48
88
6
4 113 7
1 0
8
15
15
540
40
0 18
1 850
4
43
8 50
3
1 4
24
24
470
70
2 283 3 75
55
3 85
2
85
5
39 0
3
88
88
51
52 0
8 408
10
10
4
40
0
73
7
5
4
10
10 7 7
720
20
5
599 744
0
009
09 1
9
5
555
4
7 1 2 3 88
5
88
12
93
9
90
0
NOTE: he torque values given n ths tabe should be appled whee bot toue s not specfed.
c
I
-
C
I
-
N
. RECOMMENDED LUBRICANTS FOR ALL HINO G HINO MOTORS, LD
OVEEASOPEAOS
EVC V
KY JAPAN
ATMOS·
SAE
LUBRICANS POSTONS PHRIC P CALTEX CASRO ESSO GULF MOIL SH TOTAL
NO.
TEM
o RM DL 400 Cso o Osol sso Mol Dlvc 1340
1340
M 40 TTA
J2'C 40 Vaels C SE 40 or 15W 40 CO 40 o G S D Mob Olc S
0W-40 5W40 RubS 40
40 M DEL J Q Casol o Duso D3 40 Motor Q 40 W-40 mula X l 40 TA
90 O 3 40 15W40
SE 40 Sp 40 15W 40 ,ul C 40 R TM W40
il
A Pl CO
CO M 30 TA
RPM DEL 400 O Caso! o Oeuso Mobil Olv 1JJ
1JJ 20W40 15W40
o·c
Vls C SAE J o W 40 CO 0 Essou G Sr Dy RuS 30
90 l 0 0 DJ J Mol Ov S ml X O J
P OS P DEL Casrol o Oeso O J
Moto , J 1 W40 5W40 W30 TA
M 2104C SE 30 R S 0 5W 40 a CTJ Rubi TM 15W40
M 451998
RPM OO 400 , Catro o Deso My 20 TTA
2 Vl C CD 20W 0 Essolu Mo l J
J 0 20W-4015W 40 RS 0
O'
0 SE 00W
00W 5W40 C astol o Oeo J 0W Gl Spr D Ml el Su
3 "F 0W PM DEL J Moor 0 5W40 muX 20 A
C ynde Blo SE 0•w RX Spe 0W0. 3 W-40 15W40 R,mu C20 RTM 5W40 C
leo Pmp
1w·40 m
A, Ca
bo@ RM DE 00 l Cstol o Deso z
Essolu Rol TX4020W
TX4020W50
3 40 Vs M SE 40 CX 40
HOX 40
Gl Moo Mobl Ova 1240 Ro SX 40 TOTAL m
90'F 40 RM DE 00 Casto or Oes HO 4015W40 Mob O 40 0W40 Ru 40 :
SE 40 R Sp 40 15W 40 HO Pl 40
,
P CC M DEL 00 il Cato o Oesol r
3 oc Esolu o TX300W50 TAL
f 30 u M SE 30 CR 0 Gllb Motor Mobl Olv 1
1 oa SX i 30
HOX 30
A PI OM 90 JO RPM DEL 00 Ql Catol Oesol HOX Pls 30 O J 15W
15W 40 Mol Oev 1 30
30 0W40
Ruba J z
MIL 46152 SE J RX Spr J 5W 40 -
MI1048 :
PM DE 200 l Csrl Ouol
· 2 C aell M SAE 00W CRX 20W 20 Es Gfu Mo Ml Oac 2
20
Ro X2020W50 TA 0
0 C st o Oeuol OX 0 Ra SX �
· 0W PM DE 00 l X Su 20W 20 XO 20. 15W 40 Ml Oelvc 120 20/0W20W40 Rb 20
X Pls 0W0
SAE 02w 15W 40 C
n
T Maa Esso
Engs Multiprpose 2 Csro LM Moblgs Re1n TTA
ER RE Coon mp Be Mltiprpo Gl o MUTS
MIG09248
L or Maak Gr
Gase
M 7MS aa Gse R2 0
l Pos z
Bh lh
O Sha Moe Moblgs 9
TRER REE Ao Sl Gas 7
-� - -
P Sh •"• Grease E
& Ruo Gr
EERTR & RER eto Bg Eegr RPM Gs
SRI 2
-
·
Moblgreae 8
8 Aeo Shel Ga
ER REE Be LT
Ma
NJE Enegea Mtprpo 2 Casto LM Eso Mobgr
Mobgr Re T
ER REE l eco m Te Mtppo le Pol MP MS lana Gas Muls EP
o Maa Gese Gre
M-G09248 ll Prs
Shellon S
sso
r M Gcoh Pl
Engne 0 · Freee fe Mobi (op ot) T
REEZE gne. Rdtor t Fro Csto Lon i t Feee e e Shse ANTIG
Coolt Cooln Coon
MA-5J0 Coont A re PB
Cud
o mn cc o
f
f by A P I mi Poum 22-2S D
�
ENGINE E-1-1
E811E03
CHAPTER N
HINO
HI NO EN GINE
Models H07C H07CT H07C-T H07D H07DT for
industrial use
DATA AND SPECIF
SPECIFICAI
ICAIONS
ONS ... ......
......
......
......
......
......
......
......
........
.........
........
........
........
.... EN 1 3
TROUBLE SHOOTING ......................................................
.......................................... ..................
...... EN 2 1
ENGINE
ENGINE OVERHAU
OVERHAUL L CRITERI
CRITERIA A .........
......
......
......
......
.......
........
........
........
........
........
.......
... EN 3 1
ENGINE MOVING
MOVING PARTS .............
....................
..............
..............
..................
....................
......... EN- 4 1
CYLINDER
CYLINDER HEAD
HEAD ...............
.......................
................
................
................
................
................
...............
......... 6
TIMING GEAR,
GE AR, CAMSHA AND OIL PAN ............................. ................. ............ 18
PISTON, CRANKSHA, CLINDER BLOCK
AND FLHEEL HOUSING ...................................................
............................. ...................... 26
LUBRICATING
LUBRICA TING SYSTEM .............
....................
.............
.................
....................
.................
...........
... EN 5 1
OIL PUMP AND OIL STRAINER .............. ......................
...............
..............
...............
..........
.. 2
OIL FILTER AND OIL COOLER ....... ...............
...............
...............
...............
...............
............
.... 6
FUEL SYSTEM ..............
......................
...............
..............
..............
..............
.................
....................
............
.. EN 6 1
IJECTION NOZZLE ........ ................
...............
...............
...............
...............
................
.............
.........
.... 2
FUEL FILTER ...........................•.............................
.......................... .•.................................................
.................... 10
COOLING SYSTEM ................
........................
................
.................
.................
................
...............
....... E 7 1
COOLANT PUMP ..................................................................... 2
THERMOSTAT ........................................................
............................ ..............................................
..................
RADIATOR ................................................................................ 8
COOLING FAN ..............
.....................
..............
..............
...............
..................
...................
............
... EN 8 1
AIR INTAKE
INTAKE AND
AND EXHAUST
EXHAUST SSTEM SSTEM ... .......
.......
.......
........
........
.......
.......
........
...... EN 9 1
ENGINE COMPONENT PARTS DISMOUNTING
AND MOUNTING
MOUNTING ..................
...........................
..................
.................
.................
..................
..............
..... EN10 1
INJECTION
INJECT ION PUMP ................
........................
................
................
.................
.................
................
...........
... 1
............................................................................ 4
GENERATOR .......................................................................
STARTER .................................................................................. 4
...............................................................................
ENGINE TUNEUP
TUNEUP ........
................
...............
...............
................
...............
...............
................
............
.... EN11
EN11 1
................ ....................... 4
ENGINE TUNEUP ON TEST BENCH .................................
PROCEDURE FOR INSTALLING OINTS
AND GASKETS OF ENGINE PIPES ....................................... EN12 1
LIQUID GASKET AD APPLICATION
APPLICATION POITS ..................
.....................
... EN13
EN13 1
ENGINE EN-13
DATA AND SPECIFICATIO
(FOR MODEL H07D H07DT ))
Model .............................................................. HINO H07D HINO H07D
Type ....................................................................•... Diesel, 4 cycle, veical 6-cylinder inline overhead valve
watercooled
Aspirati on .. .. .. .... ...... ....
Aspiration ..........
..........
........
......
.....................
..............
Natura asprate
Combustion sstem ... .... ........
......................
........
...........
irect injection
Bore and stroke .............................................. 110 x 130
130 mm {43 {4333 x 5.12 in}
Piston displacemen ..................................... 7.412 L{4523 cuin)
Compression ratio ................................ 197
Compression pressure ................................................. 353.82 Pa {339 {339 kgf/cm , 512555 lbf/in2} at 280 r/min
Firing order ........................................................ 125
(A number of a cylinder is to be counted in order from timing
gear side)
Dirtion of rotation ............................................... ounterclockwise viewed fr from
om flywheel
Dry weight ...
..... ...
.......
.......
......
.......
..........
..........................................
.................................... Approx. 580 kg {1279 lb}
Valve seat an
angle;
gle; Intake .............................................. 30 °
Exhaust .......................................... 45 °
Valve face angle Intake ....................................... 30
Exhaust ........................... .................. 45 °
Hino H07D H07D Va Valve
lve timing flwhe flwheel el travel; Intake ope opens
ns .......... 12 before top dead center
Intake closes ............. aer boom dead center
Exhaust opens ............ 51 before boom dead center
Exhaust closes .......... 13 aer top dead center °
Adjusting value:
Injection pump Injection Idling speed Injecion pressure Valve
Engine code
number timing r/min Pa {g/cm , lbf/in }
2 2
clearance mm
{in}
1t 17.65 {180 2,5} IN 0.30 {00118}
H07DEUA 22020290 14 B....
725-775
2nd 21.57
21.57 {220 3128} EX0.45
EX 0.45 {0.0177
1 1
17.65
7.65 {180 2,5} IN 0.30
0.30 {0.0118}
H07DNSAA 22020-3763 14 B.D..
725825
2nd 2157
2157 {220 3128} EX 045 {0.0177}
1st 17.65 {10 25} IN 0.30
0.30 {0011}
H07D-NSAB 220203763
14 B.D.. 725825
2nd 21.57
21.57 {20 3128} EX 0.45 {0.0177}
1 17.65
17.65 {180 25} IN 030 {0.0118)
H07DOPA 22020221 °
14 B..D.. 725-775
2nd 21.57 {220 3 128}
2nd EX 0.4
0.455 {0.0177}
H07-TOPB 22020221 14 B...
725775 1 17.65
2nd 2157 {180,
{0 256}
3128} IN 0.45
EX 030 {0.0177}
{0.0118}
1t 17.65 {180 2560} IN 0.30 {0.0118}
H07DDYAA 22020-39
14 B.D. 725-825
2nd 21.57 {220 312}
2nd21.57 EX0 {0.0177}
Engine oil volume
Engine code Hino Diesel Engine Parts
L
H07D-EUAA L 7 H 11 OAL13.5 ontact email:
H07DNSAA L 16 H24 TOTAL28.0 EngineParts @ HeavyE
HeavyEq uipmentR estorationPartscom
H07DSAB L
L16
16 H 24 TOAL28.0 Phone: 269 673 1638
H07DTOPA L 7 H11 OTAL13.5 W ebsite:
H07DOPB L 7 H : 11 TOTAL 13.5 wwwHeavyEq uipmentR estorationPartscom
H07DDYAA L 16 H24 TOTAL28.0
EN-1•4 ENGINE
DA T A AND SP
SPE
ECIF
IFIICA T IOS
(FOR MODEL H07C H07
(FOR H07CT
CT H07C-T)
H07C-T)
Model ............
.......................
......................
...............
.... HNO H07C HNO H07CT HNO H07C-T
Te
Te ......
..........
............
...... ............
.............
....
. DDi
il,
l, 4 cycle , ve ical,
ical, &-cylin
&-cylinder,
der, in-lin
in-lin overhead val
overhead valv
v
watrcooled
piration .............................
Combustion system ......
.......
. .....
.......
.. ...... Turbocharged
Dirct injection
Bor and stroke
stroke ..........
.................
................
......... 110 x 118 mm {433 x 465 in}
Piston displacement .........
....... .........
....... 6.72 L{4106 cuin}
Cmpressin ratio . ..... ..... .... ... .
........ 18.
Excep
xceptt H07C
H07CT-
T-S
SUFA
UFA ,HKG
,HKGA,H
A,HKFA
KFA ,HKO
,HKOC,H
C,HKD
KDDD 17 ..5
5
Comprression pressure ....
Comp ....
......
........
..........
...........
........
..... 3.7
3.72 MPa {3 {35
5 38
38 kg f/cm
f/ cm , 49
49 lbf/
lbf/iin } at 20 r
2
20 r/min
/min
3.0 MP I 31- kg / c,41 2 r/ min (HHKD)
Firing ordr .................................... 12
(A number of a cylindr is to b countd in order from timing
gear sde)
Dirtion of rotation ......
...................
.......................•..
..........•.. Countrcockwis viewed from flhel
Dry wight ..... ................ ....... Approx k
kgg {1,200 lb}
Valve sat angl; ntak .....................
...........................
...... 30
Exhaut ................
.......................
....... 45°
Valv fac angl ntak
n tak ...........
........... 30
Exhaust ............ 45
Hino H07C H07CT Valve Valve timing (flywhl travl) ntak ons . 12 bfoe top dad cntr
ntak clo 32 ar boo dead cntr
°
Exhau opns •. 5 bfor boo dea cntr
°
Exhaut clos ... 1 ar top dad cntr
°
Adjusting value:
njection pump ntion dling pd njtion prsur Valv clearance
Engine cod
nubr tiing (r/min) {kgf/cm , lbf
MP a {kgf/cm
MPa lbf/in
/in }
2 2
mm {in}
{in}
H07HA 2202061
14 BDC 1,17122
1,17122 1961 {200, 2,} N:0.30 {0.0118} EX 0.4 {0.0177}
H07CTKFA 020191 12 B.DC
7277 19.61 {200, 2,} N 030 {0.0118} EX 0.4 {00177}
H07KF C 2202091 12 BTDC
72 775 1961 {200, 2,} N:030
N:030 {0011} EX:
EX:0.4
0.4 {00177}
H07 NS 020 2 B.DC.
72775 19.61 {200, 2} N 030 {0.0118} EX 04 {00177}
H07HKGA 02042 12 BTDC.
961010 1961 {200, 2} N 030 {00118} EX
EX04
04 {00177}
H07HKFA 22020 12 B.TDC.
3 1961 {200, 2} N 030 {0011} EX 04 {0.0177}
-
176 {10, 250} N 30 {00118} E
E0.4
0.4 {00177}
- ..
17
17.6
.6 {0, 2,50} N:030
N: 030 {00118} EX:04
EX:04 {0.0177}
Engine oil volu
Engine cod
(L) Hino il ngin Part
H07CTHA L16 H:24 TOTAL280 Contact mail:
H07KFA L:16 H:20 TOAL240 nginPart @ Havyq uipmntR torationPartcom
H07CT-K L:16 H20 TOAL240 Phon: 269 673 638
H07CTNSQ L:16 H:20 TOTAL240
TOTAL240 W bit:
H07CT-HKGA L:16 H:20 TOTAL240 wwwHavyq uipmntR torationPartcom
H07CT-HKFA L16 H:20 TOAL24.0
- L: 14 H:20 TOAL
L 14
- H:20 TOAL
ENGINE EN-21
TROUBLESHOTING
Symptom Possible cuse Remy/Prevention
Remy/Prevention
Engine overheating ---- Coolant
• Insucent coolnt Add oolant.
• Defectve thermo
thermostat
stat . . . Replace the therm
thermostat
ostat
• Ovelow of oolant
oolant due to leakage of . . . Repair
Repair
exhaust int coolng system
• Coolnt lek
lekge
ge from
from clnder
clnder hed gasket . Replae gasket
• Def
Defect
ectve
ve cool
coolnt
nt p
pum
ump
p Repair or replace
Raditor
• Clog
Clogged
ged w
with
ith rus
rustt an
and
d scl
scle
e Clean raditor
• Clogged w
wth
th iron oxde due to leg
lege e . . . Clen cool
coolnt
nt passa
passagege and
of exhust nto ooling sstem . . . . . Correct exhau
exhaust
st leakage
• Clogged rdt
rdtor
or cor
core
eddue
ue to mud
mud Clean raditor
or other debrs
• Def
Defe
eve
ve rd
rdt
tor
or cap pres
pressur
sure
e vlve Replace radtor cap
Abnormal combust
combuston
on
• Inco
Incorrec
rrectt n
njec
jecto
ton
n tm
tmng
ng Adjust njecton tmng
• Reduced n
nject
jecton
on pressure
pressure . . . . . . . . . . Adjus njecon press
pressure
ure
• Poor fuel . . . . . Use good qult fuel
• Poor nozzle spr
spra
a . . . . . . Adjust or replc
replce
e no
nozzle
zzle
• Unst
Unstsfac
sfactor
tor automatc
automatc tmer
tmer adv
advne
ne angle Repa
Repar
r or rreplc
eplce
e tme
tmer.
r.
Other problems
• Defective or deter
deterorate
orated
deengne
ngne ol . . Change engne ol
ol
• Unst
Unstsfto
sfto
oper
operatio
ation
n of oil pump
pump . Rep
Replae
lae or rep
repir
ir
• Insuic
Insuicent
ent ol . . . Add oil
• Brke drag . . Repai
Repairr o
orr adju
adjust
st
Excessive ol onsumpton--
-
-
Pistons, lnder liners, and piston rings
• Wear of piston rng and lnder lner Replae pston rings and lnder
liner
• Worn, stickng
stickng or broke
broken
n p
pston
ston rng
rngss Replae piston rings and lnder
liner
• Insucent tenson
tenson on piston rings Replae piston rrngs
ngs and linder
liner
• Uns
Unsatis
atisfa
fator
tor br
break
eakin
in of pisto
piston
n rngs Repace pston rings and clnder
liner
• Unsu
Unsuit
itab
able
le oil (visosit too low) Chnge oil as requred nd replae
pston rings and clnder lners
• Inco
Incorrec
rrectl
tl fie
fied
d pi
pisto
ston
n rngs
rngs Replace pston rngs
(upside down
• Gaps of piston rrngs
ngs in line wth eh other Reassemble pston rings
EN-22 ENGINE
Symptom Possible cause Remedy/Preventn
Excessive oil consumption---- Valve and valve guides
• Wo
Won n val
valve ve ste
steam
am Repace vave and vave guide.
• Wo
Worn rn va
vavvee gui
guide
de Replace valve guide
• Incorrectyy fied vave stem seal .
Incorrect
Repace the stem sea
• Exce
Excessiv
ssivee lubica
lubicant
nt on
on ocker
ocker am
am Chec cearance of rocker arm and
shaf
Excess oi I feed
• Defective
Defective oil level
level gauge
Replace oi level gauge
• Oi
Oill lev
levelel too high
high Dain ecess oil
Other problems
• Ovecoole
Ovecooledd engine
engine (low
(low tempea
tempeature
ture wear) Wam up engine before
befo re moving
vehicle Check cooing system
• Oil leaag
leaagee fom misc
miscella
ellaneo
neous
us pas
pas Repair
Piston seizue -
Operation
• Abupt stoppage
stoppage ofof engine
engine aer unning
unning Opeate engine propely
At highspeed
• Hil cimbing
cimbing using unsuitabe
unsuitabe gear Select suitable gear
• nsu
nsui
icicienentt oil
oil Add oil
• Diy oil . Change oil
• Poo
Po o ququalalitityy oi
oill Replace with proper
proper engine oil
• High oi te tempe
mpeat atue
ue .. . . Repair
• Lo
Loww oil
oil pressu
pressue e .. Repair
• De
Defe
fectctivivee oil pump
pump ... Repair oil pump
• Reduced peomanc
peomancee ddue ue toto won
won oil Replace oi pump
pump
• Suctio
Suctionn strain
strainee suci
sucing
ng air
air Add oi and/or repair strainer
Abnorma combustion See Symptom: "Engine
oveheating
� .... See Symptom Engine
oveheating
ac of power ------ njection
njection pump
pump Refer to CHAR P, FUE
NJECTON PMP
ntake
• Clog
Clogge
gedd air
air ce
cean
aner
er Clean element or epace eement
Oveheating .
See Symptom
"Engine overheating
ENGINE EN-2-3
Symptom Possible cuse Remy/Prevenio
Remy/Prevenio
Lack of power
power -------- Fuel an
and
d nozl
nozle
e
• Po
Poor
or nozz
nozzle
le spry
spry Adjust or replace injection nozzle.
• Clo
Clogge
gged
d noz
nozle
le with crbon
crbon
.
Clen nozzle.
• Wear
Wear or eizure
eizure of noz
nozzl
zle
e .. Replace nozzle.
• Ai
Airr iin
n fuel
fuel ys
ysem
em Repir and bleed air from fue
ystem
• Clog
Clogge
ged
d ffuel
uel f
fl
ler
er Replace elemen
• U
Ue
e of
of poor
poor fue
fuell
.
..
...
.. .
. .
.
se goo
good
d quality fuel
Abnormal combustion See Symptom:
Engine overheing"
Piston, cylinder liner, and piston ring See Symptom "Engine over
heting"
Other problems
• Brea
Breakge
kge of tur
turbine
bine or blowe
blower
r Replace the turbine or blower or
turbochrger
Diicul aring engine ---�- Elecricl
Elecricl yem
• Disc
Discha
harg
rged
ed bte
btey
y harge baey
• Defec
Defecive
ive wiring in taer ci
circui
rcui . . .... Repir wiring of staer
ooe or opencircui
opencircui batt
batte
e ca
cable
ble ..
...
. Tighte
Tightenn ba
battery
ttery erminal conne
connec
c
tion or replace baery cable
• Brea
Breakd
kdow
own
n of arte
arterr .
..... ... .. .
... Replace sarter
• Break of glow plug or intke
. . Replce
air heater (f so equipped)
Inection pump Refer to CHAPER P FUE
NJECTN PUMP
Ai cleaner
• Clog
Clogge
ged
d eleme
element
nt Clean the element or replace
re place he
elemen.
Fuel yem
• No fu
fuel
el in ank
ank Supply fuel and bleed air from fuel
ytem.
• Clogged fue line . .
... . . . .. Clean fuel line
• Air u
ucke
ckedd into fu
fuel
el y
yst
stem
em hr
hroug
ough
h ighen fuel line connection.
fuel line
line connecio
connecion
n
Co
Cogge
gged
d fue
fuell fil
filer
er
. .. .
. ..
. .. Replace element.
oo
ooe
e co
connecio
nnecio
in highp
highpreu
reure
re line
line Tighten leee nu of high pre
ure line
• Waer in fuel .. . .
..... ..
. . Drain and clean fue yem
EN-2�4 ENGIN
Sympom Possible cuse Reedy/Prevention
Diculty staing engine - Nozzes
• Seize
Seized
d beari
bearing
ng . . . . . . Repac
Repace
e nozze
nozze
Broken of faigued nozze spring Repace spring
O sysem
• Oi
Oi vi
visc
scosi
osiy
y oo
oo h
high
igh Use proper viscosity oi, or insa
a oi immersion heater and warm
up oi.
Oher probems
• Seized pston . . . . . . . . . . . . Repa
Repacece pison, pisto
piston
n rings
rings and
iner
• Seize
Seized
dbbearin
earing
g . . . . . . . . . . . . . . . . . . . . Repace bearing
bearing a
and/or
nd/or cranksh
cranksha
a
• Reduced compresson pressure . . . . . . . Overhau engine
• Ring gear damaged or orn . . . . . . . . . . . Repace the ring gear
gear and/or sar
sarer
er
pinion.
• Impropery adjused or broken . . Adjust or repace he acceera
acceeraor
or
acceeraor cabe cabe
Rough ding
Injecon pump Refer o CHAPTER IP, FUEL
INJECTION PUMP
Nozes
• Une
Uneven
ven nje
njeci
cion
on pressu
pressure
re Adjus
• Poor nozze spray
spray . Adju
Adjust
st or repace nozze
• Carbon depo
deposi
si on nozze tip . . . . . Remov
Remove
e carbon
carbon
• Seize
Seized
d neede vave . . . . . . . . . . Repa
Repace
ce nozze
nozze
Engne proper
• Imp
Improp
roper
er v
vav
ave
e c
cear
earanc
ance
e Adus vave cearance
• Impro
Improper
per conac
conac of vave
vave sea Repa
Repace
ce or repai
repairr vave
vave and va
vave
ve
sea
• Idin
Iding
g speed
speed oo ow . . . . Adjus iding speed
• Cooan empera
emperaure
ure oo o Warm up eng
engine
ine
• Comp
Compress
ression
ion pressure
pressure of cyi
cyinders
nders . Over
Overhau
hau engin
engine
e
markedy dieren from one anoher
Leakage of exhaus Cynder head gaske
• a
aigu
igued
ed gas
gaske
ke (ag
(aging
ing)) Repace gaske
• ama
amage
ge . . . . Repac
Repace
e gaske
• Impro
Improper
per insaa
insaaion
ion . Repac
Repace
e gaske
gaske
ENGINE EN-25
Symptom Possible cause Remedy/Prevention
Remedy/Prevention
Leakage of
of exhaust __
__ Cylinder head bolts
• o
oos
ose
e bo
bolt
lts
s . .
..
. Tighten bolt
• El
Elon
onga
gated
ted b
bol
olts
ts ..
..
.
. Replace bolt
• Imp
Imprope
roperr tight
tighteni
ening
ng tor
torque
que o
orr Tighten properly
tightening seuence
Cylinder block
• Crac
Cracking
king .
..
.
..
..
Replac
Replace
e ccylind
ylinder
er block
• Sua
Suace
ce di
dist
sto
oio
ion
n
..
Repair o replace
• Fre
Freing
ing of cli
clinder
nder liner inse
inseion
ion Replace cylinder lner or poion
(insuficient projection of clinder block.
cylinder liner)
Cylinder head
• Crackin
Cracking
g .
.
..
..
Replac
Replace
e cclind
linder
er head
• Su
Sua
ace
ce di
dist
sto
oio
ion
n Repair or replace
Clinder liners
• Crac
Cracki
king
ng
. Replace clinder liner
• Coo
oosi
sion
on ..
.... Replace cylinder
cylinder liner
• nsu
nsuicient
icient projec
projection
tion of c
clinde
linderr liner Replace cylinder liner.
Other pobems
• ncoect injection timing .. Adjust injection timing
ENGINE -3-1
ENGINE OVERHAUL CRITERIA
SPECIAL TOO
Prior to startng an engine overhaul, t is necessary to have these special tools.
COMPRESSION COMPRESSION
GAUGE ADAPER GAUGE ADAPTER
09408-1010 095521030
FACTORS WHIC DETERNE WHE AT ENGINE OVERHAUL IS
NEEDED
1 Lowered compresson pressre
a Before the measureent
a) Correctup
Warm theengne
valve clearance
[Brng the coolant temerature to about 80 C
b °
{176 F]
°
c Charge the batery fully
d Reove the ar cleaner
b Measurement
a) Remove the six nozzle holders
b) Install the gauge adapter n the nozzle holder hole
Special Tool: Compression Gauge Adapter (094081010)
(095521030)
c Connect a copression gauge to the gauge adapter
d) Drve the engne with the starter an read the copresson
pressure
SM3-388 NOE Do not continuously operate the staer for more tha 15
seconds at a time.
e Measure the com
compresson
presson pressure fo each cyln
cylner
er If the
compression pressure s low be sure to repeat the measurng
NOTE B sure n o leak though sealing face
Unit: MPa {kgf/cm2, lbf/n }
Com- Comprssion prssur
Engin Dierence betwen Engine spd
pression
model ach cylinder (r/min)
ratio Sandard Limt
353382
H07D 197 2 75 {28, 398}
339, 512}
H07DT
30333 ess than
175 25 {25, 356} 280
{313 13} 029 {3 43}
H07C
H07CT 3372
185 2
275
75 {28, 398}
{338 90}
EN-32 ENGINE
EXAMPLE 2. Decreased oil .pressue
Check the oi pressure warning lamp wen te o a coolant
temperature s ot [about 80 C {176 F}]
°
r-7
a If the warnng amp is ighted, check te oi eve
I'9 b Check oi deteroration
f o quaity is poor repace wit a sutabe grade oil
OIL c. Remove te oi ·pressure swtc and insta the oi pressue
-
gauge
d. Measure te oi pressure at cooant temperature 8 {16 F or
S3-349
more
Standad oil pressue: 49-490 KPa {0.50 kgf/cm2,
711-7110 lbf/in2}
ATOSPHERIC EPERAURE
SAE.
Sevice imit Less than 49 KPa 05 kgf/cm2 711 lbf/in2}
GRADE -10 0 32 50 70 9000 OF
I
I
3 Other factors
238 0 0 2 32 39 oc
a Th
The
ebbo
ow-
w-by
by gas
gas inc
incre
reas
ases
es
40
b The engine does not stat easiy
30 c Engne output decreases
d Fue consupion increases
increases
0W/0
e ngne makes greater noise
15W/40 f xcessive o consumption
ENGINE EN-41
ENGINE MOVING PARTS
DESCRIPTION
15 16 17 1 2 3 4
14
1 3 7
12
8
1 10 9
SM3-2422
Repreentative engine model H07C H07CT
1. Valve 7 Cylinder lner 13 Tap
Tappe
pett
2 Nozle holder 8 Conneing rod 14
14 Ol coo
coole
lerr
3. Piston 9. Cranksha 15
15 Push
Push ro
rodd
4. Piston pin 10. Ol strainer 16 Valve
Valve rock
rockerer s
sha
ha
5 Intake manfold 11 Oil filter 17
17.. Ro
Rock
cker
er aarm
rm
6. njection pump 12 Camsha
Hino Diesel Engine Parts
Contact email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www .HeavyEquipmentRest
.HeavyEquipmentRestorat
orationPart
ionParts.com
s.com
EN-42 ENGINE
SPECIAL TOOL
Pior to saing an egine ovehaul,
ovehaul, i is necesay o have thes pecial tool.
IDR GEAR SLIDING NOZLE HOLDER ADAPTER
HAMMER (used wih 09420-12) CYLINDE HEAD BOLT WRENCH
09420-1 094621130 09411-100
VALVE SPRING PRESS VAE PG OO VAL VE S SEAL PESS
09470-1022 094311010 09472-170
SE BAL (or noze eeve, INJECION PUMP DRIVE
BAR (For nozle sleeve) sed wih 094721210) GEAR PULLER
0942-1210 980006100 094201680
INJECTION PUMP DIVE INJECTION PUP DRIVE
RONT OIL SEAL PRESS SHA SLEEVE PULLER SH SEVE PRESS
�
092-1090 09420-1670 (Model H07D) 092150 (Model H0D)
ENGINE -43
O-RING (Used with 0921850) PISTN NG EXPANDE CYLINDER NER �ULR
0
985136104 (Model H07D) 09210 094201210
FR OIL SEAL SLEEVE REAR OIL SEAL SEVE FRNT IL SEAL SLEEVE
PU PULLER PRESS
0942007 09420420 094021210
For Piston cooing jet
EAR OIL SEAL SLEEVE PESS CYLINDE LINE GUDE CONNECTOR BLT
092100 090040 90024262
GAUGE TARGET PLATE ADJUSTNG BAR
0970110 (M 07CT) 09120 Ml 07D) 0972620
EN-4-4 ENGINE
GUID PRESS SUBASSEMBLV WNG NUT
(For pon pin bushng) (Fo pston pn bushng) (For pston pn bushng)
091-1130 (Model H07C 094021450 (Model H07C-T) 9233-10360 (Mode H07T)
SPINDL GUDE BOLT
(For pon pn bushng) (Fo pston pn bushng) (For pston pn bushng)
402-10 (Mode H07D) 0911170 (Mode HD07D) 9191-08252
094021440
094021440 (Mode H07CT) 0911110 (Mode H07CT)
PISTON ING HOLDE WIRE EE BLT
11041 4911010 093-1061
ENGINE EN-4-5
IMPORTANT POINS - DISMOUNING
DISMOUNT THE ENGINE ASSEMBLY.
WARNING
To avoid the danger of burs, do not drain the engine oil and
cooant whie the engine and radiator are sti hot.
1. Drain the coolant from radiator and cyinder bock and engine oi
2 Disconnect the fue lines, cooant i
ines,
nes, air ines electric lnes and
engine control cables
3 Disconnect the intake and exhaust systems and equipment
4 Connect cable fro an engine hanger to the hanger bracke (1
point) on the front of the engine and to the hanger brackets (2
points) on the upper fywhee housing at the th e rear of the engine
Using a hoist raise the hanger it so that
t hat there is a bit of slack in
the cables
5 Remove the engine mounting nuts front and rear both sides)
6 Lift the engine hanger so that the cables are fully tightened
and then
and then aer
a er heking that the cables are securey hooked on
the hanger brackets i the engi
engine
ne assembly gently an andd remove
remove
it from the vehcle
SM3-1766
IMPORTANT POIN - MOUNTING
O THE ENGINE ASSEMBLY
Mounting of the engine is reverse sequence of dismounting
EN-46 ENGINE
CYLINDER HEAD
HI NO H07
H07 C H07CT H
H07CT 07 D H
H07 07DT CY
H07DT CY L
LI ND ER HEAD
HEAD P ARTS OVRHAUL
ARTS
T = 181. {,80, 1338}
ightening torque: N-m kgfcm lbf
CYLINDER HEAD AND RETED PARTS
Cylinder head cover 5 Cylinder head
2 Oil
Oil fill
filler
er ca
cap
p 6 Cylinder head gaket
Ventilator 7 Cylinder head additional bol
4 Cylinder
Cylinder hea
headd cove
coverr ga
gasket
sket Cylinder head bolt
ENGINE EN-47
HINO H0 7C H0 7CT H
H0 7D H07DT CY LINDER HEAD PARTS OVERHAUL
T = 4.13 {, 32}
T = 8336 {85, 61}
T = ightening torque: N-m {kgfcm, lbf}
lbf}
1. Cylinder had 12 Reainer ring 23. Valve spring upper sea
2. Cnnecor bl 13 Rcker arm sha 24. Inner valve spring (f s fied)
3. S washer 14 Valve clearance adusing screw 25..
25 Outer valve spring
4 Fuel injecin nle hlder 15 Bushing 26. Valve sem seal
5. Nzle 16 Rcer arm 27. alve spring lower sea
6 Packing ring 17 Rcker arm supp 28. Valve
7 Fuel injecin
injeci n nle sleeve 18 Spacer 2. Push rod
8. 0rng 19. Spring 30..
30 Tappe
9 Vale guide 20 Plain washer
10 Plug 21 Valve se cap
11. ale sea 22 Valve sem key
HINO ENGINE PARTS CONTACT: EMAIL,
EngineParts@HeavyEquipmentRes
EngineParts@HeavyEquipmentRestorationParts.com
torationParts.com Phone: 269 673 1638
EN-48 ENGINE
IMPORTAN POINTS - DISASSEMBLY
REMOVE THE FUEL PIPES AND NOZZLE ASSEMBLY.
Refer to "INJECTON NOZLE in SECTION FUEL SYSTEM.
C* 0• © ! ®
0 0 ¢0 0
0 0 0 0 0 0 REMOVE THE CYLINDER HEAD AND ROCKER ARM ASSEMBLY
1 Remove the cylider head additioal bolts lile by lile
li le three
0 0 0 0 0 o .
stages and in the uerial order as shown
0 9 O SM3-415
SM3-415
2
2 Remo
Remove ve the
the roc
rocke
kerr arm
arm supp
suppor
or bo
bolt
lts.
s.
oosen the ocker ar suppo bots and cylinder head bolt lile
6 4 by itle i three stages ad i the numerical order as shown
S3704
3 Remove the cylide head bots
Loose the ylide head bots ie by ile i three stages ad
i he eca oder s sow
LI THE CYLINDER HEAD FROM THE DOWELS ON THE CYLINDER
BLOCK AD PCE ON WOODEN BLKS.
f the ide
ide head s dift to f of, with a hisel bewee
the de head ad bok
_ C
P�
ER B:CKP�L l Y
U PANDOWN
NOTE: o not damage the machin suace of tthe
he head or block
block
ER y
ONL
when emoving the cylinde head
Special ool Eye Bolt (094331061)
Wie (094911010)
SM3-892
REOVE HE VAE SINGS.
e
ee
e th
the
e a
a
e
e ste
ste e
es
s
e
e s
s
seats
seats ad ie (If
ie
so ed) ad ote ae ss fo de head
pial ool alve ing ess 0470102)
ee the take ad exhast ales
' SM824
ENGINE EN-4-9
3. Tag valves to id�ntfy their cyliner numbes and to leave out
the valve lappg
IN
! 1
exI
2 3 4 5 6
SM3-98
IMPORTANT POINTS - ASSE
IMPORTANT ASSEMBL
MBLV
CLEAN THE CYLINDER HEAD HOOUGHLY WIH A SUITABLE
SOLVNT.
NOTE: Be c
careful
areful not to damage th
thee cylinder head suace
SM382
IF NECESSARY, HAND-P TH VLV ND VALV SAT
Lghtl appl lappg compound to the valve face Istall thethe
valve wth a specal tool, tap and rotate the valve agast the
seat.
Special Tool Valve Lapping Tool (09411010)
SM3-3
IF NECESSRY GRIND THE VALVS ND VALVE SETS
NOTE Grinding of valve and valve eats should only be per
formed when handlapping doe not result in proper
seating
Aer grinding, always recheck the valve sin
Valve ace angle and valve eat angle
Refe to SECTON DATA AN SPECFCATONS
°
45
INTAKE XHAUS
SM389
EN-410 ENGINE
IF NECESSARY, REPCE THE VALVE SEAT
1. Cut the circumference of a valve head t three plces wth
grinder and install
install it into the seat as shown nd weld the vlve to
the seat. Then drive the vve nd the set out wit
with
h a hm
hmmer
mer nd
a brss block
ELECTRI WEDNG
VALE APPLE
RND HS PON
H A RNDER SM3-89
SM3-895
5
2 Vle set sectio
sectionn mchining speciictions
Unit: mm {n}
Intake Exhaust
A
52.0052019 55045516
Clinder {20472-20479} {17913-17919}
30"
head
A dimenson
B 9.5- 97
97 9597
IKE EXHAUST {037381} {037381}
520852100 453-4545
�- Valve seat
dmension
C
{20502.0511} {1
{17961
79617970}
� ST 77
7.5 77
{0293031}
8082
{031322}
S3896
3 Vle set instlla
instllation
tion
Hett thecylin
He thecylinderhedto
derhedto bo
bout8
ut80
0 -100 {17621 F}with hot
° ° °
wter On the other hn, cool the alve set with d ice or liquid
freon for bout 30 minutes
minutes Hold the set with pincers and plce
it into the heted cylinder hed
SM3826
IF NECESSARY, REPCE THE HINO H07C H07CT H07D H07DT VALVE GUIDE
CYLNDR HAD Remoe the lve stm sel
2 Usin bss od nd hmmer, dive out the vle uide
A 1. Instal the alve uide
-B NOTE: Apply engine ol lghtly to the valve g
gude
ude outer circmfer
ence before nstallng.
C D
Dmension A 23
2375
75 mm {0935 n} C 4
475
75 mm 3337 in}
B 2225 mm {0876 n} D: 625 mm 3396
3396 in}
SM3389
IF NECESSRY REPCE TE VALVE TEM SEAL
1 emove the vlve stem seal
nstall the valve stem seal
First, install the lower sprig seat aand
nd vlve Then pply engine
oil to the lip of the stem seal nd drive the stem sea with a special
tool
Specal Tool Valve Stem Seal Press (09472-1770)
SM3984
ENGINE EN-4-11
NOTE: 0 Aer installing stem seal, make sure that ceck the rubber
rubber
RUBBER
position for cracks or any other damage.
0 Do not use the special
special tool if its tip (suace contacting
lower spring seat) is worn or deformed
SM3-709
IF NECESSARY REPLACE THE NOZZLE SLEEVE
1. Remove the nozzle sleeve
Place a ·brass rod with a diameter of 12 m {047 in} at the nozzle
hole at the botto of the cylinder head and reove the clinde
head by hiting the nozze seeve
SM947
Istall the nozzle sleeve.
Set the O-in into the clinde head
Apply adhesive (Super Three Bond No1210 or eqivalent) to the
lower part of the new copper nozzle sleeve and carefully insert
the nozzle sleeve into the cylinder head
NOTE A damaged O-ring may cause leaks and lead to overheating
or cracked heads
3 Sti
Stick
ck tthe
he noz
nozzle
zle se
seeve
eve fas
fas tto
o tthe
he cyl
cylder
der hea
hea y pre
pressi
ssing
ng w
with
ith
the special tool
lnsert the seat press (Special
(Special tool into
into the ozz
ozze
e seeve Psh the
ball lttle y ie through the hole wth the special
special too So that
the end of the nozze leeve wth stick fast to the cylinder head
Special Tool Sleeve Bar 9472-121
Steel Ball (98-61
SM9
ASSEMBLE THE YLNDE HEAD
NOTE Apply engine oil to contact surfaces o all pars
Make sure that the valves are installed in the correct
cylinders
Install the valve sprin
springs
gs with their painted side dow
down
n
since the have variable pitches
PAINT
186
EN-412 ENGINE
Press upper spring seats and istall he valve ste
ste eys securely
the upper sprng seats.
S Too V S (0947-1022)
NOTE: W w , f o
o m m
o
D m w mm o
o f m k
ASSEMBLE THE
T HE ROCKER ARM
ubcate the rcer ar sha ad bushg
NOTE: M o m
w "U
m o w
UP Io m z of m
___A
TIMING
GEAR SIDE
SM3-857
NOTE: ofm o o
o of ok
m
m m No o
N0.1 UPPOR
w o o
o Imo o
o w
of m
ITKE EXHA
3-938B
INSTALL THE
T HE YINDER HEAD AND ROKER AR ARM
M ASSEMB
e
e
ee t te
te
e
e e
e
e
e
e
e
e
e
e
e
te st te e e
stall te cylder head gaset
NOTE Aw w
of , ok
f of , w
3 stall the cylder head ver the dels the cylnder blc
SM3531
se te push rds n crrect rder aer applyn
applyngg enge l t
bt eds
5 unt the rcer ar assebly tthe
he clder head ae sure
hat the push rds terlc t the adjustg scres
NOTE Aw oo ok w
f o
o o
HINO DIESEL ENGINE PARTS
CONTACT EMAIL:
SM342 EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
ENGIE EN-413
6. Tighten the cyider head bots ad cyinde head addtional
En
bots(* Mak bots) i thee stages fowg the tightenng ode
as shown.
0
(
NOTE: Apply engine ol to the bolt threads and under the bolt head.
w
0 _
w No 1 - No 26 Bolts (Clind
(Clinder
er head bolt)
bolt)
e
z J
< �
No 27 - No 32 Bolts Clinder head add
additional
itional bolt)
>
_
Special Tool Wrench 094111070)
7 Tghten the ocke am suppo bots i thee stages olowg the
tighteg ode
Tghte the bots to
t o the specified toque at each stage
SM3-74
INSTALL THE NOZLE HOLDER
Refe to "INSPECTIO NOZLE in SECTIO FUE SYSEM
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRe
www.HeavyEquipmentRestorationParts.com
storationParts.com
EN-4-14 ENGINE
INSPECTION AND REPAIR
Unit: mm {n}
Ispeco Ie Sadard L Reedy Ispeo Procedure
Cylder Head Flaess Less ha 005 0 Regrd or
0.0019 00039 replace
a dreo A
Less ha 003
00012
a dreco B
Cylder Hed Hegh (H) 9495 947 Replace
37362-370 37283
Cylder Head Cracks ad Replace
Dage f ecessry
* sg a Dye Pee
Peera
ra
Nozzle Proruso fro 227 Replace ozzle
Cylder Head Suce 0083�06 sleeve sleeve
SM3-391
Valve Seag Codo There should be good
good Hadlap wh
* sg Re
Red
d Lead Mar
Markg
kg coac roud lappg co
Copoud ere crcuferece poud
o alve head
uSM3-833
Vlve Sk Ike 06595 2 Replace valve
002500374 00472 d/o
valve se
Exhu 545 7
0053�0570 00669
S3420
ENGINE EN-415
Unit: mm {}
Inspecton Item Standard Lmi Remedy Insption Predure
Valve Seat Angle Intake 30 0 30'
°
Regrind or
replace valve
Exhaust 45 5 30'
and/or valve
seat
Valve Face Angle Intake 29 30'0
u�
30V S 45
0
Exhaust 45•
INTAKE EXHAUS
SM-899
H ino H 07C H 07CT H 07D H 07DT 8947.965 890 Replace valve
Intake Valve Stem Diameter {035-35} {03504} guide and/or
valve
H ino H 07C H 07CT H 07D H 07DT 8932950 880
Exhaus Valve Stem Diameter {03717-3724} {03465}
H ino H 07C H 07CT H 07D 902035 91
H 07DT Intake
and {03551-3557} {03582}
Exhaust Valve Guide
Diameter SM85
Clearance beween Intake 005085 018 Replace valve
Valve Stem and {00022-0033} {0070} guide and/or
and/or
Valve Guide valve tem
Exhaust 0070-103 023
{000200} {00091}
Valve Spring Inne IN 1412N Replace
Seing Load (If so {144kg f , 3174Ibf} f necessary
fed) at 472 {185}
Ex 1303N
{142kgf 3130Ibf}
at 47 4 {186}
Oute IN 50N Replace
{413kgf 9104Ibf}
at 502 {197}
224
Ex 3981N
{406kgf 890lbf}
at 504 {198}
Valve Sping Seat fo Wea 200 Replace
{0078} if necessary \
�
EN-416 ENGINE
Unit: mm {n}
Io em Sadar L Reedy Ispeco Procedure
Procedure
H ino H 07 C H 0 7 C T H 0 7 D Replace Vsual chek
H 07 DT Vlve Sprg Set
@ �
for Wer
SM3-529
Rocker Ar Shaf Daeer 24.1524 180
180 2412 Replace rocker
{011-9520} {0.9496} ar bushg
d/or sha
Clearace bewee Rocker 0.03101 05
Ar Sh ad Bushg {0.0012-0039} {00059}
SM3836
H ino H 07 C H 07 C T H 0 7 D Resuce or Vsual chk
H 0 7 DT Rocker
Arm ad replace
Vale stem p Wer or
Damage
� @ SM3930
f
Push Rod Bed 025 Replce
{00098}
SM39
i=
Adjug Screws ad Replace Vsual check
Push Rods Daage
I
"� SM3419
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRes
EngineParts@He avyEquipmentRestorationParts.com
torationParts.com
Phone: 269 673 1638
Website: www.HeavyEquip
www.HeavyEquipmentRestorationPar
mentRestorationParts.com
ts.com
ENGINE EN-417
Inspction Item Standard Lmit Remedy Insption Procedure
Tappet Diameter 31.951975 31.92 Replace tappe
{1.25712589} {12567}
-"� �
Tappet Guide Insid 32.002025 32.05
I:
.
I
�·
Diameter {1.25912608 {12618}
Cearac betwn Tappe
and appet ide
0.02075
{000100}
010
{0.0039}
�(-
SM3-949
S320
Tappet for Wear Should ot e wor - Replace, if Visual hk
unevely. essa
EN-4-18 GI
HINO H07C H07CT H07D H07DT TIMING GEAR, CAMSHAFT
AND OIL PAN
OVERHAUL
SM3-241
T = Tightening torque: N-m {kgfcm, lbf }
1. Cl
Clininde
derr blo
block
ck 8. Water
Water galler
gallery
y cover ga
gaske
skett 1 late seal
2 Val
Valve
ve pus
pushh rod cov
cover
er 9 Plug 1 T
Ting
ing gear cas
case
e cove
coverr
3 Val
Valve
ve push
push rod cover
cover gas
gasket
ket 1 Sof
Softt wa
wash
sher
er 1 Front en plate
4 0ring 11 Oil pan 18. Front en plate gasket
5. Flange 12 Oil pan gasket 19 Silent block
6 Inje
Injecti
ctin
n pup
pup brabracke
ckett 1 Oil level gage guie 2 Tachometer drive
7. Water galler
gallery
y cover gasket
gasket 1. Oil level gage 21 Oil seal
ENGINE EN-419
HINO H0 7 C H0 7 CT H0 7 D H0 7 DT TIM ING G EARS VALVE TRAIN CAM SHAF T
1 B 2
7
\
.J
_ . I
\
_
SM3-236
4 5 A
OVERHAUL
T:274.59 {2,800203
T3138 {320 23}
9 4
3 SM3-437
T = Tightening torque N-m kgfcm lbf
1 Cams
Camsha haft
ft gea
gearr 8 Ca
Cams
mshahaft
ft 1 Bea
Bearin
ring
g holer
holer c
case
ase
2 Id
Idle
lerr ge
gear
ar 9 Thru
Thrustst pl
plat
atee 16
16 Oil
Oil sea
seal
3 Fue
Fuell inject
injection
ion pump
pump riv
rive
e ge
gear
ar 10
10 Bu
Bush
shin
ingg 17 Oring
4 Oil p
pum
ump p r
riv
ive
e ge
gear
ar 11 Pin A Match
tch m
maark
rks
s 1"
1"
Cran
Cranksksha
haft
ft ge
gear
ar 12 I
Iler
ler gea
gearr sh
shaft
aft Match
tch m
maark
rks
s 2"
2"
6 Camsha
Camshaft ft thrust
thrust plate
plate 13
13 Collar C Ma
Matc
tch
h ma
mark
rks
s 3
3"
"
7. Key 14 nec
nection
tion pum
pump p rive
rive s
shaft
haft
EN-420 ENGINE
IMPORTANT O
IMPORTANT ONT-
NT- DSASSEM
DSASSEMBLY
BLY
REMOVE THE CRANKSHA PULLEY
NOE: 0 Use a puer if necessary
0 Do not remove the crank
crankshaf
shaf ge
gear
ar unless i considered
absoutey necessary.
REMOVE HE IDLER GEAR SHA
Using a pecial tool, remove the idler gear ha.
Specia oo
Specia Sding Hammer {942
{942-1442)
-1442)
REMOVE THE CAMSHA
Remove the thrut bearing fttng bol and ull out the camhaf
camha f
with gear from cylnder block
NOTE P the camsha, sowy turning t so as not to damage he
eangs
SM3-839
IF NECESSARY REMOVE HE CAMSHA GEAR AN INJECTION
PUMP DRIVE GEAR
Hold the haf aembly wth a vce through wooden plate
Remove the nut then uing a gear puller, remove the gear
SM3-841
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationPar
www.HeavyEquipmentRestorationParts.com
ts.com
ENGINE EN-421
IMPORTAN POINS - ASSEM
IMPORTAN ASSEMBLY BLY
IF NECESSARY REPLACE THE FUEL IN JECTI JECTIO
O PUMP DRVE SHA
OIL SEAL SLEEVE.
1. Using a special tool, remove the sleeve.
a Put the pulle ( 1 ) (2 onto the sleeve
b Inse the hook poion of the pulle beteen shaft and sleeve
C Inse the pulle (3).
d Afe inseng the puller screw in the cente olt (4) then
DRIVE SHAF
remove the sleeve.
Speciall Tool:
Specia Puller Assembly (09420-1670)
SLEEVE
2. Using special tools inset the shaft sleeve ith a new 0-ing.
a Put the 0ring (5) into the press (6)
Inset the new oil seal sleeve ith new 0ing into the ess and
then inset them into the dive sha
. Hitting the A) lightly
yy hamme contact the press end and the
shaf end (8) with this deteine the oil seal sleeve position
NOTE Be sure to fit an Oring on the sleeve ad also apply a liberal
liberal
coating o oil to the sha
When driving on the sha sleeve, taking care that the O
ring does not get cut or torn.
Once a sleeve has been remov
removeded it cannot be rreused
eused
Special Tool Press (094821850)
(094821 850)
Oring 985136104)
O-RING SM3-1992
D C:
85258 {3355-377 }
SM371
EN-422 ENGINE
IF NECESSARY, REPLACE THE TIMING GAR COVER OIL SEAL
. Using a screwdriver, remove the oil sea
2 Inst the
the new o
oiil se
sea
Special Tool: Press (0942-1090)
SM3-718
INSTALL THE INJECTION PUMP DRIVE AR TO T SA.
Fit the co thrust bering and key to the shaf
2 nsta the gear (1) heated to bout 00 {22 } on the shaf
°
NOTE Mke sure that
that the gear (1 is closely fied against the collar
(2) and s
sha
ha (3
(3)
)
INSTALL THE INO 07C 0 7CT 07D 0 7DT
CAMSA GEAR TO THE SA
nsta the camshaf gear wth thrust pate
NOTE When ins
inslling
lling he ge o he cms
cmsh
h
Het he ge in hot we [A ppox 0 C ] hen
[Appox °
insll he ge o he cmsh
cmsh by using a pess
When ightening he n ppl pply
y engine oi
oill o he heads
nd plate suce of he nu
INSTALL THE CAMSA
Lubrcate journs of the cmsha an inse the camshaft
assemb nto the
t he cnder boc
NOTE Inse the camsha slowly turning while inserting so that the
bearing will not be daaged
M3839
INSTALL THE IDLER GAR SHA
nsta the idler ger shaf with thst lte sing sic
hmme
NOT Be sure that the oil hole is downward if installed the wrong
way daage to the idler gear sht ad bushing an result
ENGINE E-423
INSTALL THE IDLER GEAR.
When instaing the der gea, be sue that the match maks of the
canksha gea camshaft gea fuel injection pump ve gea
and ide gea ae aigned coecty.
NOTE: 0 Inc
Incorect
orect installation can esults iin
n engine damage o
loweing of engine peomance by causing impope
injection timing
0 When tightening thethe bolt, apply engine oil to the thead
and plate suace of the bol.
MEASURE THE GEAR BACKLASH
Measue the ackash of each gea using a dia cato
Repace the gea f necessa
Refe to INSPECTION AND EPAR
INSTA THE TIING GEAR COVER
Refe to "QUD GASKET AD APPLICATON POIT
INSTALL THE OIL PUMP AND OIL TRAINER
Refe to "OIL PUMP AND OIL STRANER in SECTIO BR-
CATING YSTEM.
INSTAL THE CRANKSHAF PULLEY
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipme
EngineParts@H eavyEquipmentRestorationPa
ntRestorationParts.com
rts.com
Phone: 269 673 1638
Website: www.HeavyEqu
www.HeavyEquipmentRestora
ipmentRestorationParts.com
tionParts.com
EN-424 ENGINE
INSPECTION AND RPAIR
Unit: m {}
Inspection Item Standard Limt Remedy Inspton Procedue
Gear Teeth for Png r Replace, Vsual check
Wear f necessary
SM3-845
Ol Clarance Beeen 0.03080 020 Replace gear
dler Gear Shaf and {00012003} {00078} and sha
Bearng
SM347
dler Gear Ed Play 00095 030 Replace thrst
{00010037} {00118} bearn
Camsha Bend 005 Replace
{00020}
Camsha ntake 761 753 Replace
Cam ft {026} {2964}
H07D
(A-B) Exhast 901 893
{03547} {03515}
ntake 39
7.39 759
{02909} {02595}
H07C-T
Exhast 901 893
{03547} {03515} SM3374
Camsha End Play 010178 030 Replace thrst
{0000070} {00118} plate
ENGINE -425
Unit: m i}
Ispec
speco Ie Sadard Lmi Reedy Ispeco Procedure
Casha
Daeer Jour al N o
o1 1 {2 6411932 Replace
47 {2 61415354} casha
4514200}
Joural No. No2 051043}7 {2 636}95
{2 6132
No3o 3 {2 630872
60368857 } {2 630839}5 5 SM3-849
_O
l Cl eace
bee
No. 4
8
<2 � !·
.
s
5
� 2 > > 4 }-
{
0 _ 03 - 08 - _ 0. _ 2 0 Replacece amsh
�I
amsh f �
Casha
Bearg oural oural ad {000120031) {00078) ad/or bearg �
Craksha Gear - 0011 030 Replace gear,
SM3850
Timing
dler GearDrveIGear
IPup jeco ((0000002
02
0010043}
1043) {{00000118)
118}
30 f esay
Gear
Back
lash IGear
dlerer Gear Cash
Cashaa 0 0
{000200) 1 1 0{00118}
30
Casha
Ol Pup Gear Gear - {00002 0101043} {000118}30 SM38
ClIjearaoce Pup
beeDrve {000012
03000028}
72 {000118)30 Repl
ad/oracesha
bearg
Sha ad Bearg
M31005
IGear
jecEdo Pup Drv e 0{0003 00 {0003118}0 bear
10020079} Replace hrus
SM3008
Play
SM300
EN-426 ENGINE
HINO H07C H07CT H 07D H07DT PISTON,
CRANKSHAF, CYLINDER BLOCK AND
FYWHEE HUSING
OVERHAUL
For model HI NO H07D H07DT For model Hino H07C H07CT
; �� 7
I - 1
! 4lte2
I�
I
!
I
: 7 6 • .
I
l
L _
_ -
1 17
10
8 9
(- Color of nt Tightenig torque SM3-2431
Black T = 637 {6,500, 470}
T = Tighteing torque: N-m {kg,c lb-}
lb-}
Gol T = 40 {5,000, 362}
. Pisto rig 8. Nut 15
15 Cr
Cran
anks
ksha
ha
2. Pisto 9. Collar 16 Key
3 Pi
Pist
sto
o pi
pi 10 ranksha pulley 7 ing gear
4 Rai
Raie
err ri
rig
g 11. Torsioal dumper 18
18 Flyw
Flywhe
heel
el
5 Pi
Pist
sto
o pi
pi bushi
bushing
ng 12
12 Or
ri
ig
g 19 Ma
Mai
i be
bear
arin
ing
g
6 one
onei igg ro
rod
d 13. Sleeve 20 Thrust bearig
7 oect
oecting
ing ro
rod
d cap beari
bearig
g 1 ra
rank
nksha
sha
gea
gearr
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
HINO H07C H07CT H07D H07DT ENGINE OVERHAUL PARTS
= 21.57 {220, 16}
11
T = ightening torque· Nm {kgfc lbf-
1 Cylin
Cylinde
derr line
linerr 6 Cs haft bearing 11 • sel retaer gasket
Plug 1. Oil jet pipe 1 Oi
1 Oill seal retaner
seal reta
3 Pin 8 Soft washer 1 3. Oil sel
4 Seal plate 9 Cranksha bearing cap 1
1 Fly
Flyheheeel hou�
hou�ng ng
_ ring 10: Cylinde block 1
1 Flyw
Flywheheeel dst cover
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipme
www.HeavyEquipmentRestorationParts.com
ntRestorationParts.com
EN-4-28 ENGINE
IMPORTANT PINTS - DISASSEMBL
DISASSEMBLV V
REMOVE THE PISTONS WITH CONNECTING RODS.
0 1. Remove the carbon from the upper end of the cylinder lner wth
:o
a scraper or emery paper (recomended: No. 150) a crcular
drecton
-
SM3-359
2 Extract the pston and connectng rd assembly out thugh the
- top of the cylnder
NOTE: 0 Remove the connectin
connecting g rod in such a way that the con
necting ro oes not contat the cooling jet
Aust the cooling jet if by any chance the rod and the et
make
0 Arrange the piston an connecting
connecting rod cap
capss in orer
REMOVE THE HINO H7C H7CT H7D H7DT CONNECTING ROD
Reove the retaner rg nstalled
nstall ed on both ends of the pston
psto n pn,
by eas of retane
retanerr rng plers
NOTE: arm up the piston first in hot w
water
ater 8 9 C {176194
° °
for about 5 minutes before removing the pin
SM324
REMOVE THE PISTON RINGS
Special
Special Tool: Pisto
Piston
n Ring Expaner (9442111)
NOTE 0 Hanle the piston rings carefully bause they are ade of
a special casting hich is easily broken
0 Keep the rings for each cyliner sep
separate
arate
SM321
REMOVE THE CYLINDER LINER
Before removng
remov ng the cylnder lners be sure to put match
match marks
on the cylnder block and lner flange wth a pen
NOTE: 0 o not put match marks with a punch
Ater removing the cyliner liners, put
put numb
numbers
ers on their
periphery or arrange the in sequence
ENGINE E-429
Special Tool: Cylinder Liner Puller
(942-121)
SM3-852
INSPECTION THE INO 7C 7CT 7D 7DT
PISTON COOING JE POSITIONING.
NOTE 0 Do not remove the cooling jet except when peoring
overhauls or when otherwise necessary.
0 In the event that the cooling jet is removed, be sure to
replace it on the cylinder
Inspecton of the piston coolng jet postonng
poston ng pocedure ae as
foows
1 Remove the p ston coong et connecto bolt n nst l a spec
specal
al
too
Special Tool Conneor Bolt (9124262)
2. Use commeclly vlle ol pump [pessue out 2kg/cm2
{284 lb/sq.n}, flo te out 2.5Lmn {26 US qtsmn]
3 Pep
Pep
e
e f
fes
esh
h en
engi
gine
ne oi
oi
Connect the o ines
Connect the ol pump outet to spec tool (connecto bot)
CONECTOR
OIL HOSE BOLT
FOR INSPECTION
SM3579
Instll specia tool on the cyliner bock
For Model 7D
TARGET
PLE Special Tool arget plate (941
(94129)
29)
CYLIDE
BLOCK
SM3580
For Model 7CT
SPECIAL TOOL
Special Tool Gauge 947111)
NOTE Instal the s
special
pecial tool a
aer
er removing the cylinder liner from
cylinder block.
SM56
EN-430 ENGINE
6. Operate the ol pump, and wth pressure at about 196 KPa {2kgf/
cm2 , 2844 bfn} pump fresh oil rom the jet and peform a
spray test Conditons are norma f the center o strea ts a
target plate of 0 mm {039 n.}
WIG
Engine oil is fammabe.
This spray
spray test shoud b e done in a we ventiated roo and away
fro any open fames or eectric sparks
ABNORMAL NRMA
SM3-581
7 If the spray o the coolng jet e
esses
sses the cre on the target plate,
realgn then nozzle usng a speca tool
Specia Too: djuster bar (09472-1620)
Spray pattern
SPRAY
SPRAY ATERN When nspetng the pston ongjet postnnheth
postnnhethatthe
atthe
spray is spersed as shown n" 4 an not as n 1, 2 or
n the llstraton at left
V
l
�OLI NGJET TE If the tip of the je
repace the jet
jett is damaed so
so that the sray
jet with a new one When reacing
aern
aern is bad,
reacing the cooing
jet aways inspect the new iston cooing jet's positioning
'
2 3 4
NORMAL
ABNORMAL
M82
9. Ater inspectng the pston oong et postonng, remove the
specal tool (onnector bolt), then nstall the coolng jet on the
cylnder bo usng the orret mountng bolt wth sot washer
Tightening Torque 15 {220 kgf 1591 bf}
10 Ater instainthe pston, mae sure that there s no ntererence
ntererence
between the coolng et an the pston hen -the pston s at
bottom dead enter.
97
ENGINE E-431
INSERT THE CYLNDER LINER INTO THE CYLINDER BLOCK.
LINER IDENTFCATION MARKS 1. When a new cylnder ner s used, make sure tat te iner has
(THE ORDER S CYLNDER NO. 1 CYLNDR the same mark as te m
mark
ark on tte
e cyinde
cyinderr bock
NO. 2, . CYNDER N 6 FROM FORWARD
SD BACK.) \ NOTE: Cylinder liners and cylinder block are subject to se selective
lective
--�- fiing and so in case new cylinder liners are to be used,
confirm
confirm he m marks
arks W X Y and/or Z samped at the lang
lange
e
areas o cylinder liners and any combination of he marks W
X Y and/or
suace o heZcylinder
stamped collecively
block at he
Engine No upperground)
stamping or side
and inse the ones wih identical marks
FORWARD DRECTION OF VH CL
CLEE
POSITj°N OF t w, Y OR z.
A RK X,
I SM3-387
2. Wen reusng a ner nset te ner n ts orgna poston
agnng te markg marked before dsassemby
3 Appy a sma amount of cean engne o on te outer perpe
of the ner and appy pressure on te entre fange secton of te
of the
ner If nseon by
by and s dfcut se a cynder ner gude
and te cynder ner w easy be pushed n
Special Tool Cylinder Liner Guide (09480-1040
NOE: Do not use a liner hat has been rppe
Take exra care when handling
handling h
he
e liner since he liner is
easily deformed
MEASURE THE PRORUSION OF HE CYLNDER LINER FANGE
nsta a speca too and measure the protruson of te top end
of te cynder ner from te cynder bock
Special Tool Cylinder Liner uller 0942020
Tightening Torque 90Nm 00 kgfcm 723 lbft}
Standard: 00008 m
mmm 0.000003 in}
EN-432 ENGINE
IF NECESSARY, REPCE THE CAMSHA SEAL PLATE.
1. Remove the seal plate
CYLINDER BLOCK 2 Install the seal plate
Install the 0-rig to the seal plate, then ft it to the cyider bloc
0-RNG
NOTE: 0 As a general rule fit the seseal
al plate
plate on the cylinde
cylinderr block by
hand taking care to avoid damaging (cuing, tearing or
wisting) i Also coat
coathehe periphery of he O-ring with seal
compound (Three Bond 1211)
SEA AT 0 Do not re-use the sea seall plate aer removing it
M336
IMPORTANT POINT - ASSEMBLASSEMBLV
SPE OO IF NECESSARY REPCE THE OIL SEL SLEEVE
SE O
(FRONT AND REAR)
1. emove the oi seal sleeve using a special tool
Special Tool Puller (942171) for fron sleeve
Puller (942142) for rear sleeve
NOTE o not remove the cranksha gear unless it consi
considered
dered
absolutely
absolutely necessary
(FRONT SIDE) (RER SE)
356 M3566 2 nstal ew seeve
Be sure to fit a ew 0rig o the seeve ad aso appy a iera
coatig of oi to the puley ceter side at the front, and the
FRON SIDE) crankshaft side at the rear·
When drivig o the oil seal sleeve, use a oi sea seeve press
takig care that the 0rin
0ringg does ot get cut or torn
Special ool Press (942121)
(94212 1) for front sleeve
Press (948214) for rear sleeve
SECI TOOL
RR SDE
3985 M3568
Unit: mm {in} UNDER SZE BEARING FOR CRANKSHA.
Under uside diamete
size ank pin Journal
6471.69 79.71-79.9
0.25 {2547725468} 313823137}
.46
.464 74744
050
25372.5370} {1227}
14.1 792179.19
075
25282.5271} 311831177}
.9694 7897894
100
2518225173} 108731078}
Dimension of Fillet (R)
Cran Pin: 3842 m {15165 in}
Journal 335 {1181377 in
R, � ,1 � ' �
�·-
CC I._ WG----�
M3
ENGINE -4-35
[For model H07C-T]
1. Prepare th scial toos.
Assmbe te guide and pess sbemby seng its n n
WING NUT
he guid e secr them wt the wng
Special tools: Guide (0911130)
Pess sub assembly (094021450)
Wing nut (9233-10360)
NOTE Bing lv "H punched on the guide abov th the
e pin.
Making su to align both suppoing suacs
suacs of the guid
M3-1565 and pss sub assmbly flush on a flat plan
2 Using s ol,
ol, rv ison n n
CONNEIN ROD a. Se he concing od ssebed wiou
wiou k n b e-
n on he guide d ress sbssby
PRESS SB ASSEBLY
M566
b Ia e pde o he bushg
Special tool: Spind
Spinde
e (094021440)
NOTE: Align th gooving of th spindl with the oil hole of the
bushing
OIL HOLE PRESS
SUBASEMBLY
M1704
ESS
Us
Us
g
g hyd
hydau
aui
i e
ess
ss re
remo
move
ve he
he us
us
NOTE Always opeate th pess slowly and smoothly
CNNECTING ROD
M-1568
3. Asseb son in bsg
0.50 m Cmf on dg o th usng o a sm e o h
{00196093 in}
cncn d unfom b C 0510 m {09600393 }
NOTE: Igula chamfing can
can ccaus
aus out
outof-oundness
of-oundness of th
pessed bushing, which may esult in jamming duing
instion
Remo dust fom the inne suac of the smalln
smallnd
d hol
CNNECN
M31569
EN-436 EGIE
4. Mount the bushing on the spndle
a. Set the bushng and g ud
udee on the spndle, the secur
secure
e them wth
the bolt.
GROOVE Special tools: Spindle (09402-1440)
Guide (091-1110)
Bolt (9191082
(919108252)
52)
OIL HOE
GUIDE (A) NOTE Align oil hole (A) in the bushing with both groove on the
spindle and guide making sure oil hole (B) will meat with
GROOVE oil path in the connecting rod led from cank pin bore iin
n the
GUDE
SM3-170 rod.
Tightening torque of bolt
.06 N,m {070
{07 0 kgfcm 3.61.06 lb }
b. Aply the fesh engne ol aound the bushng and gude
� PRESS 5 Install the bushng n he onnetng od
Poston the ushng - tool assebly so that ol hol
hole
e (B) algn
OOLL HOLE(B ) - PIN
BUHIDL
DLE
N
GUDE N
E
G
th the ol ath though the onnetng od
NOTE Before installing fully coat the bore in the conne
with fresh engine oil
connecting
cting rod
PATHCONNEC ROD
6 Ins
Inspe
pet
t he
he b
bus
ush
hng
ng po
pos
st
ton
on a
ae
e nst
nstal
alla
lat
ton
on
a Make sue hat he ol hole of the bushng and the ol path of the
onnetng od ae sutaby algned allong a 6 m {0.23 n}
daete od to penetae
NOTE Misalignment can leads to insuicient lubricaion which ma
result in seizue.
b Make sue hat
hat a ne so n nsee
nseedd n the son n bushng
an be otated by hand thout alng
ASSEMBLE THE PISTON AND CONNECTING ROD.
Make sue that the 0ak at the to of the psto and the
onnetng od ath maks n opposte detons
NOTE Use the new retainer rings
Heat the piston to about 90 C {1719°F}
{1719°F} in hot water
°
about minutes.
M MKS S340
ENGINE EN-437
INSTAL THE PISTO RING.
1. nstall
nstall the pison
pison rrings
ings in he sequ
sequence
ence ol ring,
ring, hird
hird rrin
ing
g second
second
RING t
UPER
ring and op ring with he identification mark a the top of the ring
FACE facing up
NOTE: Apply oil to the piston rings
Special Tool Pston Ring Expander (0942-1011)
Z,oNI
MARK
SM3-2100 SM395
Descripton
RING No
H07D H07D H07C H07C
Top E �
2nd I a L
3rd -
Ol
a
2 Connec the ends of the coil expander and hen f he co inside
he pison ring afer ensuring tha the gap of the pison ring is
JOT 80 away from he join of he coil
°
�
GAP
SM3443
HINO H07D H07D 3 Arrange the pison rings so ha heir gaps are equall spaced
I 2ND RNG
SM3034
HINO DIESEL ENGINE PARTS CONTACT
HINO H07C H07C EMAIL:
0MAR
EngineParts@HeavyEquipmentResto
EngineParts@Hea vyEquipmentRestorationParts.com
rationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipm
www.HeavyEquipmentRestorationPar
entRestorationParts.com
ts.com
SM303
EN-4-38 ENGINE
INSTALL THE
THE PISTON WITH CONNECTING ROD INTO THE CYLINDE CYLINDER R
0 LINER.
�o 1 App
Applyly eng
engin
ine
e oil to the p
beang suface.
pist
iston,
on, c
cyli
ylinde
nderr line
line an
an
con
conne
necti
cting
ng od
)� MARK 2 Usin
Usingg a spe
specia
ciall to
with connecting
tool
ol ho
hold
ld tthe
he pi
pisto
ston
n ings
ings and push
connecting o assembly with a wooden o
NOTE: 0 Check the piston tha he O-mark on the top iis
push the
s on h
the pis
piston
ton
SM3-857 TAPPET CHAMBER
S3444
0 appe chamber
When insalli ng side
insalling the earings on he connecing rod and
ca, align the oi holes
When installing he pison wih conneconnecing
cing rod assemy
sure tha the piston cooling je is no sruck y the
connecting
connectin g rod If the piston cooling jet is struck adjus or
replace i
Speciall Tool
Specia Pison Ring Holder (9441141)
SM3-2106
NSTALL THE CONNECTNG ROD CAP
1 Ap
Appl
ply
y eng
engin
ine
e oil
oil tto
o th
the
e be
bea
ain
ing
gss
ac
ace
e
2 Al
Alig
ign
n tthe
he match
match ma
maksks on the con
connec
nectin
tingg od and
and cap
cap
MATC ARK
S307
TIGHTEN
TIGHTEN THE CAP BOLT For HINO H7D H7DT
1 Mease the oveall length of the bolt i the overall lengt is (A)
mm or moe eplace with new bolt
Dimension A) 835 mm {328 in}
S32032
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRes
www.HeavyEquipmentRestorationParts.com
torationParts.com
ENGINE E -439
2. ighten the bolt alternately in the ollowing order
a Tighten the
the nut to 68.65 -m {00 kgfcm, 5063 lbfft}
b Retighten
Retighten the nut 1/4 turn (90 ) °
c Retighten the nut 1/8 turn (45 ) °
NOE: App
s s
se
e
e
W
q
q
v s v
ve
e
ve v
v
SM3-2033
F HINO H7C H7C
ighten the bolt alternately in three tage
orue the bolt on inal tage.
ightening true 11.623 m {150 kgfcm 265 lb}
NOE p s s
INSALL HE CANKSHA PULY
ntall the torional dumer () n the cranha.
2 ighten the nut (B) with the collar () in lace.
NOE s p
p
s s
s pps Nv s ss ss
App
s
3 . ntall the ound inulator (Dl o itte) into he torional
dumer, then intall the crankha ulley ().
NOE W p s s p
s p p F)
4 tach the hiel aembly (Gl
(Gl ited ) and tighte
tightenn the mou
mounting
nting
bolt with lane waher (l o ied)
5. er intaling the hield(l ited) make ure that there i
clearance 05mm {0.019 in or mre between crankha ulley
and shield all aroun
shield all aroundd the
the perimeter
perime (I}.
ter (I}.
D A B C
IF NECESSAY EPE HE IL SEAL
1 Remoe th the oi
oil e
eal.
2.
lyly a ma
mall
ll amo
amoun untt o cl
clean
ean en
engine
gine iill on tthe
he u
uter
ter e
eri
rih
her
ery
y
ofthe
oft he oil eal and then intall the il
il eal to the lywheel houing
enuring that it i luh with the end the oil eal retainer.
NOE Es
p s s s
s s)
SM3383
EN-440 ENGINE
IF NECEARY, REPCE THE O-RING
Instal the 0-ing
NOTE: Apply adhesive (Three Bond 1141) r the flywheel husing t
prevent drp f O-ring.
INSTALL THE FLYWHEEL HOUSING
Refer to "LIQUID GASKET AND APPLICATION POINTS
IF NECEARY REPCE THE HINO H7 C H7 CT
H7 D H 7 DT FLYWHEEL RING GEAR
1. Remove the ing gea
Heat the ing ge with a blow toch in a unifom manner
[Appox 00 {22 }]
°
b Using a metl od as a pad and stike all aound the rng gea in
a unfom mnner and emove the ing gea
NOTE Be careful no
nott to overheat the ring gear
SM3-428
2 nstll th
the
e ng gea
et the ing gea unfomly using a blow toch Appox 00 °
22 }
b Dv
Dve
e tthe
he ing
ing gea
gea wi
with
th it
its
s ch
chamfe
amfeed
ed ge
gea
a teet
teeth
h faci
facing
ng th
the
e bl
bloc
ock
k
onto the flywheel usng a metl od
NOTE Be careful not to overheat the ring gear
INSTAL THE LVWHEEL
1. Mk sue that thee e no bu nd dust on each contac
suaces nd tpped holes of the cnkst nd flywheel, and
inset the guide b into the cnksht
Spia tool
tool Guide bar
bar (9113
NOTE Inse one of the guide bar int the coar noc and the
other one into the opposite side of the coar noc
GUIDE BAR
nse the flywheel into the guide bas sotly thout shocking
until the flywheel contact the colla knock and then push
pefectly
3 Apply the engine oil to the flywheel bolt theads and bolt
being sufaces of the flywheel nd tighten the flywheel
bolts tempoaily by hnds
GUDE BAR 4 Pull out the guide bas and tighten the est to flywheel bolts
tempoily in the
the sme ay s step 3
ENGINE EN-441
5. Tighten te bolts through several repetition the tightening
TGHENING
ORDER orde so as to reac speciied torque evenly ad gradally,
then slacken and tighten them one by one to the speciied
toque
WARNING
The flwheel is heavy, when installing be careful not to drop it
on your feet.
NOTE: o Align the 0" mark on the flywheel and cranksha colla
1
__ _ __= _
__= M
S
S -17'.
:3� 5 knock pin
o When tightening the bolt, appl engine oil to the threads
and flwheel suace of the bolts.
IMPORTAT PTS ADJUSMT
FLYHEE HOUSING GRATR
GRA TR US OL
OLV
V
ANGUR AND PARALL ALINEN
1 Checig agular (ac) algme
a Attach the dial idicator stad to the lywheel
b Apply the dial indi
indicator
cator at right angle o plane surface
surf ace of ly-
wheel hosing
c Pretension the gauge and step to "O
d rn te flywheel slowly and measure the agular aligment
Repair limit 2 mm {8 in}
e I the anglar aligmet exceeds the limit install the shim
between
betwe en the cylider bloc ad flywheel housing
NO The following shims are available
Thickness;
mm 2 in}
mm 9 in}
2 mm 9 in}
M-6
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRe
www.HeavyEquipmentRestorationParts.com
storationParts.com
EN-4-2 ENGINE
2. Checking parallel (bore) aignment.
a Att
Attach
ach the dial
dial indica
indicator
tor stand
stand tto
o th
the
e fl
flyw
yweeel.
el.
App
Apply
ly the
the dia
dia indica
indicato
torr a
att rigt
rigt ang
angle
le tto
o enteri
entering
ng suac
suace
e o
lyweel housing
c. Pretension the gauge and set to "O.
d Turn the flyweel slowy and measure the paralle algnment
Repair imit: 020 mm {0.0078 in}
e. I te parallel alignment exceeds the limit, change te straigt
pins.
NOTE: The following saigh pins ae a
available
vailable
Eccenticity (A);
5 mm in}
1 mm 03
039
9 in}
mm 9 in}
SM-1975
FLHEEL
OUSING CYNDER
BC DE
A1®;r PUNCHED MARK
(DREC F
ECCENTRC)
S39
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquip
EngineParts@HeavyEquipmentRestoratio
mentRestorationParts.com
nParts.com
Phone: 269 673 1638
Website: www.HeavyEqu
www.HeavyEquipmentRestora
ipmentRestorationParts.com
tionParts.com
ENGINE -4-43
INSPECTION AND REPAIR
Unit: mm in
Ispeco Ie Sadard L Reedy speco Procedure
Ps Daeer 110 {4.331} a A - Replace po
H0721{08267 ad/or ler
S� OUTSIDE
I
1
I
H07C-T422528 y DAMTR- v
-8
Cylder Ler Ide 110 11015 �u
433} 43366) SM3-910
Daeer
-
1�}
Clearace HINO H07D 0053085 -
( ,;
_ .
�
bwe HINO H07DT {000210033 -�
["'
Po ad
Cylder Ler HINO H07C 01924
HINO H07CT {0.7600}
�
�1
Proje of 001-08 - SM432 SM33
Cylder Ler {000030031
HIN O P Top H07 300 290 Replace
H07DT
Rg
Breadh
2d
H07C
H07CT
{01181
-
200
01141
-
190
I
/�'
{087 {007
3rd
H07D
H07DT
- - u_ � I
I
H07C 250 2
�iI
H07CT {00984} {009}
SM3379
Ol 400 390
01574 {01535}
Tp H07 300 320 Replace ps
HIN O
H07DT {01181} 01259}
P Rg
H07C - -
Grove H07CT
Breadh
2d 200 220
0787} 00866}
-
-
. _
H07D - -
3rd
H07DT - �
,
H07C 250 270
H07CT 00984} {01062}
M3201
Ol 400 410
{01574} {01614
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
EN-4-44 ENGINE
Unit: m {}
Inspon Item Standard Limit Remedy Insption Procedure
Clearane Top H07D 0010 Rlace piston
bn -�
{0.0020039} ring and/or pston
Pon Rng H07C-T
and iton
Ring Brea h 2nd H07D 0008
{00010031}
07 TT 0010
{00020039}
3rd H07D
H07C-T 00
{020035} SM3-210
Oil 00206
{000024}
Pion Rng Top H07D 03 15 Replace
Gap {001101575} {00590}
*Inser
*In ser the
the H07C
07C --T
T 03.45
3.45 15
15
piston
w here rngs
here the
2nd {0
_ 01
1
034
0 17
7 } {
{ 0 120
0 0 } �
�
w ear
ear of the {00110177} {00472}
liner is 3rd H07D
small
HINO H07C H07C-T
0345 120
HINO H07CT {00110177} {00472}
HINO H07D Oil 0350 120 SM3302
HINO H07DT {00110196} {00472}
Pston Pn HIN O H07D 3693700
36937 00 3696 Replace pon
Dameter H07DT {145614569} {14551} and/or pston pin
1
HIN O H07C H07CT 389839000 3896
{153515354} {15339}
Piston Pin HIN O H07D H07DT 36977003
36977 003 3605
Hole Inside {14621456} {14192}
Diamer HIN O H07C H07CT 3898739003 3905 SM3297
{15315356} {1537
{15374}
4}
Clearance been Pston 013014L 005
Pin and iston Pin Hole {00051T00055L} {00019}
T:Tght
L Clearance
SM3585
nnng HIN O H07D 37017025 3710 Rlace bushing
R Sall End H07DT {1457314576} {14606} and/or piston pn
1
Bushng In HINO H07C 390139025 3910
Diaer H07CT {153 15364}
15364} {15393}
Clearance beteen Pston 001036 008
Pn andEnd
Sall Connng
Bushng Rod {00000014} {00031}
SM3296
ENGINE -4-45
Unit: mm {i}
Ispeco Ie Sadard Lmi Reedy Ispeo Procedure
Coecg Rod Replace
Cracks or Daage
SM3-363
Cog Rod Clea
Ol Hole Clogged
SM3424
Cog Rod Sraghess 0.1 Replace
{00039}
Per
200
{7874}
SM3-541
Cog Rod Tws 01 Replace
{00039}
Per
200
{7874}
SM3542
Crakshaf
Crakshaf P Daeer 64.996 20 Regrd crak- ,
{25567-25575} {0078} shaf ad use
udersze beargs
680 Replace
{25118} crakshaf
SM3860
Clearace bew Coeg 0031082 020 Replace bearg
Rod ad Crak P {00013032} {00078}
Coecg Rod Ed Pla 0252 100 Replace
{00070205} {009} coecg
rod
EN-446 ENGINE
Unit: mm {}
Ispeo Ie Sadard L Reedy speco Proedure
Craksha Ol Hole Clogged Clea
Craksha Cracks ad Replace
Daage
Craksha Bed 0.09 Replace
0.0035
SM3-861
Craksha Joural Daeer 799479960 20 Regrd
31472-3
31472-3 10 .0078 udersze
788 Replace
3.1023 raksha SM3860
Clearace beee Crakshaf 0051102 0.30 Replae bear
Joural ad Ma Bearg 00020040 0.0118
SM3436
Craksha Rod Ed Play 00219 050 Replae hrus
00020086 00393 bearg
SM3-362
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationPart
www.HeavyEquipmentRestorationParts.com
s.com
ENGINE EN-47
Unit: mm {n}
Ispeco Ie Sadard Lmi Reedy speco Procedure
Cylder Block Fless Less ha 0.05 010 Regrd ad/or
00019 00039 replace
Flywhee Face Alge 004 Regrd ad/or
00015 replace
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
ENGINE EN-51
LUBRICATING SYTEM
HINO H07 C H07 CT H07 D H07 DT DATA AND SPECIFICATIONS SPECIFICATIONS
Oil pump
Type . . . . . . . . . . . Full forced pressure feed by gear pump
Drive . . . . . . . . . . . By gear
Oil cooler
Type . . . . . . . . . . . . . . . . . . . Multiplte tye, water-cooled
Oil filter
Type . . . . . . . . . . . . . . . . . Paper element type
H INO H07 C H07 CT H07 D H07 DT LUBRICAING SYSTEM
SYSTEM DIAGRAM
1
/ SM3-2036
Unit: KPa {kgfcm, lbf/n2 )
1. Ol pan
pan 10 Regulat
Regulator or val
valve
ve 21 Valve
2. Ol stranr 36321 {3.7.3, 5263116} 2. Valve clearance adjusting screw
3. Oil pump 11 Ol pressure gauge 23 Vave push rod
4. Ol pump safety valve 12. Man oil ole 24 Tappe
9 {95, 1350
13509
9 13. Pst
Pston on coolng jet 25 Ca
5 . Oil cooler 14 Crnksa journal 26. Fuel njetion pump
6 Oil cooler safety valve 15. Crnks pin 27 Idler gear
177215 1.22, 25.13129 16 Connectng rod 28 Ck valve for turbo carger
7. Oil filter (full flow) 1 . Pi s t o n (Mode H0C)
8 . Ol flter (bypass
(bypass)) 18 Casa 29 Tubo carger (Mode 0C)
9 Oil flter safey valve 1 Rocker arm sa A. o oil pan
12166 131, 18.5024.1 20 Rocker r B. To cranksaf
EN-52 ENGINE
H IO H07C H07C T H0
H077D H0
H077DT OIL PUMP AND IL
STRAIE
OVERHAUL
T = 24.51 {2, 18)
T = 2451 {, 18)
SM3-99
T = Tightening torque: Nm {kgfcm lbf}
1 Oil pump 5 Driv
Drivenen ge
gear
ar
Oil pipe with
with str
strain
ainer
er 6 Collar
0ring 7 Oi
Oill pump
pump b body
ody ass
assembl
embly
y
Oil
Oil pum
pumpp co
cove
verr
IMPORT
IMPORTANT
ANT POINT
POINT - MOUNTI
MOUNTING
NG
ITAL THE OIL TRAINER
Rear ump Oil trainer
1. Tighten bolts 1, 2 ad 3 temporary
2 Ag bot hoes of ce bock ad bacet
3 Tghten bolts 1, 2 ad 3 to specfed torque
NOTE Be sure to insta
install
ll 0ring
SM
ENGINE EN-5-3
OIL PUMP SAFT VALV
REMOVE THE SAF VALVE.
1. Remo
Remove
ve the safety
safety valv
valve
e frm tthe
he bot
bottom
tom of te cyl
cylind
inder
er block
block
SM3-1290
2 Remove the retaine ring, a d then disasseble te safety valve
S329
S3293
INSALL HE SAFE VAVE
Istall te valve spig sim seat and etaie ig in that
sequece
Istall te safety vave to te bottom o the cyider block
Tightening Torque: 83.36 N-m {850 kgf
kgf-cm,
-cm, 61 lbft}
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
EN-5-4 EGIE
INSPECTIO AND REPAI
Unit: mm {in}
Insption Item Standard Limit Remedy Inspection Procedue
Valve and Spring Replace, 1. Slidin face of valve or
Wear or Damage. if necessary possible damage.
2 Valve
V alve moves smoothly
Cleaance etween Gear 0033-100 015
and Case {00013-039} {00059}
SM3-970
Gear End Play 005.095 0.15
{0.002.0037} {00059}
SM3927
Gear Backlas 0.072-277
0002.109
SM337
Cleaance etween Diven 004083
Gea and Sha {000160032}
SM3868
ENGINE EN-55
INSPECTION AND REPAIR
Uni: m {n}
Ispecto Ite Stadard Lmi Redy Ispecto Procedure
Clearace betwee Drve Shaf 0.04085
ad Ol up over {000160033}
SM3-2039
M3038
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
EN-56 GI
HINO H07
H07CC H07 CT H07
H07CT H07DD H07 DT OIL COOLER
H07DT
OVERHAUL
13
1 Oil co
cool
oler
er 9 Oil filter element 16. Oil cooler
cooler elemen
element
t
2 Oil cooler case gasket 10 Oil cooler safety valve 17 Gasket
3 Wat
Waterer galle
galley
y cover
cover 11 Check
Check va valve
lve for
for turb
turbocharge
ochargerr 18 Plug
4 Reamer bolt (Model H0-T) 19 Oil pipe
5 Coolant ppe 12 Oil filter safety valve
6 Oring 13
13 Pre
Press
ssur
ure
e regulator
regulator va
valve
lve
Oi
Oill ffil
ilte
terr 14 Spr
prin
ingg
8 Element cover 15 Oil cooler case
ENGINE EN-5-7
SPECIAL TOOL
Prior to stating an enine ovehaul, it is necessa to have these specia toos.
WRENCH
095531021
IMPORTANT POINT - DISMUNTIG
REMOVE THE OIL LTER ELEMENT.
Using a specia too unscew the oi fite
Special Tool: Wrench (09553101)
IMPORTANT POINTS - ASSEBLY
NSTALL THE OIL FILTER ELEME
1. Appy a sigt amount of engine oi to the gasket of the ne fiter
2 Tighten
Tighten te new fiter by hand unti te gasket touches the cover
and then tigten anote 3/4 to 1 fu tun with a specia too
Special Tool: Wrench (09553101)
INSTALL THE OL COOLER ASEMBLY
ighten te to eame bots.
2 te other bos ony aer continuing th
ighten te
ighten that
at the gap at the
joint between the
th e oi ppe an oi fiter (A) is 05 mm {0019 in} or
ess
NOTE Be sue to install ing on the oi pipe.
SM3-2040
EN-58 ENGINE
INSPECTION AND REPAI
Unit: mm {i}
Ispeco Ie Sadard W Reedy Ispo Procedure
Valves ad Sprgs. - - Replace, 1 Sldg face of valve for
ear or Daage f ecessay possble daage
2 Valve ove soo
soohl
hly
y
Ol Cooler A Tgess
Ar Pressure
- - Replace
f ecessa
=-&
� -
588 KPa 6 kgf/c
kgf/c2, 853 lbf/}
.
SM3-516
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRe
www.HeavyEquipmentRestorationParts.com
storationParts.com
ENGINE EN-61
HINO H07C H07CT H07D H07D T FUEL SYSTEM
DATA AND SPECIFICATION
H ino H07C H07C T H07D H07D T Injection nozzle
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-hole nozzle type
FUEL SYSTEM DIAGRAM
1. Fuel tank
2. Water separator
3. Fuel feed pump
4. Fuel flter
5 Injection pump
6 Intion nole
X SM3-243
AIR BLEEDING FUEL SYSTEM.
1. Loosen the bleeder plug on te fuel ilte
2. Loosen the piming pump knob
3 Opeate the piming pump knob until the ai wl not come out
om th e bleede
bleede plug
4 Tighten the bleede plug
Tightening Torque: 39388 N-m {40 kgfcm, 3 lbf}
NOTE The beeder pug shou
shou be tightened whie he priming
pump knob is operated
5 Once again, opeate the piming pump knob seveal times
6 Push back the piming pump knob and tighten t
NOTE Wipe o any spashed fue
EN-62 ENGINE
HIO H07 C H07 CT H07D H07D T
INJECTON OZZLE
[For modelH H07D H H07D J
INO INO IN EC OR
11214 -�P·
i:8 31(9.7351409600623878.6.931329}}
=
T {5680.870 ,643350.61}°
=
7 ,
0
2
1 9
l �:
= {5808708..5 3784}6:i
�
T = Tightening torque: N-m {kgcm lbfft}
lbfft}
SM3-240
..
1. Inlet conor
Gasket
3 Nozle holder assembly
Nole dowel pin
6
7
8
9
Nozle
Nozle retai
retaii
Joint bot
ig
g nut
Nozle holder cap ut
11
11 No
Nozle
12 S
Sh
zle spri
him
spring
ng
13 Diance pie
Nozle holder adjuing screw 14. Nozle holer press pi
5. Nozle 10 Nozle holder adjuig screw
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmen
EngineParts@ HeavyEquipmentRestorationParts
tRestorationParts.com
.com
Phone: 269 673 1638
Website: www.HeavyEqu
www.HeavyEquipmentRestorationP
ipmentRestorationParts.com
arts.com
ENGINE EN-6-3
OVERHAUL
[Fo model HIN H07C HIN H07CT
O O
=
t T {.10150
81-1.707210.8}
t- 2
� T = 1 9 9
_ _ 2
2
: !, 1447-28.93)
T = 58..
{670, 4.}
2
T 58800,
= 78453.57.8}
T Tightehtenining toque Nm kggffcm lbft}
12 IGnlaestkecoector
t 56 NNozzl
Nozozzlzlee hetaioldeninipgeutssue pi 10 AdjPesusiunegsscpineewgw
3 Nozzl
Nozzele holder assembly 8.7 Nol
Nozzlee holdowelde cappi ut
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
EN-64 ENGINE
SPECIAL TOOL
Prior to staing an egine verhaul, t is necessary t have these special tos.
IDLER GEAR SLIDING NOLE HOLDER ADAER
HAMMER (Used with 09420-1442)
0012 09462-1130
IMPORANT POINT
POINT - DMOUNG
CLEAN FF SURROUNDING AREA OF THE NOZZLE AND THE FUEL
LINE CONNECTORS
NOTE: If foreign maer is allowed to enter the combustion chamber,
engine trouble may result.
REMOVE THE FUEL INJECTION PIPE.
NOTE: Cover open ends o off the pipes and fuel iinjection
njection pump to
prevent entry of di.
REMOVE THE NOZZLE HOLDER.
Usng special toos, f the nzzle is dficult t remve by han
Speial Tool Sliding Hammer (042
(0420-1442)
0-1442)
Adapter (094621130)
NOTE: Aer removal of the nozzle holder
holder cov
cover
er the nozzle holder
with cloth Also over the ylnder head with a cloth to
prevent dust from geing in
SM3-356
ENGINE EN-65
IMPORTANT PONTS - ASSEMBLY
ASSEMBLY FOR HINO MODE
MODEL
L
H07D HINO H07DT
H NOL INKING.
Wash the nozzle proper with diesel fel oil, them immerse it in
diesel el oil.
ext slide the needle insie the nozzle proper an ensre that
it move moothly he needle valve shold fall nder its own
weight when withdrawn
withd rawn verticall abot 1/3 an reeaed its
motion i lggish replace the nole with a new one
STEP-1 ADJU H NJCON RUR
1 djsting 1st opening pressre
a. nstall the 1st opening presre adjsting shim an pacer
b nstall
nstall tthe
he special
special too
tooll on tthe
he n
nozz
ozzle
le holde
holde an
an tigh
tighten
ten w
wit
ith
h
speciie torqe
SCRW
: 090)
u 988
988
N {000
68 }
SPACR C. ntall the nozzle holder to the nozzle teter check the 1t
opening pressre
1ST OENING u u u
PRESSURE 8.89 M {89 2 67
ADJSN
SHM
d Peform the adjstment of the 1st opening pressre with the
1st opening pressre adsting shim
shim When replace the 1t
NOZLE HOLDER
opening pressre adjsting shim remove the special too an
spacer
. I Au
Thickne Part nmer
SM3-2425
53 kinds in thickne from 5 to 1 3
3
154 mm to 1 in each to
SEP- differing . mm in 1
1 14
N FO ADJSN DVSE
2ND S ROD NO ' C u u
00 {000079 }
uu
2
u K { , .
u u
.
I u u
u u
u
AJSN
DVS
dstin
dsting g prelift
a ligning to "" (ZE point of ating eie
ntall the dial gage an pin to the ating eie
BAS ntall
nt all the bae on ice tan an iner the nph ro fter
set the asting eie align the ial gage to " (ZE
S SAN point
Au 0900
0900
0900
B 0900
2 PS O w 000
SM26
EN-- ENGINE
b. Insert the 2nd push rod n the nozzle holder and instal to the
screw using the middle screw of adjusting devise
NOTE: Do not install the pre-li adjusting shim
c When push down the part of dial gauge holder supporting by
DIAL GAUGE hand, read the lift measurement "H of dia gauge
HOLDER
d. Measure the thickness of pre-liftadjustng shim and calcul
calculate
ate the
pre-lif value according to following expression
Pre-lif value = thickness of prelit adj
adjusting
usting shm lift meas
ureen UH'
PN
e. f prelift value is deviated from standard value
value adjust wth pre
SCREW
li adjusting shi
2ND PSH ROD
Prel value: 0.08 mm {0003 in}
H NOTE The prelft adjusting shim is identica with the 1s opening
pressure adjusting shim
SM3-2427
3 Adjusting 2nd opening pressure
a Pull out the prelt adjusting shi and insert the 2nd push rod
and 2nd sring then tigten the set screw with specified torque
ADJUSTNG HOLDER To set screw should be set the adjusting screw and lock nut
LOCK N
Tighteing torque:
torqu e: 4905883 Nm {500600 kgf cm,
SESCREW 364338 lbf
2ND SPRNG NOTE It is impossible to get he corrt ope
opening
ning pressure ith pre
2D PS ROD _. lift adusting shim in
b. Install the nozzle holder to the nozzle tester check the 2nd
openin
peningg press
pressure.
ure.
2nd opening pressure 2682745 MPa {27280 kgf/m2,
389398 lbf/sqin
c
c Aer peform the adjustent of the 2nd opening pressure with
the adjusting screw tighten the lock nut with speciied torque
Tghtening torqe
torq e 962245 Nm {20250 kgfc
kgfcm,
m,
447245 lbf
NOTE: Do not loose the lok nut aer adjusting
SM32428
ENGINE E-67
4. Installatio and ispectio
a. Remove the set srew then inse the pre-li adjustig shim
Retighte the set scew with specified torque
ightening Torque: 49.05883 N,m {50000 kgf-cm
CAP NUT
361338 lbf}
b Tighte the cap ut with specified torue
SETSCREW Tightening Torque: 392303 Nm {{40500
40500 kgf-cm
GASKET 2893361 lbf }
}
PRE-LF ADJUSTIN
NGG
NOTE Replace te gasket with ew one
SHM
c After finsh to istall, set the nozzle holde to the nozzle teste
the chek the 1st openig pressue ad the spay conditio
SM3-2392
ST THE SPRAY PROFI.
I the case of the ew ozzle operate the leve at the ate of 30
to 60 strokes per minute and for a used ozzle opeate the leve
at the rate o 5 to 60 stokes per miute
GOOD COARSE COARSE COARSE
S3450
ST THE FUEL LEAKAGE
Whe chekig for fuel leakage from the nole apply a pressue
of about 098196 MPa {020 kgf/cm2, 142-284 lfi} lowe tha
the oect inectio pressure o the ozzle y meas of the
ozzle
GOOD
S3881
EN-68 ENGINE
[FOR HIN O MODEL H07C H07CT H07C-T]
ST THE NOZLE SINKING
Wash the nozzle proper with diese fue i, them immerse it in
diese fue oi
Next side the needle inside
i nside the nozzle proper and ensure that it
move smoothly. The neede valve shoud fa un under
der its own
weight when withdran veicay about 1/3 and reeased If its
motion is suggish repace the nozze with a new ne
ne
ADJUS HE INJECION PRESSURE.
Connect the nozze hoder with a nozze tester and mve the ever
at the rate f aout 50 to 60 ties per minute
Injection pressure:
20.1-206 MPa {205210 kgf/cm2, 2,912986 lbf /in}
Except H07CHKFA
181-186 MPa {185190 kgf/cm 2632-2702 lbf/in }
WARNING
SM3-2392 esel fuel s flammable
his nozzle adjung should be done a well ventlated room
and away from any open flames or eleric spark
he spray mut a
always
lways be covered Keep your face and body
away from the spray. his is bause of the risk of fuel oil'
geing in your eyes or passing nt your body
S E SPRV
SPRV PROF.
n the case f the ne nle operate the lever at the
the rate of 0
t 0 strkes per minute and fr a used nozze operate the lever
at the rate of 5 t 60 strkes per minute
GOOD COARSE COARSE COARSE
SM3450
ST HE FUEL LEAKAGE
hen checking for fuel leakage frm the nozzle apply a pressure
f aut 098- 96 MPa {0-20 kgcm2, 4-284 lin2} oer than
the correct injection pressure to the nozle y means f the
nzzle
GOOD FAULl
SM31
ENGINE EN-69
IMPORTANT POINT MOUNING
-
INSTAL THE OZLE HOLDER ASSEMBLY
NTE: Tighten the
the nozzle olde bolts altenately ight an le,
tigtening the bolts gadually
gadually unti
untill the specied torque is
eaced evenly.
Tightening toque 147 N-m {150 kgfcm, 108 lbf}
WARNING
f a single bolt is tightened fist to the specified toque, when the
othe bolts
bolts ae tightened the actual eective toque will be exces
sive, esulting in possible damage to the nozzle olde and o bolt
On te ote and, if the bolts ae not tigtened suiciently, gas
way leak esulting in scoching of te nozzle.
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
EN-6-10 ENGIN
FUEL FITER
SPECIAL TOO
Prior to stating an engine overhaul, it is necessary to hae these special tools.
WRENCH
503-10
IMPORANT
IMPORAN T POINT - DISMOUTIG
RMOV THE FUEL FILTER
Using a special tool unscew the fuel fiter
NO: Be carul not to spll diesel fuel
Spal Tool Wrench (503-1040)
IMPORANT
IMPORANT POINT - MOUNI
MOUNIG
G
INSTALL TE FEL FILTER.
1 Apply a small amount of diesel fuel to the gasket of a new fuel
filter
2 Manally tighten the new fel filter until its gasket touches the
cover and hen tighten another 2/3 tun with a special too
Specal Tool Wrench (095031040)
ENGINE EN-71
COOLING SYSTEM
DATA AND SPECIFICATION
SPECIFICATIONS S
Coolant pump
Type ..... Forced circulaion by volue pump
Drive . By V-belt
Thermoat
Type Wax type, boom bypass sys tem
COOLING SYSTEM DAGRAM
13
9 7
r-
r-
I
- _ - _ J
\
/- . '
I 10 /
'- r.
r.
I _
2 11 8
I
I
3 4
14
SM3-2041
1. Radiator ap 6 Cylinder head 11 Ca heate ((f
f sso
o fi
fied
ed))
2. Radiato 7 hermosat 12 Coolant tempea
tempeature ture g
gaug
auge
e
3. Coolant pump 8 By
Bypa
pass
ss hose
hose 13 Reseoi tan (f so fied)
4. Cylinde lok 9 hemostat ove 14 Dan plug
5. Ol ooler 10 ub
uboo
arge
arge (Mode
(Modell H7C
H7C)
)
EN-7-2 ENGINE
HINO H07C H07CT H07D H07DT WATER PUMP
DESCRIPTION
1 2 34 5 6
TypeA TyB
OVERHAUL
Type A
Type
TyB
1 . Ke y 6 Shf
11 Pulley cener
7. Cas e
2 Collar 1 Sh assembly
3 Retainer ring 8 Sel 13 Gsk
skee
4 Bearing 9 Vne 14. Lu icaion
b rrica
Lub ing
ion fit ing
5 Collar 10 Cve
ENGINE EN-7-3
[FOR YPE-A]
IMPORTANT
IMPOR TANT POINTS
POINTS DISASSEMBLY
DISASSEMBLY
REMOVE THE RETAINER RING.
emove the retaner rig usig retaer rig pes
SM3-996
REMOVE THE VANE AND SHA
Usg a press, push the ed of the sha o the vane sde
NOTE: I l w
c wll b
SM32042
REMOVE COONT SEAL FROM THE CASE
sg a opper od stke he ooat sea
NOTE I bl l
c. Accly b c w w
SM32044
REMOVE THE BEARIN AND COLR SIN A PRESS
NOTE bl l l
c. Accly b lc w w .
IMPORTAN
IMPORTAN OINTS
OINTS ASSEMBV
ASSEMBV
INSTALL THE BEARING TO THE SHA.
nsta the a eargs th oar o the sh usig a press
NOTE 0 Il b ly l c 3
cll.
0 D sll
bs y w
0 W ll s s s-c
EN-74 ENGI
INSTALL THE COONT SEAL
1. ppy
ppy a tt
tte
e qu
qud
d sea
seaer
er to th
the
e coo
cooan
antt se
sea
a o
ote
te ci
circu
rcumfe
mferen
rence
ce
and case
2. nsta the cooant sea
NOTE: Rl l
l
l w
w
w
FT THE SHA NTO
NT O THE CASE UNG A PE.
SM3-995
INSTALL HE RETAINE ING
er fing the
t he sha, nsta the pan ashe then n
nsta
sta the ne
retner rng by means of an expander
SM3996
INSTALL THE VANE
ress the vane onto the shaf
NO T l l
S2047
IMPORTANT POINT - MOUNTING
INSTA THE COONT PUMP ASS
eae bot fing posto
SM2055
ENGINE EN-75
[FOR TYPE-BJ
IMPORTANT POINTS - DSASSEMBLY
REMOVE THE VANE AND SHA.
Using a press, push the end of the shaft on the vne side
REMOVE THE PLY CENTER
Usng a press, push the end o the sh on the puley cente
cente sde
SM3-2043
REMOVE CONT SEAL FROM THE CASE
Using a copper rod strike the coolant sea
NOTE: I b
m
m m
. A
A b w w
S32044
IMORTANT POINTS - ASSEMBL V
INTALL THE SHA ASSEMBLY
ess the sh assely into the case
NOTE: T b
SM32045
INSTALL THE PLLEY CENTER
ess the pulley cente onto the sha
Dm A 31 mm {0122 }
S32046
EN-76 ENGIE
INSTALL HE COOLANT SEL
1. Appl
Applyy a llit
ittl
tle
e liq
liquid
uid s
seal
ealer
er to the coo
coolan
lantt sea
sea out
oute
e ci
cicu
cumfe
mfeen
ence
ce
and case
2 Install the coolat seal
NOTE: Replace the coolant seal with new one.
INSTALL HE VANE
Press the vae oto the shaft
NOTE The vane face i to flush until end of th
thee shaf.
/
SM3-2047
IMPORTANT POINT - MOUNTING
NSALL HE COON PUMP SS
Remer bot g osto
SM32055
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRe
www.HeavyEquipmentRestorationParts.com
storationParts.com
ENGINE EN-77
THERMOSTAT
OVERHAUL
1. Thermo
Thermosta
statt case
case cove
cove
2 Gasket
3 Ther
Thermo
moa
att
4 Thermo
Thermosta
statt case
case
SM3-2432
IMPORTANT POINTS - ASSEMBLY
T,: Valve openng teerture INSPE THE THERMOSTAT FUNCTION
T Valve opened teperature
2
1 Place the thermostat n hot water and check the valve openng
10{0.4mmin} teperature and
an d the valve l.
t O: e hermostat valve opening emperaure (T,) s egraved
egraved
i on he hermosa seat an i should be onfirmed
;
Therostat valve oening tperature;
Thermostat valve Sece standard
ec
TMP.
TMP. openng tep (T)
SM-888 765 C °
74785 C {167173 F
82 C
°
84 C {145215 F
° °
Thermostatt vave
Thermosta
Themostat valve Measurng
Measurn g te Valve lf (.
(2)
openng765tem
°
C (T 90 C {194 F}
°
10 {0394 n}
or ore
L WHEN
WHEN COD°C 82 °C {03 F
0 °
u: )
j VALVE IF Ierse a heated thermostat n water
water of normal teerature If
it comletely
comletely closes wthn
wthn 5 minutes t s satsfacto If t
reans even slghtly oen, t s deectve and must
must be repaced
MOU THE THERMOSTAT
/GASK 1 Reove the water and d adherng to the thermostat case
2 Repace the gasket wthout fa f t s corroded daaged or
�PAT fattened
3 Before stalng the hose apy lqud gasket to the hose sta-
ato of the thermostat case cover
TRMSTAT 4. n order to revent cloggg of the radator, do not se a arge
aont of lqd gasket
SM412
EN-7-8 ENGINE
RADIATOR
ADIATOR
1. Radiator SM3-2264
IMPORTANT POINT - DISMOUNTIN
DISMOUNTING
G
DSMOUNT THE ADIATR.
WARNING
To avoid the danger of burns to not drain the coolant while the
engine and radiator are still hot
NO: When dismounting and mounting the radiator, do not da-
age the radiator core
INSPECTION AND REPAIR
nit: KPa {kgf/cm 2, lb/in}
Inon em Standard Lmit Remedy Inspon Procedure
Colant leakage Rlace
radiator
Cogging of the Fins Clean
S3224
Radiator cap valve 0.5 39.3-588 Replace
ening prsure {0..6, 5 75}
09 731029
0.7.05 10.7-4.9
NOTE: The coolant ller cap valve opening pressure is shown on the cap and it should be conrmed.
If the cap pressure is incorrect there is a risk of abnorally high pressure being g
generated
enerated in
i n the cooling sye which
ay cause the hose to drop off or burst and in turn, damage the engine
NGINE -81
COOLING FAN
OVERHAUL
SEEL 6-BDE, BLOWOFF YPE PPG 8-BDE SUCO PE, WH F CLTCH
= 47 .07 {0, 34.72} T = 47 .07 {480, 34 72}
PPG 8-BDE BLOWOFF YPE
= 4707 {480, 34.72}
1. Co
Cool
olin
ing
g fan
fan
2. Fa
Fan
n spa
spacecerr
2 3. Fa
Fan
n clu
clutc
tch
h
VARIAIN
= 47 .07 {480, 34
3472
72
= ghtenng torque: m {kgfcm lbfft
1. Sh
Shoc
ock k tt
the
the fan
fan c
clu
lutc
tch
haan
nd fan
fan
During maintenance and nspecton be careful not to drop or
stre the fan clutch r
rfan
fan tsef The resuting damage may lower
the peormance of the fan Also, note that the fan is made of
plastc and may become damaged or deformed f frce f rce s appled
t t
2 Repacng the fan
D not
not repace the fan uness
uness it iis
s fauty When replacing the fan
replace t wth the same type as the o one
ne which was remved If
the fan is repaced with ne f a larger capacty because of
verheating or cnversey is repaced with ne f a smaler
capacty
capac ty due t vercolng the coing permance may n fact
reduced and durabty may be jepardzed
3 Other ems
Chec the temperature detectr (bmeta) t see f there s any
mud r dust n it
f the bmeta s cvered with mud f dust the fan performance
be
be erratc and any resut n verheating r vercing n
such case carefuly remve mud and dust adherng t the
surace
surac e f the b metal usng a wiwire
re brush r the ie
ae care ntnt t apy excessve force pacuar
D
D nt
nt pant
pacethe fanpaint
any r fan
rcutch
other reagents hich are liey t
dssve
dssve pastic in cntact wth the fan
EN-8-2 ENGIE
BLOWOFF TYPE 1 IREC T
DIRE TION
ION
IMPORTANT POINT - MOUNTING
INSTALL THE COOLING FAN.
R O T
OF RO A T
TA TIO N
ION OTE: The oolin
ooling
g fan
fan should be instaled rightly
rightly as shown
FAN BLADE
SUCTION TYPE DIRECTION
ENGISIDENE-OF ROTATION�
AIR �
CURRENT - JI!I!
FAN BADE
INSPECTIO AND REPAIR
Inspon Iem Standard mit Remed Inspection Procedure
Cooling fan and fan cltch Replace
dformaon and damage if neessary
ENGINE -91
HINO H07C HINO H07CT HINO H07D HINO
H07DT AIR INTAKE AND XHAUST SYSTEM
OVERHAUL
HINO H07D HINO H07DT
T = 24.52 {250, 18.08}
T Tightenng torque: N•m {kgf-cm, bf}
1. Hino
Hino E
Exha
xhast
st Gas
Gaske
ke 4. Hino
Hino Int
Intak
akee man
manfo
fod
d
2. Spacer 5. Inta
Intake
ke p
pp
pe
e
3. Hin
Hino
o Exh
Exhaus
austt manfo
manfold
ld
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentResto
EngineParts@Hea vyEquipmentRestorationParts.com
rationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipm
www.HeavyEquipmentRestorationPar
entRestorationParts.com
ts.com
OVERHAUL
HINO H07C
HINO H07CT
7
3
. H
Hno
no C
Coo
oola
lant
nt p
pip
ipe
e 5· Connector
or IHno ntke manfold
2. H
Hno
no O
Oll pip
pipe
e 6. Braket 0.Hno Exhast
Exhast Manfold
3· Hno Intake ppe 7. Safety vave
vave11 11 Spacer
4· Turbcharger
Turbcharger 8. 8· Hn
Hno
o Ex
Exha
hast
st G
Gask
asket
et
ENGINE EN-93
IMPORTANT POINTS - MOUNTING
INSTALL THE ITAKE
ITAKE PIPE.
Refer to "LIQUID GASKET APPLICATION POINTS in SCTION
ENGINE MVING ARTS
LIQUID GASKET
INSTALL THE INTAKE MANIFOLD
Refe to "LIQUID GASKET APPLICATION POINTS n SECTION
ENGINE VING ARTS
IQU GASKET
L � : =l -• .
INSTALL TH6 INTAKE PIPE
NOTE: Do not twist the hose
hose too much
Hose nseon A: 3040 mm {1.182-1
{1.182-1574
574 }
NOTE Ensure that
that the
the clearance
clearance between tthe
he hose and ventilator a
ass
shown
Cleaance B 150 mm 0591787 n
Cleaance C 1015 mm 0390590 n
NDER
HED COVER
INSTALL THE Hino H0 7 C Hino H0 7 C T Hino
H ino H 0 7 D Hino H0 7 DT
EXHAUST MANIFOL
1 Through the exhaust manfod wth the gasket n place
NOTE Make sure that blac
black
k side of the gasket s opposte to the
exhaust aniold
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
BLK SDE SM3-2048 Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
EN-9-4 ENGINE
I
P
SK E T
G A SK
CYLINDER
HEAD
A
T
� . mm(
mm (
H AU
1 7 7
T M A
AU S T
i n !
FOLD
N I FO
AN 2. Through the
the spacer in pace as shown
Al bl yld
�E
yld N.
I II
SUD L
LOCK NT H07D 1, 5, 6 23,4
GASK EXHAUST MANIFOLD H07C- 1 6 2 3 4,
YLINE STU
II
3 ig
ight
hten
en th
the
e ange nut by han
nu
C ACER 8 mm {031 i
HEA
LO CK NU
3-2049 NOE: W f ,
d d f
fl
fl
f
d
d f
IE
4. Tighten the ange nuts it by itte in three stags an in th
numerica orer as shown torque the nuts on ina stage
5 Tightn the ock nuts.
3050
INSPECTION AND REPAI
Unit {in}
I I Sdd L Rdy I Pd
H H07C 010 00 R
H H07C 0009 00196 l
H H07D R
H H07D 01 0009
Ex Mfld Fl
S371
Ex Mfld R
W D l
ENGINE EN-101
HINO H07C HINO H0
H07 7CT HINO H0
H07 7D HINO H0
H07 7DT
H07
ENGIE COMPNENT PARS DISMOUNTING
DISM OUNTING ND
OUNING
SPECIAL TOOL
Prior to staig an engie overhaul, it is ecessay to ave these special tools.
WRENCH
INJECTION PUMP COUPING V-BELT TENSION GAGE
09819-
09819-13705
004 09-1210
EXMPL
A INJECTION PUMP
MPOTANT
MPOTANT PONTS - DSMOUNTNG
REMOVE TE FEL INJEION PUMP
1. Disconnect the fue ies, oi ines ad egine contro ines
2. Remove te tough bolt "B a te o fage bots A (in
sloe hoes) at te coupig
3 Reo
Reove
ve t
te
eppum
ump p mou
moutiting
ng ot
ots
saand
nd te
ten
n i
iso
soun
untthe
tthe pu
pump
mp
NOT: Cover open ed ofthe pippeses ad pupump
mp tQpevet ety ofdi
B A
S3-1799 Special Tool Wrench ((009819 1 70)
98193004)
IMPORTANT
IMPORTANT PON
PONTS-
TS- MOUNT
MOUNTNG
NG
INSPECON HOLE INSTALL TE
1.
T E FEL INJECTION PMP.
Adjust te ijection timig
FLYHEEL Tur the caksaft couter-clockwise viewed from the fywheel
side to aign the injection tiig ark on te fyweel aA befoe
0
top dead cete for No cyie o compess
c ompessio
io stoke wit
poiter on the flywheel housing.
◊ � ;D'RNI
NG ):
Ijectio timig Refer to SECTION AT AN SPECIICATION
0
POER
S885
EN-102 GI
2. Check the push ods on No 1 cylinder ae loose ad push rods o
No 6 are tght
NOTE: If not, turn the c
cranks
ranksha
ha one complete revolution and ali
alig
g
marks as above.
3 Slowly
Slowly tur
tur he au
auoma
omac
c tm
tmer
er fla
flage
ge o clo
clocw
cwse
se vewe
vewed
d fro
from
m
couplg sde to alg he
he njecton mng mar o the automac
tmer wh pump
pu mp body ponter
TMING MARK
SM3-337A
4 Poston the pump o the pump backe ad adjus he poso
of he pump so hat ts moung holes alg wh those of the
bace
bac e and he tghte the moung bols eely followng
oder
Tghtening order 1-23
Unt m {kgcm lb}
lb}
ghteng torque
1st stge 197-4 {250 16
2nd stage 981-1470 {10150 72-108}
3rd stage 186549 {1260 118}
EXMPLE
TIMER
PUMP BODY
2 4
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
ENGINE EN-10-3
5. Usng a specal tool, tighten the to flange bolts (n sloed holes)
at the coupling
NOTE: Tr e y w m r
y rm e rer m
.
S T: Ij m wr 09819-170
09193004
Trq;
mm {0.31 } 29.42 m {300 km 21.70 }
10 mm {039 } .4 m {600 km 43.40 }
i
igh
ghte
ten
n th
the
e tho
thog
gh
hbbol
oltt a
att tthe
he flan
flange
ge
NOTE: D e w
T rq
10 mm {0.39 } 4 m {600 km 4340 }
12 mm {047 } : 26 m {600 km 610 }
Con
Conne
net
t the el
el ln
lnes
es oil lne
lness an eng
engine
ine c
con
onto
toll lne
lnes
s
EN-104 ENGINE
TYP-I
COOLANT PUMP GENRATOR
ALTERNATO
IMPORTANT POINT- MOUNTING
V-BELT ADJUSTMENT
ADJUSTMENT
1. In
Insta
stal
l th
the
eVV-b
-bel
elts,
ts, and
and a
adju
djust
st tthe
he b
bel
eltt ten
tenso
so
NOTE: 0 Do nonott under any circumstances apply the lever directl
again the generator body owing to the risk of dama
damaging
ging
the generator.
0 When installing
installing a new Vbelt or adjusting the tensi
tension,
on, be
sure to repeat the adjustment two or three times, aer
running the engine for several minutes each time
TP COLANT PUP 2 Vbelt deflection
Apply a load of abot 98N {10 kgf 22 lb} by pressing wth yor
inger or speca too
Assebly standard (A) 115 mm {459 in}
(B) 1 mm {2
{239
39 in
Special
Special Tool Vbelt tension gauge 9421
CANKSHAFT
NOTE If the belt is excessively
excessively tensioned, there is a ris of da
damaging
maging
the bearings
bearings of the generator or coolant pump and also
shoing the life of the Vbelt
Conversely if there is insuficient tension on the Vbelt the
belt will slip, unusual noise will be emited the baery a
run down and the engine may overheat
Trough Bolt Tightening Torque
83.36 Nm 85 kgfcm
kgfcm 6.48 lbf
STATER
IMPORTANT POINT- MOUNTING
INSTALL THE STARTER ON THE ENGINE
1 Ist
Istal
alll the
the st
sta
aer
er o the
the e
egi
gie
e
Fiing Bolt and Nuts Tightening Torque
8336 Nm 8 kgf cm 6. llbf
bf
2 Coect the haress to match the marks.
3 Conect the battery cable
SM3683
IMPORTANT
IMPORTANT POINT
POINT - DISMOUNTI
DISMOUNTIG
G
REMOVE THE STARTER
STARTER FROM THE ENGINE
1 Dscoect the battery cable rom the egatve () terminal o
battery
2. Put the
th e match marks o the haress ad starter termials with a
pe and then dsconnect the harness.
3 Re
Remo
move ve the
the st
star
arte
terr fr
from
om tthe
he engi
engine
ne
ENGINE EN-111
HINO H07C HINO H07CT HINO H07D HINO H07DT
ENGINE TUNE-UP
METHOD FOR DETERMINJNG IF THE NO. 1 OR NO 6 PISTON
IS AT TE TOP DEAD CENTER ON COMPRESSION SROKE
NOTE: 0 Turning the cranksha, align the mark "1- on the fly
wheel with the pointer on the flywheel housing
0 In this position either the No 1 or No 6 piston is at te top
dead center on compression stroke
1. If both No intake and exhaust rocker
rocker arms can be oved easly
by hand, the No pston is at top dead cene on copesson
stoke
VARIATON 2. f the njecton tiing ak is neay aigned wth the pup ody
ponte, the No 1 pston is at top dead cente on copesson
stroke
NOTE: If not turn the cranksha one complete revolution and align
marks as above
3 Whe ockng at the push ods of No 1 and No 6 pistons
piston s turn the
crankshaft counte-cockwise and cockwise about30 to 4 (see
°
eft figue)
If the piston hose exhaust and ntake push ods do not ove
duing the interva, t s at the top dead cente on copresson
stoke
If the piston whose push rods have oved t is at the copetion
PUSH ODS: MOVE USH RODS
(Compression stoke) STADG of the exhaust and begun of the intake stroke (oveappng
(Overlappg troke stoke)
NOTE: Alwas loosen the lo lock
ck nu
nutt and raise the adjusting screws
fully to the top If the adjusting screws are too low the piston
and · valves may strike each other during valve clearance
adjustment
SM3-713
EN-11-2 ENGINE
H I NO H0 7 C HI NO H 07 CT HI NO H07D
H07D H I NO H07DT
H07DT
INSPECTIO HOL VALVE CLEARNCE
1 et the o. 1 piston to top dead center on compres ion stroke
INSPEION AD ADJUSMEN OF THE VALVE CLEARANCE
FYHEE
POIER SM3-885
2 Wsaoutnhestht.reokoe, a1dpijussttotnhpose oito1nevadlvaet tcopeaderaandceceusntienrgona cthomprckneess
he thcknes gauge shoud move wth a very slght pul
3 urwheAdjnuesltthsihedeecoratAdjhnekrsuhsaatlvthecesoaunteer-ccleoacrkawncsee f1o8r0eacvhecwyeldndefrormin tfhlye
°
rn order
Firing order: 123-5
Hino H07C Intake Valve Lash Clearance 0.30MM or 0.012 Inch
Hino H07C Exhaust Valve Lash Clearance 0.45MM or 0.018 Inch
Hino H07CT Intake Valve Lash Clearance 0.30MM or 0.012 Inch
Hino H07CT Exhaust Valve Lash Clearance 0.45MM or 0.018 Inch
Hino H07D Intake Valve Lash Clearance 0.31MM or 0.0118 Inch
Hino H07D Exhaust Valve Lash Clearance 0.46MM or 0.0177 Inch
Hino H07DT Intake Valve Lash Clearance 0.31MM or 0.0118 Inch
Hino H07DT Exhaust Valve Lash Clearance 0.46MM or 0.0177 Inch
SM3715
INSEIONHOE INJECTION TIMIG
INSPEC E IJECTION TIMING.
F� DUHEEENINIG 1. urcsiyhdentdeopulhheraeloncgeraynctodkhmprsehmanpee csrotauntotnAestrm-ocbeknoefgcokrmawestroekpvonedewthaedflcryoewmnheterhelforolrcorahenke1
Injection ming (A0): Refer o SEION
SEION DATA AND SPEIFICA
0
POINER SM3885
TIONS
VARIATON 2. henotnec)chtk)monthnatghtephteamteineonrjehousctthoennpumptmsnahousgmanedrnwi(tthethsecpoirentlenr et,henotscthee
f not, adjust the injection tming
NOE When austing the injeion tiing, refer to FUEL INJEC
TION PUMP" in section ENGINE COMPONENT PARTS fo
details.
ENGINE E-113
ENGINE CONTROL
LNK ROD
ADJUST THE SOLENOID (ENGINE SOP) LINK ROD.
1. Adjust the link rod length so that the clearance btween the
stopper of the
the goveno case and t he engne stop lvr bcom
bcoms
s
"A when the solenod plngr s lly pshed in
Assembly Standard "A : 2-3 mm {008.11 in}
n
NOTE If the clearance adjustment is unstisactory
unstisactory or the action of
the solenoid is slugg
sluggish,
ish, solenoid seizure insuicient outp
or engine stoppage may result
2. Aft
Aftr
r thaove
aove adj
adjst
stmn
mntt is
is ove
over,
r, mov
move
e the
the lin
link
k ro
rod
d by h
hand
and an
and
d
ENGINE STOP SOLENOID
LEVER SM1950
mae sue that it moves lghtly
A
M3-98
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRes
www.HeavyEquipmentRestorationParts.com
torationParts.com
EN-1-4 ENGINE
ENGINE TUNE-UP ON TEST BENCH
NOT: 0 the engine is staed with the power eering oil pump
intalled, the oil pump may burn or oil may spu out
remove the oil pump from the engine and ntall a cover to
ALTERNTOR prevent oil leakage from the point of removal.
0 Staing the engine w hen
hen the alternator is not connected
to the baery may damage the alternato Always con-
nect to the baery
SM3-907
S THE ENGINE ASSEMBLY ON A TEST BENCH.
1. Add the proper amount
amount of the specifed engne
en gne oil through the o
fier cap on the cynder head cover.
2. Add cooant.
Beed out ar from nsde the cooant gaery through the cyinder
bock dran pug.
BLEED AIR FROM FUEL SYSTEM
Refer to secton FUEL SYSTEM.
CHECK THE INJEION IMING
Refer to FUEL INJECTION PUMP" n section EGINE COMO
NENT PARTS DSMOUNTIN AND MOUTN
CHECK THE VALVE CLEARANCE
START THE ENGINE
FACE FACE NOTE: Befoe stai
staing
ng tthe
he engine, ma
make
ke sue that th
the
e fuel cut lever
A B
of the fuel injection pump is opeating nomally
1. Chec
Check k tthe
he o
o feed
feed to ro
rockcker
er ar
arms
ms
a. Se
Sett the
the en
eng
gne
ne sp
spee
eedd tto
o6600
006
650
50 /m
/mn
n..
b. When one minu minutete aer stang th engne, o sh
shoud
oud fow to
to the
head (Face A) of a push rods and the head (Face B) of a vaves
If the tme requred for the o to fow to the rocker arms s ong,
varous troubes such as sezng, abnorma wear and unusua
SM3399 nose may occur
2. Retghtenng the cynder head bot.
Retghten the cynder head bots accordng to the foowing
nstructons.
(
()) R
Rttgh
ghte
tennng
ng sc
sche
hedu
due
e
Retghten
the at theor
oosenng frst 30 hoursoffoowng
remova secng
any cynder whch
had botnvoes
Such
secng ncudes repacement of the cynder head gasket,
secng of the vave gear pas, and the ke
(
()) Rt
Rtgh
ghte
ten
nng
ng p pro
roce
cedu
dure
re
Stp 1: Warm up the engne n the same way as n engne
turnng.
Stp Fo
Foowng
owng the cyinder head bobottghtenng
ttghtenng order oosen
the frst cyndr
cyndr head bot by 14 to 1 turns as shown
s g 1 ft mblig SM3-57), then tghten nto t to ts specfed torque
Presu
Presu on Repeat unt a the bots have been retghtened.
gak!
ghtening pocedue
Refe to CYLIER HEAD" in SECTIO ENGINE MOVING
-.-"'Mi cy
p
PARTS
dp ime , ten etighten it
NOTE 0 Be sue to loosen one bolt at a ime,
g g
befoe going on the nex bolt
0 By etighten,
etighten, face pessue of
of cylinde head is estoed
fom point B to C as shown
SM31180 RECHECK THE VAL VE CLEARANCE, WHEN ENGINE IS COL
ENGINE EN-121
PROCEDURE FOR INST ALLING JOINTS AND
PROCEDURE
GASKES OF ENGINE PIPE
PIPES
S
1. Gasket
Gasket seal ty
type
pe (alu
(aluminum+
minum+ ru
rubber,
bber, aest
aestos
os or copper).
Lation
L ation of gasket seal Tightening torque cha
Clamping screw size
Tightening torqu
(Diameter)
N, {kf,cm
{kf,cm lbf
lbf•}
•}
mm {n
8 {0.315}
{0.315} 12-16 {12170, 8.612.29}
10 {0394} 122 {18230, 1302-1663}
12 {0472} -27 {23280, 1662025}
14 {0.551} 2327 {2380,
{2380, 1662025}
16 {00
{00}} 334 {30(50, 216250}
18 {0.709} 44 {4050, 28.954}
20 {0.787} 44 {4050,
{4050, 289254}
22 {08} 5258 {5300, 38.3339}
24 {045}
{045} 778 {72, 5207.86}
28 {1.102} 12147 {1,31,500, 9403-10849}
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRe
www.HeavyEquipmentRestorationParts.com
storationParts.com
2 Metal sseal
eal ty
type
pe Fl
Flares
ares co
connector
nnector ty
type)
pe)
Location of metal seal Tightening torque cha
Clamping sew se
Tghtening trque
CONNECTOR FLRE NUT Dimeter
mm {in N-m {kfcm lbf}
lbf}
12 {0472} 222 {20220, 14471663}
14 {0551} 33-35 {33(60, 2387-2603}
16 {00} 4 {40O0, 289616}
18 {0709} 5! {00, 3063}
20 {0787} 64 {6500, 47 0061}
EN-12-2 ENGINE
3. Mal seal ty
type
pe (Nipp
(Nipples
les conn
conneors
eors ype)
Lion of metal seal Tghtening orque cha
GASK N NU Clamping sew size
Tighteng torque
(Dimee)
, (kgf-cm bf}
bf}
m (in
10 {0.394} 114 {10150, 7 .2-10.84
20 {0.787} 224 {20250 14 47-1808
CONNECTOR
FLARE FRE CONNECTOR
CONNECTOR CONNECTOR
NO: o Before installing he joints, ensure hat there is no di or burrs adhering to the various sea faces (pipe oints,
gaskets, ec)
o Because he pips can move relativly free during insallaion and he ea faces are liable to il, first temporarily
tighten the pipes, then tighen hem o spificaion an
andd ensure tha here is no leakage from them
o When gtening o pipes ogeher, be very carul ha hey do not rotae ogeher
o Ae inalling the pipes apply the corre pressure o each pipe joint and ensure hat there is no leakage
o Ensure ha he various tighening orques conform o he above able
o If a so washer #4 F-N (aluminum + bber and carbon press fi pa) is loosened or removd subsequent o
being intalld, be sure and replace wih a new one
Tere is no need o replace i, however, for normal retighening
ENGINE -13-1
LIQUID GASKET AND APPLICATION POINS
The engine use qud gasket nstea o coventiona seet gaskets. Appy qud gasket, tereoe takng te oowig tems
nto account
1 LQUID GSKE
GSKE PP
PPLICION
LICION POINS ND CO CONG
NG WI WIDH
DH
R l ;
B B1207D
B1 207D : 04132-1207 (Sl l) f (()
) (b) ()
B B1207B 04132-217 (Bl l) f () () nit n}
l C
C
()
F l bl 1525
(fl f b f) {006
{006 010
Liquid gasket
Liquid gasket
(b)
(b) Fl
Fl
l
l
Fl f 1525
l bl {006010
{006010
Lquid gasket
Bot hole on cyider boc
() fl Fl f l 1525
006010
006010
EN-132 ENGINE
Unt: mm {in}
Pas name Application point Coating width
(d) Intake air pipe Flange face which mates with itake 1.5-25
manifold {006 010}
Lquid gasket
2. COATING LIQUID GASKET AND PARTS ASSEMBLY PROCEDURE
1. Coplet
Copletelyely re
reove
ove o
od
d i
iquid
quid gask
gasket
et fr
from
om each pa and the respecrespectve
tve atn
atngg par
part,
t, and remove oi
oi water a
and
nd drt
usng coth
coth
2 Be car
carefu
efu not
not to appl
apply
y ex
excessi
cessive
ve or insuf
insufcient
cient li
liquid
quid gas
gasket
ket Also be sur
sure
e to overl
overlap
ap the ssta
ta and end of eac coa
coatn
tng.
g.
3 When assembing oated parts parts be careful tat t tere
ere i no isalignment beween mating parts If there s any
isalignment
isalig nment coat the pas aga in
4 Asseble the various pas withinwithin 20 inutes after appng liquid gasket f or ore e than 2 nutes have elapsed
remove the iquid gasket and appy it again
5 Ater
Ater ass
assembli
emblingng th
the
e var
varo
ous
us par
parts
ts wai
waitt for at east
east 5 i
intes
ntes befor
beforee sta
start
rting
ing th
the
e engi
engine
ne
3 REMOVING PARTS
hen removing each part do not attept to pry on
one
e poton of the fange aone but use the fange coar or cearance to pry
the flange at several points alternately
NOTE: When removing the oioill pan, th
the
e ange of the ol pa
pan
n may sometim
sometimeses become defor
deformed
med preventing it from being
reused To prevent this thereore, ir inse pates wth a thin edge at several points around the periphery of the
oil pan then remove the oil pan using a rewdriver
ELECTRICAL EQUIPMENT EE-1
EES2E02
CHAPTER
HINO ELECRICAL
EQUIPMEN
Models: H07C H07CT H07D H07DT
DATA AND SPECIFI
SPECIFICATIONS
CATIONS .
.
EE- 2
LOCATION
LOCATION OF ELCR
ELCRICAL
ICAL EQUI
EQUIPMENT
PMENT
EE- 2
ROUBLESHOOTING .
.
EE 3
GENERAL
GENERAL INSTRUCTIO
INSTRUCTION
N
.
.
.
.
EE 5
BAERY
EE- 6
NGINE
NGINE STARTING
STARTING CIRC
CIRCUIT
UIT
EE 7
INAKE
INAKE AIR HEAER IRU
IRUIT
IT
.
.
EE 9
ENGINE STOP IRUIT ..
...
.
EE10
ETER AND GAUGE IRUIT
EE11
LETRIAL WIRING DIAGRAM
EE-2
EE-2 ELECTRICAL EQUPMENT
DATA ND SPECIFIC
SPECIFICTIONS
TIONS
Electrical system
Voltage ..................... Dirct current 24 volts
Ground ...............
............... Ngati (-) ground
HINO H07C HINO H07CT HINO H07 D HINO H07 DT
LOAO OF ELETRIL QUPMENT
QUPMENT
A�
1 3
4
I
8 9 10
11 1
r ( 13
14 15
17
@ f[
1. Coola
Coolant
nt temper
temperature
ature switc
switch
h 6 Oil pre
pressu
ssurere swtch
swtch 1 Glo
Glo plug
plug contro
controll
llrr
2. Cool
Coolan emperatur gauge
antt tte 7 Oil pr
press
essure
ure gaug
gaugee sendr
sendr un
un 13 S
Sar
arte
terr block
block relay
relay
sender unit 8 Coo
Coolan
lantt temper
temperatu
ature
re gau
gaug
g 14 Ba
Ba
swit
switch
ch
3. Hino Glow plug 9 Oi
Oill pres
pressur
sur gaug
gaug
1 Ba
Ba m main
ain swi
switch
tch
4. Sole
Soleno
noid
id coi
coill 10
10 Ta
Tacho
chomt
mtrr 1
1 Ba
Ba
rla
rlay
y
5. Revo
Revolu
lution sensor
tion 11 Ammet
mmetr r 17
17 Sa
Sa
rr swch
swch
ELECTRICAL EQUIPMENT EE-3
TROUBLESHOOTING
Symptom Possible cause Remedy I Preventon
A lot f exhaust is emitted-- uxiiay stating device
but the engine does nt
stat is diicut
(Auxiliay stating todevice:
sta. • heate
Lose wiing
signao heate signa o deective Repai o repace
Standad specifications) • Deectve heate pug .. Repace
• Deective iing etween heater and pug Repai
Auxiliay stating device • Deective poer reay ......
...... Repia r repace
repace
Optin secifications) • Deective heater pug ..
. Repace
• efete
ng between heate and ug ug Repai
Repai
• Deective sensing
sensing esisto
esisto ..... Repace
• Deective heater
heater conto timer Repace.
oenoid does not opate --�a ergency stop reay
when egne
egne is unnng,
unnng, • tenato maunction ......
..... . Repair or epace
epace
iseven
input
Enginei abnma
abdoes
nma
not signa
stop) •• IFauty
suicient batteyatvotage
connection temina
temina.......
...
o .... Cage
o ....... Repar or repace
emegency eay
• Deective soenoid ....... Repace
Soenoid opeates ith ' ergency stop rea
starte switch is tned / • Fauty connection at R 1 termina . Repair
ON j • Fauty connection at Band C teina .... Repai
atte
When the stae switc - --
is tuned O the batte • Insuicient
suicient votage ..... Chage r epace
eay sitch ges O
opeate
and the senid ais to • ternat
Maunctions .............
......... .....
....
... Repai or epace
epace
-- � atter
o --
State chatteng o
State
imppe punging • sucient votage
votage ............
..... ...........
.... Chage or epace.
tate bock eay
• Fauty connectio
connectionn at temnas ...... Repair.
• ntena circuit abnma ........
... ..... Repace
• Reay sitch abnomaity auty contacts Repace
ipoper siding beteen od an moving
coe o openccuit
openccuit or unt out co
arter stch
• auty connection at termnas
EE-4 ELECTRICAL EQUPMEN
Sympto Possible cause Remedy/ reventon
Improe dsengageent - � � Alnao
ofuncton
starerwen
oatng o deective
engne hod
s I • Deectve
(corect
Sae bock eayotage
/ no geneaed) . Rpa eace
• e
e eemna
mna cnnec
Rea
• Ree
Reese
se cnnecto
cnnectonsns o eenas
nas 8 and C Rea
Re-plugg dring
ate ock eay
�
nera rotaton • Ree
Reese
se connect
connectons
ons to tens
ns B and Rea
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRe
www.HeavyEquipmentRestorationParts.com
storationParts.com
ELECTRICAL EQUPMENT EE-5
GENERAL INSTRUCTION
WARNING
Be sure to disconnet the ground cable before seicng the
electrical ircuits except for o-vehicle testing.
EXAMPLE: WRING CODE
3WB iring colors are indicated by a code.
ack g ight green
1.
r rown R Red
G Green hite
ue Y Yeow
3 mm 2
he first etter indicates the ground wire coor ad second
etter indicates the stripe coor.
{0.0047 in 2} 2.
3. rabic numerals indicates the cross sectiona area of wire
Example: 3 indicates 3 mm2 {00047 in 2}
SM20-4
CONNECTOR
he connectors exist as male and female conectors.
ae and emae connectors are classiied according to the
shape o the terminals n the connector (reer to the igure
on the left).
FEMALE AE e and eae connectors are provided wth a lock, so
that they can no be separated easiy
or connector separation hold the connector unlock the
ock and separte the connector
NOE Whe the conector is pulled by pullig the wires, the
coectio betwee the terminals ad the wires will be
damaged.
1. Remove the terminal ro the connector
M2044 a nsert a mniature screwdrver or a terina puer between
terina
na and connector and unock the lock between teri-
and connector
b hen the lock has been reeased pu the wire to remove
the termina.
2 nsta the terina in the connector
DETAI nsert the terina nto the connector unti the cicking sound
o ock engageent can be heard
a.
' ' u the wire to conirm correct ock engagement
\
- �
b
FUSE
SM204
he powe suppy ust be switche o or use repace
ent
Use a use with a suitable amperage
OE Wire burnn
burnngg may be caused whe a fusfuse
e wth an exces
sively large current capacity is used
the use
us e shoud bow requenty inestigate the cause and
reove it
0
S2048
EE-6 ELECTRICAL EQUIPMN
BATTERY
OVO OM O P V.
ENSUR THA THE 0 The specfc gravty of eectrolyte changes accordg to the
BARYIS
AWAYS FULY temperature of the eectroyte self, hece t s based o
CHRGD temperature of 20 C {68 F}.
° °
Cosequety if the temperature s ot 20 C whe the
°
specfc gravty s measured t s ecessary to cove the
measured vaue to the euvaet vae at 20 C
emperature conversion fo
formu
rmula:
la: 20 =+ 00007 ( -20)
Where
• S20 s the specfc gravty at 20 C (referece temperature)
°
• St s the sp
specfc
ecfc gravty at te mea
measur
surgg te
tempera
mperature
ture
• t s the te
tempe
mperat
rature
ure dur
durg
g mmeas
easure
ureme
mett
• 00
00007
007 s the te
tempera
mperature
ture coeff
coeffcet
cet o
off the ee
eectroy
ctroyte
te
O: s a ough guide, if the temperature of the eectrolye
rises or falls by 15 ° {9 } the specific grvy of the
electrolyte wll va by about 001
Be carefu of the foog pots
1) Whe the attery s beg charged esure that the tem
perature of the eectroyte does ot rse above 45 C 3
2) Whe the battery s beg charged, be pacuary caref
to keep t away from sources of fre
) he amout of electroyte must be th the specfed
eve
pecific gavity hen bae is full chaed
SM20-088C 10 170 a
att 0 68
If te termas at the top of te battery are dy cea
them th
Appy cod
a gt ater of
coatg or grease
uearm ater
to the termas to prevet
them from rustg so as to prevet fauty cotact
O
Camp the cabes securey to preet mproper cotact
betee te cabes ad te baer termas
e ery carefu ot to coect the +) ad -) eads
reverse ecause ts may cause equpmet ru off the
batter to be damaged)
ELECTRICAL EQUIPMENT EE-7
ENGIN STARTING CUIT
BATTERY MAIN SWITCH INSPECTION
Check continuity between temnas.
Terminal
Between terminal
terminalss
Switch position "
ON Continuity
OFF No continuity
SM20-139
BARY SWITCH INSPECTION
Ceck continuty between termnals
A !
8
Terminal
Between terminals
Switch position "
ON Continuity
OFF No continuity
M20527
BATTERY RELAY INSPECTION
Ap
Appp
volt
voltag
ag t te
ten
na
as;
s;
4 V to temnal ,
Goun to teina
. If eay s noa tenas and 4 goes be continuty
r� - -4
3
M20582
STARTR
STARTR RELAY INSPCTION
s 1. ppy voltage to teinas
to terinal
Groun to termina E
2. eay s noa teinal Ban goes be continuity
SM206
EE-8 ELECTRICAL EQUIPMENT
TPE-I
STARTER
STARTER BLOCK REAY INSPECTIN
1 Apply voltage to terminals;
24V o termnal S,
Gound to temnal E.
2 If elay is norma termnal C and B oes be contnuy
3 Then apply oltage to temnals;
24V to termnal S
2V to temnal N
E Gound to temnal E
�-SW 4, elay nomal elay does no opeate (Saety system op-
SM20-153
ates)
TE
S201098
STARTER
STARTER SWTCH INSPECTION
G2
heck contnuty etween temnals
G,
Type-I
Trminals
B, B2 G G2 M s
Switch poston �
OFF
EAT "
( -
ON .
SM20 START f'
-
r, n
-
i
'
, ll
TypeII
Terminas
R
BR Swich posiion
OFF
B
0
ACC R2 C BR
i '
II C
Ill
S09
TypeI
I� Terminas
B ACC C BR R2
Switch posiion
OFF
0
II _, -
ELECTRICAL EQUIPMENT EE-9
INTAKE AIR HEATE CIUIT
GLOW PLUG INSPECTION
Check ontinuiy between terminal and boy goun.
TRMINAL
SM20-127
YPE-I INTAKE AIR HEATER RELAY INSPETION
1 ply vovolltae
tae to ter
terminals
als;
2V o ermna SW,
Gound o emnal
2 f ela
elay
y s
snnomal
omal e
em
mn
nal
als
sSSan
an F goes be cont
contin
inu
uy
y
SM20306
GLOW PLUG CONTROLLER INSPECTION
Cec coninuy between ermnals an
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
SM04 Website: www.HeavyEquipmentRes
www.HeavyEquipmentRestorationParts.com
torationParts.com
EE-10 ELECTRICAL EQUIPMENT
ENGINE STOP CIRCUIT
SOLENOID AND INK ROD INSPCTION
1. Connect
Connect the batter
battery
y to th
the
e sole
soleno
noid
id ter
terma
mas
s ad co
cof
frm
rm
that the
th e sonod s draw
2. Push n the puge by hand an corm that there s a
cearace betwee the stopper ad the sop ever
Standard clearance: 2-3 mm {0.0118801181 in}
I there s no ceaance, peom adjstmet wh the k
NOT o If the clearance adjustment is unsatisfactry
unsatisfactr y r the
actn f the slenid is sluggish, slenid burnut
insuffcient utput r insuicient engine stppage may
result
Ins
Instal
talll th
the
e link rd with
with the
the nut at the tp
tp
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRe
www.HeavyEquipmentRestorationParts.com
storationParts.com
LINK ROD SM20-1357
COOANT TMPRTUR SWITCH INSPCTION
heck contny w ermas
TypeI
" Terminals
1 2
Temperatre oc {Of}
re than 96100 205212} 0 -
ess than 91 19}
S2-A
TypeII
!" Terminals
1 2
Temperature c f
re than 100104 212219 C )
ess than 95 203
ELECTRICAL EQUPMENT EE"11
OIL PRESSURE SWITCH INSPECTION
1. Start the engine and dsconnect the coupler
2 Check contnuty between termna and engne ground
- Terminal Body
Engine stop 0 -
Engine runnig
SM20-037
METER AND GAUGE CIRCUIT
COOLANT TEMPERATRE GAUGE SENDER UNIT INSPECTION
Warm up sende gauge and measure resstance between
termna and bod ground
Temperure 80 C {1 76 F}
°
100 C {22�
Resistance (Q) 73.7 :n 37 :-
S20-042
COOLANT TEMERATRE GAUGE NSECTO
We gages, esstes and vaae esste as shown n
fgue
hec ndcated vaue on gauges
Varibe resistor (Q) 80 C {6 F
100 C {22 F}
°
- Gauge reading 65 :� 36.S
-
I
SM201152
COOLANT LEVEL SWITCH INSPECTION
heck contnty between tenas
I UP
" Terminals
2
t
+
0
Flat positon
UP
DOWN n n
FLOAT
2
SM2080
EE-12 ELECTRICAL QUIPMENT
OIL PRESSRE GAUGE NSECTON
1. Wire the receve gaug and snd as sown n gu
2 Apply a pssu o snd gug nd cck -
ceve
3 If s no coc, plc h on (c o sn)
and chec ga
_24 V
AIR PRESSUR
SM20-153
AMMETER ISPECTO
Cc connuy bw tmnals an 2
SM20
REVOLTIO SENSOR INSPECTION
Cec connuy bwn emnals
s noml bewen mnls s connuy
SM205
(T.SD)
ELECTRICA WIRING DIAGRAM MODE H07D, H07C-
EMERGENCY RELAY SOLENO I D COIL GLOW PLUG SENSO , GIOW LUG
CUENT
5 0.85
I l
C
c
C
c
C
c
C
c
5 STAT BLOCK
EAY 5 INTKE AI ET ELY
FUSE
� 5 , 2
5( H7
1 7AHO7
� 11 I;I I
5
D
5
I 11)
5
15 CHARGE LAMP
C
C
C
c STATER
55KW
I 60
ATRNATO
AC 4V-A) 5 7�
HO?
AC V35A
o
5 �9- ILOT AMP
STARTER . 3W
SWITCH
5
5HO
5
BATTEY REAY BATTERY
CNNECN AE TARER WCH
1 I I 1 I M I
PRE HEAT
N
AR HDS-0008-0105B
ELECTRICAL WIRING DIAGRAM MODEL H07, H07C-T
GLOW PU
EMERENY RELY
5
SOOD OI
1.5
2
rm-
_
- -
-
BOK L
O SS. CAT
SW CH I I L
" "
,
1.25 8
8
5 5
15
D 25
15 15
S
O OW U
5 O
( 4V-0)
24V3W)
5 60
S 5 L
SW
60 60 60
25
CA
O SSU A OEO
OF S SW
U O
A
A A
HDS-0008147B
ELECTRICAL WIRING DIAGRAM
DIAGRAM MODE H07D, H07C-T
EMEGENY ELAY SENID CO UG
.2 5
1 - G.BUTN
I
SP -�
7
r fn
1 _ � 7 -
r
FUSE X R K REA
SSR
PSSU SWH
SWH M 25
-� l&
5
1
D
2
1.
A
SSA
AENAR A 2 U
60
AP (3) t25
AY S
SA
S A
NNS
AE
60
1.25
±
ESSUE A PA PRE EA
A A OF
AY SA
ON
AUPSS
N A
AS
A
p HDS-0088028C
TURBOCHARGER TU-1
TUS31E03
CHAPTER U
TRBOHAGR
Model IHI RHC6
DATA AND SPECIFICATIONS .......................•..................
................... ....•...........................
......... U-2
TROBLESHOOTING ........................... ..............
..........................•......
..............•.........
... U-3
OVERHAL CRITERIA ......................
............................................
...........................................
..................... U-5
TRBOCHARGER .................................. .........•...............
.................
........
... U-7
HINO DIESEL ENGINE PARTS CONTACT
EMAIL:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
Website: www.HeavyEquipmentRe
www.HeavyEquipmentRestorationParts.com
storationParts.com
TU-2 TURBOCHARGER
DATA
DATA AND SPECIFICATION
SPECIFICATIONS
S
Pars No. 24100-2202,22032531 24100-2780, -290
Type RHC6W RHC62
Turbine type Radial flow type Radil flow type
Blower type Cetrifugal type Centrifugal type
Lubricatig method Exteral lubricatio type Eeral lubricatio type
Bearing type Full floatig type Full floating pe
Coutercckise
Couterc ckise as seen Couterclockise as seen
Directio of rotatio
from the turbine side from the turbine side
Cooling type Oil ad water cooling type Oil coolig type
Waste gate valve Equipped Equipped
Application Costruction equipment ir compressor
TURBOCHARGER TU-3
TROUBLESHOOTING
TROUBLESHOOTING
Symptom Possible cause Remedy /Prevento
Dense black smoke - Insuicent air intake
• Ar cleaner s choked wth dust ...... Dsassemble and clean or replace
casing greater ntake air resstance the ar cleaner element
• Air inlet is choked .
.
Repair
• Ar s lleakng
eakng from inta
intake
ke manifo
manifo
Repai
Repair
r
Turbocharger does not rotate smoothly
• Engine ol impurties deposited on ... Overhal and clean turbocharger
rotor, resutng in heavy rotation
or stcking and/or change engne oil
Bearng stcking
• Insucie
Insucient
nt lubrcat
lubrcaton
on or block
blockage
age Check lbrcating o system
of ubrcatng ol nes and/or repair
• Abno
Abnorma
rma wea
wearr or damag
damage e of s
seal
eal ..
.....
..... Repar
..
ring caused by
b y wear of jornal bearng
due to nsufcent brcat
brcaton
on
• Tempe
Temperatu
rature
re of lu
lubrcat
brcating
ing o
oil
il too
too hg Check coolng system
• Unbala
Unbalanced
nced rotatng
rotatng pars
.
..
..
.. Change rotatng pas
.
• Incompl
Incomplete
ete warmng
warmngup
up fal
falure
ure
Operate
Operate vehic
vehicle
le prop
properly
erly
to dle before stoppng engine or
ack rabbt stars
Loose or damaged turbine rotor or bower impeller
• Overrotaton . Check and adust the engne
• Tempe
Temperatre
ratre of exh
exhaust
aust g
gas
as to
too
o hg
hgh
h Check and adjust the engne.
• Fore
Foregn
gn matter p
presen
resentt
.. Remove foregn material
..
nspect the air ceaner and air
ntake manfold
Repar f necessary
• Worn thrust bearing
..
.. Overhal and repair
• Incomplet
Incomplete
e asse
assemby
mby
.
.
Reassemby
Reassemby
High volume exhast Exhast gas leaking before turbocharger ....
.... Check and repair connectons
lke nose therefore nsuffcent revouton
-L eformed or bocked exhaust gas lnes Repair
-
therefore nsuffcient revoution
White smoke Choking defects or deformation o Repar and replace th nes
L
o return lnes so that oil leaks around
blower or turbne sdes
Sea rng may be broken o worn due
Replace the thrst washer
to abnormal wear of thrust washer
TU-4 TRBOCHARGER
Symptom Possible cause Remedy /Prevention
Loss of power
Air leakage from air manifold ............................ Repair
Clogged air cleaner element .................... Clean or replace.
Turbocharger diy or damaged .................... Repar or replace
Poor response o Carbon accumulaton on the turbine ................... Change engine oil, lea turb
turocharger side seal rng and heavy rotation charger.
------L - Poor ombuston ..................................
.................................. Check fue system and improve
ombuston
High ptched noise -----Noise
_
and ibraton
• So called "surging" .............................. Oerhaul and clean turboharger.
Surging sometimes occurs when the gas
passage at the nozle of the turbne
housing s choked or when ompressed
ar does not flow in proper responses to
acceleration.
• oosen rotatng parts .........................
................................
....... Replace.
Vbration
• Joints loose beeen tturbocharger
urbocharger ............... Check the mountng a
and
nd repair.
and ntake exhaust anfold or ol lnes
• Daaged earng loose ro
rotatng
tatng pas ........ Repar.
mbalanced rotatng pats etc.
TURBOCHARGER T-5
OVERHAUL CRITERIA
SPECIAL TOOLS
Pio to staing a tubochager ovehaul, it is necessay to have these spial tools.
AACHMEN FOR MEASURING
BOOST PRESSURE GAUGE BOOST PREURE GAUGE HOE RBINE HA RADIAL PLAV
PLAV
091250 17108-100 091230
CONDTIONS WHCH DETERMINE HEN TURBOCHARG-
ER OVERHAUL AY BE NEEDED.
EXAMPLE
INPEC HE TURBOCHARGER BOOS PRESSURE
Inspect the turbochager boost pessure according to the
olowing pocedures.
NO: Befoe measuement
o Coolant tempeatue sould appoxiately 80 C {176
° °
o Ai cleane eleent sould be clean
WARNING
When making a pessue test, be sue tat pesonnel ae ade
quately potected against any steam of pessuized ai that
might be eleased by a leak o te uptue of a hose
1 Remove the blind pug on the iintake
ntake pipe an insta he hos
hose
e
and pessure gauge (special tools)
pial Tools Pessue Gauge ((09-1250)
09-1250)
Hose 17108100
2. Disengage the cutch and run the engine at maximum r/min
3 Read
Read boost p
pes
essu
sue
e..
f the boost pessure is beow the noma vaue, tubocharger
overhau is needed
Boost Pessue;
SM51-016
2410002
2410003
7943 kPa 081 kf/cm , 1152 lbf/in }
2 2
241002531
24100-90
241002780 2941 kPa 030 kf/cm 426 lbf/in
TU-6 TRBOCHAGE
ISPECT TE TURBNE SHA ROTATIO.
Rotate the blower impeller by hand to see if it turns smoohly.
If it does not turn smoothly, clean and inspect the bearing and
turbine rotor.
SM51-002A
ISPECT THE TURINE ROTOR FOR AXIAL PLAY
If the axial play is greater than the sice limit rplace the
thrust bearing and/or thrust spacer
Aial Pay: 0.0508 mm {00020031 in
Serice Limit 010 mm {00039 in}
ISPECT THE TURBINE ROTOR OR RADIAL PAY
f the radial play is greater than the seice limit rplac the
bearings and/or urbine rotor.
Spia Too (1230)
Radia Pay 0012 mm {00030047 in
Serice Limit
Limit 017 mm {00067 in}
SM51-002A
OTHER ACTORS
1 The ngine lacks power or ngine exhaust emits black smoke.
2 Nose of xcessive vibration of the turbocharger
3 Excssive ngine oil consumpton
4 Gas leleak
akage
age at the turb
turbin
ine
end
nd o
orr blo
blowe
werr en
end
d
5 Oil leaage from the turbochargr
TURBOCHAGE TU-7
TURBOCHAGE
DESCRIPTION
1 2
1. Tu
Turbrbin
inee ca
case
se
2. Turbine rotor
3. Cooling channel
cha nnel
4. Bearing case
5 Blower impeller
6 Blower case
A Oil inlet
B i
i tl
tlet
et
-)
�,_ -=
i _
Representative type RHC62W
OVERHAUL
7
T 111.38
{1214 0.87101}
18
8
T Tightenig torque: N {gfcm lbf
1. il th
thro
rowe
werr 7 Blower case 13. Journal bearing
2. Se
Seal
al rrin
ingg 8 Turbine case 14. Retainer rig
3. Seal plate 9. Loc plate 15
15 Th
Thru
rust
st spa
spacer
cer
4. Bloer impeller 10. Turbne sha 16. Thrust bearg
5. Lock nt 11. Hea
Heatt pro
protec
tector
tor 17
17 Retai
Retainin
ningg wash
washer
er
6 Lock plate 12
12 Bear
Bearin
ingg case
case 18
18 Actu
Actuat
ator
or
TU-8 TURBOCHARGER
IMPORTAN
IMPORTANT
T POIT
POITS
S - DISASSEMB
DISASSEMBLY
LY
Make matching marks on the turbine case, bearing case and
blower case to aid algnment durng reassemby.
REOVING THE CONNECTING PART OF WASTE GATE ACTUA-
TOR (IF SO EQIPPED)
1 emove the actuator hose.
2 emo
emove
ve tthe
he a
act
ctua
uato
torr co
cont
ntr
r rod reta
retan
nng
ng wash
washer
er..
REOVING THE BLOWER CASE
NO: o If
p f p
D
p
p
REOVING THE LOWER IPELLER
NOE C
f
MATCHING MARK
TURBOCHARGER TU-9
1. Remove the blower impeller ng nt.
NO: Tu ck u cckws s
s u (L ad
ads)
ads)
EMOVING THE TUBINE CASE
NOTE caus
caus s
u sd a xsd
au, y a szd, d ay a
uasa c cas y ay
a Say a uca , a au
5 us ad s
f u
u
cas ca asy d y a
ad,
d,
a cauy a d
d us a asc a
a ad
cafuy
NO D
d u sa u
sa a cas.
NO Was a sys s sa d
,
,
WASTE GATE dsass ad adjus . ( s qud)
PUNG OUT THE TBINE SHAF.
e
emo
move
ve th
the
e t
trb
rbn
ne
e ro
roto
torr t
t
e
et
t r
rt
te
eto
tor
r
NO: o u sa ca asy d y ad,
a sa d f sd
f a
a c ca asy d,
d, a
cs.
TU-10 TURBOCHAGE
REMOVE THE BEARING.
1 Remove the seal plate
Pul out the sea pate using the two screws.
2 Remove the ol thrower fro the seal pate
3 Remove the thrust bearing and thrust spacer
Loosen the bolt, then remove the thrust bushng using a 8 dia
copper rod
NO: When re
removing
moving the thrust be
bearing
aring and thrust spacer, be
carefull not to damage the thrust bearing hole in the
carefu
bring se
SM51-022 SM5062
4 Remo
Remove
ve the
the o oute
outerr re
reta
tan
ner
er rng
rngs
s of e
eac
ach
h be
bern
rng
g
NO When removing the retainer ring be careful not to damage
the front face of the hole in the bari
baring
ng ca
case
se
5 Reove th
the
e b
be
earings
OIL THROWER REMOVE THE SEAL RNGS
NO When removing the seal ring do not the turb
turbine
ine sha
suace groove of the seal ring
SM5024 SM5025
TURBOCHAGE TU-11
IMPORTANT POINTS - ASSEMBLV
ASSEMBL V
CAN A PAS.
1. Befoe ceaning, the disassembed pas shoud be visuay
inspected to check for burning abasion cabon deposits gas
and oi eaage
2 Tooughy cean a the pas wit diese fue using a so
brus and d with compssed ai
NO: o N l l
l
o N w
OIL INLE
ASSEM HE JOURNAL EAINGS
0
1 nsta
nsta
tte
e fi
firs
rstt eta
etain
iner
er rin
ring
g in the
the bea
beain
ing
g casi
casing
ng
NO o ll l w
.
o M l
o Ill w w
w
2 nsta te beaing in the bearing case
NO: Al l l
3 nsta te oter retaine ing
NOE l
l
OI OUTET ll l
4 epeat step ) though 4 to insta te second bearing
OIL NE
VIEWFROM
$ RBINE ROTOR
S51-2
ASSEM HE URINE SHAF
1 nsta a ne sea ring in te ring groove of te turbine sha
NO: I l w I
w l
2.
OIL INL SEAL RIG GP ostion
oat tete heat protecto
jounas protect
o theoturbine
on the beaing case
oto th cean engine oi;
3.
an nsta te turbne otor
otor in the beang case
NO l
w l
W
l
l
l
SM566
TU-12 TURBOCHARGE
ASEMB THE THRUST SPAE AND THUST BEARING
1. er buit in the turbine sha to bearing case, plce i to
turbine case
case and insta the thru
thrust
st space
2 Coat the cean engine oi to the thrust bearing.
3 nsa the thrust bearing by ock tight appied sce
NO: fm f f
f
w
NSTALL E SEAL P
OIL NLE
0 nse o nene sea rings
rings on he oi- throer
2. nsta the oi throer in the sea pae
NO o T f
w
o If m
m
SM51-024 S51005A
3 nsa the pate in he bearing case
NO o T ff
o A q ( B N N
07 N 5
v) f f
o I w
o T q
fm f
ASSEMB THE BLOWE IMPELLER ON THE TURBINE TUR BINE SHAF
nsa
nsa th
the
e b
boe
oerr ipe
ipeer
er o u
urbin
rbine
e sha
sha and tighten
tighten the nut.
nut.
NOTE T s
TURBOCHARGER TU-13
2. Al
Alig
ign
n the
the matc
matchi
hing
ng mar
mark
k of blow
blower
er im
impe
peller,
ller, lock nut and
turbine sha
MATCHING MARK
ASSEMBLE THE TURBINE CASE.
1 lgn the matching mark which put befoe disassembly
MACNG
MARK NOTE: In case of replaing the pas, onfirm the oil po position
and
and exhaust gas inlet po position
2 In
Inst
stal
alll the tu
tub
bn
ne
e cas
case
e to
ea
ean
ng
g case
case by
by llo
ock plate
NO Coat tigtening bolt wit antiseize ompound before
installation
INSTALION OF BLOWER CASE
1 pply lquid packing (Three Bond No 1207C o No 1215 o
euivalent) to blower side flange
flange face of bearng case
NO Take are that the liquid paking does not protrude to
blower case inside
2 lign the matching mak of blower case and bearing case
NOTE In ase o
NOTE off replaing the pas, onfirm the oi
oill po postion
and air outlet po postion
INSTATION OF WASTE GATE ACTUATOR (IF SO EQUIPPED)
1 n
nst
stal
alll th
the
ewwas
aste
te ga
gate
te actu
actuat
ato
o tto
o lo
lowe case
TU-14 TURBOCHARGE
ASSEMBLY TEST
1. Rotate the bower impeer by hand to see if it turns smoothy
Refer to SECTION OVERHAUL CRITERIA
2. Check the turbine rotor for axial pay
Refer to SECTION OVERHAUL CRITERIA.
3 Chec
Checkk th
the
e turbi
turbine
ne rot
rotor
or for
for radi
radia
a pay
pay using
using a specia
specia too
too
Refer to SECTION OVERAUL CRITERIA
4 Check the w
wast
astee gate
gate vave
vave operat
operating
ing conditio
condition
n (f
(f sso
o eq
equipp
uipped)
ed)
a) Appy air pressure
pressure to aste gate actuator
actuat or and confirm the
contro rod i
P {} P {/2 /
,
2 56-5
000 A
{00079} {8-8, 8-96}
8-96}
000
00 5 -59
-59
B
{0.197} {1.46-158, 2077 2247}
2 1069116.6
A
{0.0079} {1.091.9 15.51 16.92}
241002531
5 060-76
B
{097} {08-0 7-706}
7-706}
099-96
A
{00079} {- 9-7}
00780
07-86
B
{057} {-
{- 750-7}
b) Raise the air pressure from ka kgcm2, bin} an
air
confirm the air pressure as above vaue hen contro rod if
to A and B
T: oW
D 78 P {8 /2
596 /
/
c) Reduce the air
air pressur
pressure e ffrom
rom contro
contro i A
A at thi
thiss ti
time
me con
con
firm the air pressure does not don move than ka
in}.
kgf/cm2, 0.853 lbf
If no ih in above vaue check or repace he urbine case
unit
TURBOCHAGER T-15
INSPECTION AND REPAIR
Unt: mm n}
Iio Ie Sadard Lii Reedy Ispecio Procedure
Turbie Sha Ouside 10.39 Replace
Diaeer {04090}
SM51-033
Turbie Sha Bed 0011 Replace
0.0004}
SM5034
Seal Rig Groove Widh 133 Replace sha
of Turbie Sha 00524} assebly
Bearig Case side A: Replace
Diaeer 1703
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