Eploot: L:mfi:l

HIND
INDUSTRIAL ENGINE
CONTENTS
MODEL
EPlOOT
GENERAL
INSTRUCTION
ENGINE
FUEL INJECTION
PUMP
GENERATOR
I STARTER
TURBOCHARGER
l:mfi:l HIND MOTORS. LTU

TOK YO .JAPAN
Hino Engine Parts

email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
website: www.HeavyEquipmentRestorationParts.com
FOREWORD
This shop manual is a general description of the instructions and repairs required for HINO
MODEL EP1 00T industrial diesel engine. It also covers the constructions and operational
characteristics of the engine.
Daily and periodical inspection and maintenance are the most important factors governing
the high performance of the engine. The proper sequences and methods outlined should be
followed in repairs.
It is recommended that the customers make full use of this manual in order to attain the
maximum efficiency maintenance and repair
NOTE:
All specifications appearing in this manual are based on the metric system. However. as ready
reference, conversion has been made as shown below:
mm (in), m (ft), km (mile)

cm2 (sq.in)
mm3 (cu.in). cc (cu.in), m3 (cu.ft), liter (lmp.gal/U.S.gal)
g (oz). kg (lb)
kg-cm (lb.ft.), kg-m (lb.ft.), kg/mm (lb/in), kg/cm2 (lb/sq.in)
m/s (ft/s), km/h (mph)
1-100E-01
GENERAL INSTRUCTIONS
GENERAL INSTRUCTIONS ................................... 1-1
CHASSIS & ENGINE SERIAL NUMBERS .......................... 1-2

SPECIFICATIONS .......................................... 1-3
BOLT TIGHTENING ........................................ 1-7

RECOMMENDED LUBRICANT LIST ............................. 1-9
1-1
GENERAL INSTRUCTIONS
Fig. 1-1 03-2252

1-2
ENGINE SERIAL NUMBER

The engine serial number is engraved on the left side of the cylinder block.
ENGINE MODEL
SM3-1035
. Fig. 1-2
1-3
SPECIFICATIONS
DIESEL ENGINE FOR INDUSTRIAL USE
HIND EPlOOT 8.821 liters, 4-cycle,

6-cyl., water-cooled
APPLICATION: ELECTRICAL GENERATORS, WATER PUMPS, AIR COMPRESSORS, HYDRAULIC

CRANES & SHOVELS, ROLLERS, TOWING TRACTORS, FORK-LIFT TRUCKS,
SHUNTING LOCOMOTIVES AND OTHER GENERAL POWER PLANTS
e PERFORMANCE & PERFORMANCE CURVE (STD. specs.)

GENERAL USE (SAE J1349 Gross) GENERATOR USE (SAE J1349 Gross)
Min. fuel Stand-by Power Prime Power
Output, Output, Max. torque
intermittent rating consumption Output at Output at Output at Output at
continuous rating Nm (lbt·tt)
kW (HP) at rpm g/kWh (lb/HPh) 1,500rpm 1,800rpm 1,500rpm 1,800rpm
kW (HP) at rpm at rpm
at rpm kW (HP) kW (HP) kW (HP) kW (HP)
149 1200) at 2,200 127 1170) at 2,200 711 (525) at 1,600 215 10.353) at 1,600 110 (.148) 129 1173) 94 (126) 110 (1481
Ambient conditions: SAE DIN

° °
Intake air temperature 25 C 20 c
Barometric pressure 100 kPa 736 mmHg
Water vapour pressure 1.0 kPa 10.5 mmHg
e ENGINE DESCRIPTION
1. Type Diesel, 4-cyc., 6-cyl., in-line, overhead valve,
water-cooled, turbocharged
2. Combustion system Direct injection type
3. Cylinder
Bore x Stroke 120 x 130 mm (4.72 x 5.12 in)
4. Piston displacement 8.821 liters (538.3 cu. in)
5. Compression ratio 17.0
6. Direction of rotation Counter-clockwise viewed from flywheel
7. Dimensions (L X W x H) Approx. 1,255 x 820 x 1,100 mm (49.4 x 32.3 x 43.3 in)
8. Dryweight Approx. 770 kg (1,700 lb)
e FEATURES
1. Cylinder block Mono block cast iron with replaceable dry type liners
2. Cylinder head Single piece cast iron
3. Crank shaft Induction-hardened die forged special steel with
counter weights
4. Piston and rings Heat-resistance aluminum alloy
Three compression rings, chrome plated
One oil ring, chrome plated with coil expander
5. Camshaft Induction hardened carbon steel
6. Valves Heat resistance steel
1-4
e STANDARD EQUIPMENT
1. Flywheel housing HI NO own (SAE No.2 type)
2. Flywheel HINO own (SAE 11-1/2 in. type)
3. Fuel injection pump BOSCH "P" type
4. Governor Centrifugal, all speed control type
5. Fuel injection nozzle BOSCH hole type
6. Fuel filter Paper element type
7. Water separator
8. Cooling system Forced-circulation by volute pump
9. Lubricating system Full-forced pressure feed by gear pump
10. Oil filter Paper element type (full flow & by-pass flow)
11. Intake manifold Inlet position at front or right side
12. Exhaust manifold with
flange plate Rearward exhaust
13. Generator Alternator with integral regulator
24V-20A
14. Starter 24V-6KW
15. Safety valve
16. Connectors of electrical
equipments
e OPTIONAL EQUIPMENT
1. Cooling fan (suction or blowout)
2. Main switch
3. Battery switch
4. Battery relay
5. Starter switch with key
6. Ammeter
7. Fuse box
8. Engine shut off solenoid
9. Emergency relay
10. Coolant temperature switch
11. Coolant temperature gauge sender
12. Coolant temperature gauge
13. Oil pressure switch
14. Oil pressure gauge sendet
15. Oil pressure gauge
16. Intake heater
17. Intake heater relay
18. intake heater indicator
19. Tachometer with hourmeter
20. Tachometer cable
21. Muffler ................2-3 type available
22. Air cleaner
23. Air cleaner cap
24. Radiator with cooling fan shroud
1-5
SM3-1033
FRONT SIDE VIEW
LJ
SM3-1034
LEFT SIDE VIEW
NOTE: 1 i These specifications are subject to change without notice.

2) These specifications are for export models.
3) All specifications of the products are with normal manufacturing allowances and tolerances.
4) The performance and drawings are for standard specifications.
HIND MOTORS, LTD. TOKYO, JAPAN

1-7
BOLT TIGHTENING
:�
Bolt tightening torque chart-for general purpose
Unit: kg·cm (lb.ft)
4
Bolt
indentification
6 8 10 12 14 16 18 20 22 24
Even tightening area. Bolt nut, coating, 10-15 ~ 53 ~ 128 174 ~ 255 ~ 712 ~ 1,530 ~ 2,170 ~ 2,980 ~ 3,750
0
36 88 304~ 445 486 758 ~ 1,110 1,040 1,480 2,030 2,560
naked bolt, lubricant, etc.
Optimum conditions.
10.8~1.01 12.7 ~ 3.81 17 ~ 91 113 ~ 181 122~ 321 (36 ~ 511 155 ~ 801 (76 ~ 1101 1108 ~ 1561 1147 ~ 2151 (186 ~ 2711
Cast iron or aluminium tightening

14 ~ 20 48 ~ 71 117~172 ~ 340 ~ 592 ~ 950 ~ 1,480 ~ 3,970 ~ 5,000
0
surface, Washers.
232 405 647 1,010 1,390 ~ 2,040- 1$970 ~ 2,900 2,700 3,410
Medium conditions. (1.1~1.41 (3.5 ~ 5.11 (9~121 (17~ 241 (30~421 (47 ~ 681 (74~ 107) 1101 ~ 1471 (143 ~ 2091 (196 ~ 2871 (247 ~ 3611
Tightening area having black coarse

surface. Rusty. Naked bolt or lubricant
17 ~ 25 60 ~ 88 146 ~ 2·14 290 ~ 425 506 ~ 742 809~ 1,180 1,260~ 1,850 1,740~ 2,540 2,460 ~ 3,620 3,380 ~ 4,950 4,260 ~ 6,250
(1.3 ~ 1.81 14.4~ 6.31 (11 ~ 151 (21 ~ 301 (37 ~ 531 (59 ~ 851 (92 ~ 1331 (126~1831 (178 ~ 2611 (245 ~ 3581 1309 ~ 4521
unavailable. Poor tightening conditions.
Even tightening area. Bolt nut, coating,

~ 1,750 ~ 5,360
0
16 ~ 24 58 ~ 83 138 ~ 201 273 ~ 400 477~700 764 ~ 1.120 1,190 1,640~2,400 2,320 ~ 3,410 3,180~4,680 4,020
naked bolt. lubricant, etc.
11.2 ~ 1.7) 14.2 ~ 6.01 (10 ~141 (20 ~ 281 (35 ~ 501 {56 ~ 81) (87 ~ 126) 1119~1731 (168~ 2461 (231 ~ 3381 (291 ~ 3871
Optimum conditions.

22 ~ 32 75 ~ 110 183 ~ 270 ~ 3,200
0
364 ~ 533 636 ~ 932 1.020 ~ 1,500 1,590~ 2,330 2,180 3,100~ 4,550 4,250 ~ 6,210 5,360 ~ 7,850
surface. Washers.
Medium conditions. (1.6~ 2.31 15.5 ~ 7.91 114 ~ 19) 127 ~ 381 147 ~ 671 174~ 1081 1116 ~ 1681 (158 ~ 2311 (225 ~ 3291 (308 ~ 4491 1388 ~ 5671

27 ~ 40 94 ~ 138 229 ~ 336 455 ~ 667 795~ 1,165 1,270 ~ 1,870 1,990 ~ 2,920 2,730 ~4,000 3,870 ~ 5,680 5,310 ~ 7,800 6, 700 ~ 9,850
unavailable. Poor tightening conditions. (2.0 ~ 2.81 16.8 ~ 9.91 117 ~ 241 133 ~ 481 (58 ~ 841 192 ~ 1351 (144 ~ 2111 (198 ~ 2891 (280 ~ 4101 (385 ~ 5641 1485 ~ 7121
0 Even tightening area. Bolt nut, coating,

naked bolt, lubricant, etc.
24 ~ 32 82 ~ 110 200 ~ 267 397 ~574 694~ 925 1,010 ~ 1,480 1,730 ~ 2,310 2,380 ~ 3,170 3,380 ~ 4.510 4,630 ~ 6,170 5,850 ~ 7,790
0
Optimum conditions. (1.8 ~ 2.31 (6.0 ~ 7.91 (15 ~ 191 (29 ~ 411 (51 ~ 661 (74~1071 1126 ~ 1671 (173 ~ 2291 (244 ~ 3261 (335 ~ 4461 (424 ~ 5631
e
surface. Washers.
32 ~ 42 110~146 267 ~ 356 529 ~ 706 925 ~ 1,230 1,480 ~ 1,970 2,310~ 3,080 3,170 ~ 4,230 4.510~ 6,010 6,170 ~8,230 7,790 ~ 10,390
Medium conditions. (2.4 ~ 3.0f (8 .0 ~ 10.51 (19 ~ 25) (3!J~61) (67 ~ BBi (108~1421 (168~222) (230 ~ 305) (327 ~ 434) (447 ~ 595) 1564 ~ 751)
e
40 ~ 53 137 ~ 183 334 ~ 445 662~ 882 1,160 ~ 1,540 1,850 ~ 2,470 2,890 ~ 3,850 3,970~ 5,290 5,640 ~ 7,510 7,720 ~ 10,290 9,740 ~ 12,990
unavailable. Poor tightening conditions. (2.9 ~ 3.8) (10,0~ 13.2) 125 ~ 32) (48~ 631 (84 ~ 111) (134 ~ 1781 (210 ~ 2781 (288 ~ 3821 1408 ~ 5431 (559 ~ 744) (705 ~ 939)
NOTE: The torque values given in this table should be applilld where bott torque is not IJM(:ifilld.
RECOMMENDED LUBRICANTS FOR ALL HINO ENGINE HINO MOTORS. LTD.
OVERSEAS OPERATIONS
TECHNICAL DIV
TOKYO. JAPAN
ATMOS- S.A.E.
LUBRICANTS POSITIONS PHERIC BP CALTEX CASTROL ESSO GULF MOBIL SHELL TOTAL
TEMP. NO.
RPM DELO 400 Otl Castrol or Deusol Myr1na 0.1 40. TOTAL
Above Essolube Mobd Oelvac 1 340
Vanellus C-3 SAE 40 01' 1 5Wt40 CAD 40. Turbomu Gulf Super Oury 20W•40. 1 SW-40 Aub,a S 40
32'C 40 0-3 40. Mobil Oelvac Super
I90'FI 40 RPM DELO 300 011 Castrol or Deusol Motor 011 40. 1 SW-40 A1mula X Otl 40 TOTAL
XD-3 40 15W-40
SAE 40 RX Super 40. 1 SW/40 R1mula CT 40 Rubra TM 1 SW40
ENGINE OIL
IA PI. COi Myrina Oil 30.
RPM DELO 400 Oil Castrol or Otusol TOTAL
20W•40, 1 SW-40
Previous Class,fication 32' o·c 30
Vanellus C-3 SAE 30 or 1 5Wt40 CRD 30
Essolube
D-3 30.
Gutf Super Dutv
Mobtt Delvac 1 330
Mobtt Deh,ac Super Atmula X Otl 30.
Rubia S 30
IA PI OSI 190' 32'F1 30 RPM DELO 300 Cit Castro, or Deusol Motor Oil 30, 1 SW-40 TOTAL
IMIL•L·2104CI X0-3 30 15W-40 10W•30
SAE 30 AX Super 30. 1 SW/40 Atmula CTJO
Rubia TM 1 5W40
IMIL-L-4519981
Castrot or Oeusol TOTAL
RPM DELO 400 011 Myrina 011 20.
o· 12'C
20 Vanellus C-3 SAE 20120W. 1 SW:40
CAD 2ow,20
Castro! or Deusol
Essolube
0-3 20W.
Gutf Super Duty
Mobtl Delvac 1310
Mobtt Oelvac Super
20W-40. 1 SW-40 Rubia S 20
132' 10'FI 20W RPM DELO 300 011 Motor 011 20. 1 SW-40 R1mula X 011 20 TOTAL
RX Super 20Wt20. XD-3 1 SW,40 15W-40 A1mula CT20 Rubia TM 15W40
Cyhnde, Block SAE 20t20W
1SW140
tnIect10n Pump
Air Cleaner RPM DELO 200 Oil Castrol or Deusol
Above Essolube Rotella TX40.20W-50
Vanellus M SAE 40 CRX 40 Gulflube Motor 011 Mobil Oelvac 1240 TOTAL
32'C 40 HOX 40. Rotella SX 011 40,
I90'FI 40 RPM DELO 100 0,1 Cawol or Deusol
HOX Plus 40
XHD 40. 1 SW-40 Mobtl Oelvac 1 140
20W·40
Rubta H 40
SAE 40 AX Super 40. 1 5Wt40
ENGINE OIL
IA. P.1. CCI RPM DELO 200 Oil Castro! or Deusol
Previous Class1f1cat1on 32' o·c 30
Vanenus M SAE 30 CRX 30 Essolube
HOX 30
Gulflube Motor 0.1 Mobil Delvac 1230
Rotella TX30.20W·50
Rotella SX Oil 30.
TOTAL
IA P.1 DMI 190' 32'F) 30 RPM DELO 100 01! Castro! or Deusol XHD 30. 1 SW-40 Mobil Oelvac 1130 Rubia H 30
HOX Plus 30 20W-40
IMIL-L-46152I SAE 30 RX Super 30. 15Wi40
IMIL-L-210481
Castro! or Deusol
RPM DELO 200 Q,1
o· 12·c
20
Vanellus M SAE 20t20W
CRX 2ow.-20
Castro! or Deusol
Essolube
HDX 20.
Gulflube Motor 011 Mobil Delvac 1220
Rotelta TX20,20W-50
Rotella SX 011
TOTAL
132' 10-FJ 20W RPM DELO 100 Oil XHO 20. 1 SW-40 Mobd Oelvac 1120 Rubia H 20
RX Super 20W120. HOX Plus 20W-20 20/20W.20W-40
SAE 20120W 15W 40
COOLANT PUMP Marfak

Esso Retina.: A TOTAL
BEARING GREASE Coolan! Pump Bearing Energrease Multipurpose 2 Castro! LM Mob1lgrease
Multipurpose Gulfle� Poly MP,77.MS Alvania Grease R2 MULTIS 2
(MIL-G-109248) L·2 o, Mar1ak Grease
Grease
All P\l"lpose 2
Bushmg. Clulch.
STARTER GREASE Onve Shah.
P1nton Shih lever
--- Molyt!!l
Grease EP2
--- --- --- Mob1lgrease 29 A-,ro Shell Grease 1 7 ---
& Reduction Gear
GENERATOR & STARTER Generator Bearing RPM Grease --- ---

Energrease --- --- Mob,lgrease 2B Aero Shell Grease 7
BEARING GREASE Si,rter Beanng LT 2 SRI 2
INJECTION PUMP Mar1ak

Essa Mob1lgrease Ret1nax A TOTAL
TIMER GREASE lnIact10n Pump Timer Energrease Multipurpose 2 Castrol LM Mul11pwpose Gulflel Poly MP.77.MS Alvama Grease R2 Mult1s EP 1
L-2 or Marfak Grease
IMIL•G· 1092481 All PurposP. 2 Grease
Shellzone!U S A.)
Cruise Master Glycoshetl Plus
Casl/OI An11-Freeze esso
ANTI FREEZE Engine, Rad11to1
An11 Fros1
AF Engine
Cas11ol Long Lile Anti Freeze
Antifreeze Mobil (Europian Countries!
Shellsafe
TOTAL
IMIL-H-5559AI Coolant And Summer Permazone ANTIGEL
Cool11nt Cootani Al'lt1-FrHze P281
Coolant
CoolQuard
Note: Lubricants were amended ,ccording to ntW clauifie1t1on by A P.l <Amencan Petroleum Institute) '82-12-200 rT.S.DH!!I
3-17ESF-01E
ENGINE
MOTOR
MOTEUR
SYMBOL MARKS
SIMBOLOS
SYMBOLES .............................................
· 3-1-1
A GLOSSARY OF TECHNICAL TERMS
GLOSARIO DE TERMINOS TECNICOS
LEXIOUE DE TERMES TECHNIQUES ........................... 3-1-2
INTRODUCTION
INTRODUCCION
INTRODUCTION .......................................... 3-1-5
SPECIAL TOOLS
HERRAMIENTAS ESPECIALES
OUTILLAGE SPECIAL ...................................... 3-1-12
OVERHAUL
REPARACION GENERAL
REVISION
ENGINE OVERHAUL CRITERIA

CRITERIOS SOBRE REPARACION GENERAL DEL MOTOR
CRITERE DE REVISION OU MOTEUR ......................... 3-2-1
CYLINDER HEAD AND VALVE MECHANISM
CULATA DEL CILINDRO Y MECANISMO DE VALVULA
CULASSE ET MECHANISME DE SOUPAPE ...................... 3-3-1
TIMING GEAR AND CAMSHAFT
ENGRANAJE DE LA DISTRIBUCION Y ARBOL DE LEVAS
PIGNONS DE DISTRIBUTION ET ARBRE A CAMES ................ 3-4-1
CYLINDER BLOCK, PISTON AND CRANKSHAFT

BLOOUE DE CILINDROS PISTON Y SIGUENAL
BLOC-CYLINORES, PISTON ET VILEBREOUIN ................... 3-5-1
LUBRICATING SYSTEM
SISTEMA DE LUBRICACION
SYSTE:Mt DU G�lAISS/\G[ ........................... 3-6-1
COOLING SYSTEM
SISTEMA DE ENFRIAMIENTO
SYSTEM[ Of_ Rf·f·HOIUISSI fv1LNT ...................... 3-7-1
FUEL SYSTEM
SISTEMA DE COMBUSTIBLE
SYSTE ME. COMfllJS 11 Ill I ............................ 3-8-1
AIR CLEANER
FILTRO DE AIRE
� I L TR L A A I H .. . .... . . . . . .... ... . .. ..... ..... . .. . 3-9-1
TUNING THE ENGINE

PUESTA A PUMTO DEL MOTOR
GONFLAGE OE MOTEUR ............................ 3-10-1
TROUBLESHOOTING
LOCALIZACION DE AVERIAS
RECHERCHE DE LA PANNE ......•...............•... 3-11-1
SERVICE STANDARD
NORMAS DE SERVICIO
CARACTERISTIQUES DE REPARATION ................. 3-12-1
3-1-1
SYMBOL MARKS
The following symbols have been adapted for simplicity and for easy comprehension.
SIMBOLOS
Se han adoptado las siguientes simbolos para simplidad y facil comprensi6n.
SYMBOLFS
LPs symboles suivants ont ete adoptes ,1fin de simplifier et de faciliter la comprehension.
EJ
ASSEMBLY TIGHTENING
1..1"1
ARMADO APRIETE
MONl!\(;1- IHfMONT/\GE) SER RAGE (RESSERRAGE)
E1
DISASSEMBLY CLEAN
l}�I
DESARMADO LIMPIEZA
DE MONTAGE: NETTOYAGE
B Iii
INSTALLATION IMPORTANT
INSTALACION IMPORT ANTE
MISE EN PLACE (POSE OU REPOSE) IMPORTANT
E1 81
REMOVAL ADJUSTMENT
REMOCION AJUSTE
DE'POSE REG LAGE (MISE AU POINT)
INSPECTION LUBRICATION
[I]
INSPECCION LUBRICACION
� CONTROLE GRAISSAGE
l!t1
MEASUREMENT
MEDICION
MESURE
3-1-2

LEXIOUE DES TERMES TECHNIQUES
ENGLISH ESPANOL FRANCA IS
1. Air compressor gear 1. Engranaje del compresor de aire 1. Pignon du cornpresst�ur d'a1r
2. Approx. (Approximately) 2. Approx. (aproximadamente) 2. Approx. (Appru>:i1n;Jtivement)
3. Arc welding 3. Soldadula electrica 3. Soudure a l'arc electrique
4. Assembly standard 4. Estandard de armado 4. Norrne rJe montaqe
5. Bushing inside diameter 5. Diametro interio del casquillo �-
r· Diametre interipur de la bague
6. Cam height: A 6. Altura de levas: A 6. Hauteur de la came A
7. Case bushing inside diameter 7. Diametro interior del casquillo 7. Diametre interieur du carter de
8. Cam gear de caja baque
9. Clearance 8. Engranaje de eje de levas a
8. Pignon de l'arbre cames
10. Clearance between valve stem 9. Holgura 9. Jeu
and guide 10. Holgura entre vastago de valvula 10. .Jeu entre la tige de soupap1-, et
11. Clearance between liner and y guia le guide
piston 11. Holgura entre camisa y piston 11. Jeu entre la chemise et le piston
12. Coolant pump gear 12. Engranaje de la bomba de 12. Pignon rJ'entraineinent de la
13. Cooling jet enfriador pompe eau a
14. Correct 13. Chorro de enfriamiento 13. G icleur de refoidissement
15. Crankshaft gear 14. Correcto 14. Correct
16. Crankshaft matching 15. E ngranaje del ciguenal �-
p· Pignon du vilebrequin
17. Crank pin 16. Rectificaci6n del ciguenal 16. Equilibrage de vilebrequin
18. Cut-off valve 17. Codo de ciguenal 17. Maneton de vilcllrequin
19. Cylinder block 18. Valvula cierra 18. Soupape de detente
20. Cylinder liner 19. Bloque del cilindro 19. Bloc-cylindres
21. Cylinder head 20. Camisa del cilindro 20. Chemise de cylindre
22. Cylinder head lower face 21. Culata del cilindro 21. Culasse
23. Deflection 22. Superficie inferior de la culata 22. Face inferieure de la culasse
24. Dimension del cilindro 23. Flex ion
25. Dimension of fillet R 23. Defleci6n 24. Dimension
26. Difference between cylinders 24. Dimension 25. Dimension de rayons de
27. Drive shaft 25. Dimension de filete R raccordement
28. Drive gear shaft outside 26. Diferencia entre cilindros 26. Difference entre les cyl incl res
diameter 27. Eje impulsor 27. Arbre d'entrainemenl
29. Driven gear shaft outside 28. Diametro interior del eje de 28. Diametre exterieur de l'arbre de
diameter engranaje impulsor pignon d'entraInement
30. Driven gear bushing inside 29. Diametro exterior del eje de 29. Diametre exterieur de l'arbre de
dimaeter engranaje impulsion pignon entra1ne
31. Engine speed (r.p.m.) 30. diametro interior del casquillo 30. Diametre interieur de la bague
32. End play de engranaje impulsion du pignon entralne
33. Exhaust 31. Velocidad del motor (r.p.m.) 31. Regime de moteur ( tr/mn)
34. Exhaust manifold 32. Juego longitudinal 32. Jeu axial
35. 1st ring 33. Escape 33. Echappement
36. 1st step 34. Multiple de escape 34. Collecteur d'echappement
37. Force about 35. Aro 10 35. Segment coup de feu (Segment 1)
38. Free length a 36. 1 ere et ape
36. 1 etapa
39. Gasket 37. F uerza aprox imadamente 37. Effort approximatif
40. Groove breadth 38. Longitud libre 38. Longueur libre
41. Idle gear 39. Junta 39. Joint
42. Incorrect 40. Anchura de ranura 40. Largeur de la rainure
43. Injection pump 41. Engranaje loco 41. Pignon intermediaire
3-1-3
44. Inner spring 42. lncorrecto 42. lncorrect(e)

45. Intake 43. Bomba de inyeccion 43. Pompe d'injection
46. Inside diameter 44. Resorte interior 44. Ressort interieur
47. Journal 45. Adomisi6n 45. Admission
48. kg,cm (lb.ft) 46. Diametro interior 46. Diametre int�rieur
49. kg/cm 2 (lb/sq.in) 47. Muiion 47. Tourillon
50. Less 48. kg-cm (lb.pie) 48. kg-cm
51. Less than 49. 2
kg/cm (lb/pul.cuad) 49. kg/cm 2
52. Lower seat 50. Menos 50. Moins
53. More than 51. Menos de 51. lnferieur(e) a
54. No.1 - No.5 bearing inside 52. Asiento interior 52. Coupelle inferieure
diameter 53. Mas de 53. Superieur(e) a
55. No.1 - No.5 journal outside 54. Diametro interior de\ cojinete 54. Diametre interieur du coussinet
diameter No.1 - No.5 du palier nOl - n05
56. Not easily measured 55. Oiametro exterior de\ muiion 55. Diametre exterieur du tourillon
57. Nut No.1 - No.5 n01 - n05
58. Oil clearance 56. No puede medido facilmente 56. Difficilement mesurable
59. Oil pump drive gear 57. Tuerca 57. Ecrou
60. 0-ring 58. Holgura de aceite 5 8. Film d'huile
61. Oil ring 59. Engranaje impulsor de la bomba 59. Pignon d'entra1nement de la
62. Oil seal sleere de aceite pompe a huile
63. Outer spring 60. Anillo-0 60. Joint torique
64. Outside diameter 61. Aro de aceite 61. Segment racleur d'huile
65. Piston pin bore inside 62. Manquito de\ sello de aceite 62. Manchon de bague d'etancheite
diameter 63. Resorte exterior 63. Ressort exterieur
66. Piston pin outside diameter 64. Oiametro exterior 64. Diametre exterieur
67. Power steering oil pump gear 65. Oiametro interior de\ oriticio 65. Oiametre interieur de l'alesage
68. Regulator valve de pasador de piston de \'axe de piston
69. Relief valve 66. Diametro exterior del pasador de 66. Diametre exterieur de l'axe de
70. Repair limit piston piston
71. Repair limit of bent 67. Engranaje de la bomba de aceite 67. Pignon d'entra1nement de la
72. Repair limit of twist de la direccion hidraulica pompe a huile de la direction
73. Ring breadth 68. Valvula regulador assistee
74. Ring gap 69. Valvu\a descarga 68. Soupape regulatrice
75. Rocker arm bushing inside 70. Limite de reparaci6n 69. Soupape de surete
diameter 71. Limite de reparaci6n de comba 70. Limite de reparation
76. Rocker arm shaft outside 72. Limite de reparaci6n de 71. Limite de reparation de voile flexion
diameter corcedura 72. Limite de reparation de torsion
77. Rotating torque 73. Anchura de\ aro 73. Largeur du segment
78. Roundness 74. Entre chierro de aro 74. Jeu a lacoupe de segment
79. 2nd ring 75. Diametro interior de casquillo 75. Diametre interieur de la bague
80. 2nd step del brazo de balaci n du culbuteur
81. Service limit 76. Diametro exterior del eje del 76. Diametre exterieur de l'axe de
82. Setting length brazo de balanci n culbuteur
83. Setting load 77. Par de rotacion 77. Couple de rotation
84. Shim thickness 78. Redondez 78. Rondite
85. Sleeve 79. Aro i2 79. 1 er segment d'etancheite
86. Spacer 80. 21J. etapa (Segment 2)
87. Special tool 81. Limite de servicio 80. 2e etape
88. Standard 82. Longitud de ajuste 81. Limite d'utilisation
89. Stem cap 83. Carga de ajuste 82. Longueur comprimee
90. Tappet outside diameter 84. Espaciador de lamina 83. Sous charge de
91. Tappet guide inside diameter 85. Manguito 84. Epaisseur de la cale
92. 3rd ring 86. Espaciador 85. Manchon
93. 3rd step 87. Herramienta especial 86. E ntretoise
94. Tightening torque 88. Estandard 87. Outil special
95. Unit 89. Tapa de\ vastago 88. Normal(e)
3-1-4
96. Upper seat 90. Diametro exterior de levanta- 89. Capuchon de queue de soupape
97. Valve clearance valvula couple de serrage
98. Valve guide inside diameter 91. Diametro interior del guia de 90. Diametre exterieur du poussoir
99. Valve stem outside diameter levantavalvula 91. Diametre interieur du guide de
100. Wear 92. Aro 3Q poussoir
101. Within 93. � etapa 92. 2 e segment d'etancheite (Segment 3)
102. Wrong 94. Par de apriete 93. 3 8 etape
95. Unidad 94. Couple de serrage
96. Asiento superior 95. Unite
97. Holgura de valvula 96. Coupelle superieure
98. Diametro interior de la guia 97. Jeu de soupape
de valvula 98. Diametre interieur du guide de
99. Diametro exterior del vastago soupape
valvula 99. Diametre exterieur de la queue de
100. Desgaste soupape
101. Dentro de 100. Usu re
102. Err6neo 101. a l'interieur
102. Mauvais(e)
3-1-5
ENGINE {Model EP100T)
INTRODUCTION
Model EP100T industrial diesel engine is 4-cycle, direct injection type diesel engine having 6 cylinder in-line water
cooled and overhead valves.
DIFFINITION OF TERMS
The terms adopted in this Workshop Manual are defined as follows.
Rotation:
This engine rotates clockwise seen from the timing gear side.
Nominal dimension:
Basic dimension excluding tolerance.
Nominal clearance:
Space allowed between two parts on account of difference of tolerance when fixed together.
Repair limit:
Parts which reach this limit should be repaired. The mark (+)or (-) expresses increase or decrease
as compared with the nominal dimension.
Serviceable:
The utmost that can be serviceable and parts which reach this limit should be replaced. The mark
(+)or(-) expresses increase or decrease as compared with the nominal dimension.
3-1-6
DATA & SPECIFICATIONS

GENERAL
Model ........ : ........................ HINO EP100T
Model . . . . . . . . . . . . . . . . .. . .. . . . .. . . .. . . . Diesel, 4 stroke cycle, vertical 6 cylinder in-line,
overhead valve, water-colled direct injection type
Bore and stroke . . . . . . . . . . . . .... . . . . . . . . . . 120 x 130 mm (4.72 x 5.12 in)
Piston displacement· . . . . . . . . . . . . .. . . . . . . . . . 8.821 liters (538.3 Cu.in)
C ompression ratio. . ...... . . . . .. . ..... . . . . . 17.0 : 1
Firing order ............................. 1-4-2-6-3-5
Compression pressure . . . . . . . . . .. . . . . . . . . ... 2 8-30 kg/cm 2 ( 399-426 lb/sq.in) at 200 rpm
Maximum revolution (at full load) . . . . . . . . . . . . . . 2,200 rpm
Idling speed . . . . . . . . .. . . . . . . . . . . .. . . . . . . . 700 - 750 rpm
Weight ................................ 770 kg (1,700 lb)
CYLINDER HEAD
Type . . . . . . . . . . .. . . . . . .... . . . . . . . . . . . . Single piece casting
Material . . . . . . . . . . . . ... . . . ...... . . .. . . ... C ast iron
VALVE MECHANISM
°
Valve seat angle; Inlet .................. 30
°
Exhaust ............... 45
°
Valve face angle; Inlet .................. 30
°
Exhaust ... . ...... . .... 45
Valve material; Inlet.. . . . . . . . . . . . . .. . . Heat-resisting steel
Exhaust Special heat resistance steel
°
Valve timing (flywheel travel); Inlet opens .... . 6 before T.D.C.
°
Inlet closes ..... 22 after B.D.C.
°
Exhaust opens .. . 32 before B.D.C.
°
Exhaust closes .. . 6 after T.D.C.
Valve clearance (when cold) Inlet .......... 0.40 mm (0.0157 in)
Exhaust ....... 0.50 mm (0.0197 in)
Tappet ................................ Special cast iron
Push rod . . . .. . . . . . . . . . .. . . . . . . . . . . . . . .. Hollow, carbon steel
CYLINDER BLOCK, CYLINDER LINER AND CAMSHAFT

Cylinder block ........................... Mono-block, 6 cylinder, cast iron
Cylinder liner . . . . . . . . . . . . . . . . . . . . .. . .. . . . Dry type, replaceable, special cast iron, centrifugally cast
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Induction hardened die-forged carbon steel in material
Camshaft bearing; Number and material ........7, white metal with carbon steel back metal
Hino Engine Parts

Phone: 269 673 1638
3-1-7
CONNECTING ROD AND PISTON

Connecting rod . . .. . . .. . . .. . . .. . . . . . . . . . . 6, carbon steel
Small end bearing, Material .. . .. . .. . . . . . . . . . . . Leaded tin bronze
Large end bearing, Material . . . . . . . . . . . . . . . . . . . Thin-kelmet with lead alloy
Piston . . . ....... . . . . . . . .. . . . . . . . . . . . . . . Heat-resistance aluminum alloy
Piston ring; Compression .................. Three with chrome-plated
Oil ring ..... . . .... . . . .... . ... One, chrome-plated with coil expander
CRANKSHAFT AND CRANKSHAFT BEARING

Crankshaft .. . . ... . . . . . . . . . . . . . . . . . . . . . . Induction-hardened die forged special steel with counter
weights
Crankshaft bearing: Material . . . . . . . . .. . . . . . . . Lead indium and kelmet over steel back metal
TIMING GEAR
Timing gear drive . . . . . . . .. .... . . . . . . . . . . . . Helical gear
FUEL SYSTEM
Fuel injection pump BOSCH line type, driven by engine, 1/2 x engine rpm,
clockwise seen from the drive side
°
Injection timing (flywheel travel) ............... 16 before 1st cyl. T.D.C.(Top dead center)
Governor .............. .... . ........... BOSCH type, mechanical all speed control (RSV)
Fuel feed pump Piston type, driven by injection pump camshaft, max.
feeding pressure 3.4 kg/cm2 (48.3 lb/sq. in)
Nozzle . .. . . . . . . . . . .. . . . . . . . . . . . . .. . . .. Multi-hole nozzle type
Nozzle holder ........................... Injection pressure 220 kg/cm 2 (3,125 Ibis.in)
Fuel filter . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . Replaceable paper element type
LUBRICATING SYSTEM
Type . . . . . . . .. . . . . . . . . . . . . . . . .. . . . .. . . Forced-feed lubrication with oil pump
Oil capacity ............................. 26 liters (5.72 Imp. gal/6.87 U.S. gal)
Oil pressure ............................. 0.5-5.0 kg/cm 2 (7.11-71.1 lb/sq.in)
Oil filter . . . . . .. . . . .. . . . . . .. .. . . . . .. . . . . Full flow type using paper element and bypass type using
depth element
COOLING SYSTEM
Type . . ... . . . .. . . . . . . . . . . . . . . . . . . . . . . .
Forced recirculation type
Radiator cap pressure ..... ................. 0.5 kg/cm2 (7.11 lb/sq.in) than atmospheric pressure
° °
106 - 110 C (222.8-230 F)
Water boiling temperature . . . . . . . . . . . . . . . . . . .
Cooling system water capacity (only cylinder block) .. 15.5 liters (3.41 lmp.gal/4.10 U.S.gal)
Coolant pump . . . ..... . . . . .. . . . . . . . .. . . . .
Centrifugal, belt-driven by engine crankshaft
Fan: Type . . . . . . ... . . . . . . . . . . . . . . . . . . .
Mounted on coolant pump, 2-3 type available
Drive . . . . . . .. . . . . . .. . . ... .. . . . . . .
6-blades type, fully shrouded belt-driven by engine
crankshaft pulley
Radiator: Type .... . ................. .... Corrugate type
Mounting .... .. . .. . . . . . .. .. . . .. Rubber shock insulators
° °
Thermostat ............................. Wax type, bottom by pass system, open at 76.5 C (169 F)
° °
max. lift 10.0 mm (0.393 in) at 90 C (194 F)
AIR CLEANER
Type .... ...... ................. ...... Dry type (paper element), 2-3 type available
3-1-8
PERFORMANCE & PERFORMANCE CURVE

Output, intermittent rating KW (HP) rpm ........... 149 (200) at 2,200 rpm
SAE J1349, Gross (without cooling fan) 139 (186) at 2,000 rpm
129 (173) at 1,800 rpm
118 (153) at 1,600 rpm
Output, continuous rating KW (HP) at rpm .......... 127 (170) at 2,200 rpm
SAE J1349, Gross (without cooling fan) 119 ( 159) at 2,000 rpm
110 (148) at 1,800 rpm
100 (134) at 1,600 rpm
Max. torque Nm (lb.ft) at rpm .......... 711 (525) at 1,600 rpm
NOTE: Outputs are converted to SAE J1349 standard ambient conditions;

Intake air temperature 25 C
°
Barometric pressure 100 KPa

Water vaper pressure in atmosphere 1.0 KPa
E
-
+-
z
SAE Jl349 (Gross)
550
700
�.,,,,..- �....__ --.. 500
650 ::::>
0
LU W
a: cc ::i
_j
600 450 0 <(0

(L
200 150 I- a.. u

V
140 /
180 /
130 /
Intermittent /
<( 160 120 .. �
V
1-u
t;
::::> z (/)
z
\ /
.. .. w
a. w 110 \y,...
_j
I/
l-1-�
<( a)
::::> 0 ::i 140

100
V .. "'/ w C/l
..J ::i
Ill ro
-2
0 a..
\continuous 1-Q
(L
/
/ (/) u
120 90
Z�z
80 .. 2�w
I-OZ
;1'
/ ,
100 / � I--
a..uo
70 / ::) W
04 0 Z02
Cl> 0 <(
80 60
.....
- i-- - 240
230
220
210
l
038
0·36
0·34
0�2
U::::>o
..J
::::>OO
wzz
Cl)(/)
LL (.) U
1,000 1,200 1,400 �600 1,800 2,000 2,200
ENGINE SPEED (r.p.m.)
VELOCIDAD DEL MOTOR (r.p.m.)
REGIME DU MOTEUR (tr/mn)
SM3-1036
Fig. 3-1-1 Engine perfomance curves

Curvas caracteristicas del motor
Courbes des performances du moteur
3-1-9
Output, intermittent rating PS (KW) at rpm 188 (138.3) at 2,200 rpm

DIN 62708 (with cooling fan) 180 (132.3) at 2,000 rpm
166 (122.1) at 1,800 rpm
151 ( 111. 1) at 1,600 rpm
Output, continuous rating PS ( KW) at rpm 160 (117.4) at 2,200 rpm
DIN 6270A (with cooling fan) 151 (111.0) at 2,000 rpm
141 (103.7) at 1,800 rpm
129 ( 94.9) at 1,600 rpm
Max. torque Kgm (Nm) at rpm . . . . . . . 68 (666.8) at 1,600 rpm
NOTE: Outputs are converted to DIN 6270 standard ambient conditions;

°
Intake air temperature 20 C
Barometric pressure 735 mmHg
Water vaper pressure in atmosphere 10.5 mmHg
---
DIN 6270 E
z
(/)
a. 70 700
150 � w
200 I........ 60 600 o �
e 6: s
a: cc :J
14 50 soo
180 400
130
✓
120 /
/
160
��
t-u z 627 08 / /
/
y ., ,.,,
::> z <! II 0
t-1-�
Q. w (/)
::> 0 :J /'
0 Q. a. 140
,.
100
A
90 ..,, t\6270A
V V
120
I
80
100
70
I /
' ..........
j I80
60
I / .,,.,,,
V
80 I 70
-�__..,.l---'"'... I 60
1,000 1,200 1,400 1,600 1,800 2,000 2,200

ENGINE SPEED (r.p.m.)
VELOCIDAD DEL MOTOR (r.p.m.)
REGIME OU MOTEUR (trs/mn)
SM3-1037
Fig. 3-1-2 Engine performance curves
Curvas caracteristicas del motor
Courbes des performances du moteur
3-1-10
DESCRIPTION
(General views)
SM3-1034
LEFT SIDE VIEW
SM3-1033
FRONT VIEW
Fig_ 3-1-3
3-1-11
(Remarkable tightening torque positions)
¢12P1.75 1,100-1,200 kg·cm

¢17 P2.0 3,300-3,500 kg•cm
I ¢10P1.5 I 300-500 kg•cm I

c/>10 Pl.5 650-750 kg•cm
¢14P2 1,000-1,300 kg-cm
¢16P1 .5 2,600-2,900 kg•cm
c/J22P1.5 5,500-7,000 kg•cm
,,....._--------1 ¢30P1 .5 I 1,000-1,200 kg•cm I SM3-588
¢8 P1.25 190-270 kg•cm
q,14 P2.,0 1, 100-1,500 kg•cm

c/>8 P1.25 190-270 kg•cm
¢16 P2.0 2,700-2,900 kg•cm

¢15 P1.5 2,200-2,400 kg·cm
SM3-1039
Fig. 3-1-4
3-1-12
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have the following.
Illustration Tool No. Tool name Usage
/ 09442-1200 ./PISTON RING For removing and install the

I EXPANDER piston rings
\ /
,..____...,,,.,,,...
0 964507-435
985136-104 O-RING
/
) (Used with 09402-1280)
(Used with 09402-1161)
For installing or removing

09470-1022 VALVE SPRING valve spring and lifting
09433-1061 PRESS cylinder head
For removing the nozzle holder

09420-1442 SLIDING HAMMER (Used with nozzle holder
puller 09462-1130)
0�402-1140. PRESS For camshaft end plug
··�-----
To tighten the cylinder head

0$839-2205 WRENCH
bolt
3-1-13
w
c- 09444-1210 V-BEL T TENSION For V-belt tension
,·"" GAUGE
Is,
'--
09482-1350 .' PRESS For the injection pump drive

shaft sleeve
�
09420-1180/ PULLER For the injection pump drive

shaft sleeve
-�·""
.� -" ·
_ .. -··
\ For with drawing the idle
/09462-1410 ADAPTOR gear shaft
'
\
(Used with 09420-1442)
)
09451-1040 STOPPER For tappet hold
09412-1080 WRENCH For water pump vane

puller
_09552-1030 PRESSURE GAUGE For the compression gauge

ADAPTER
3-1-14
For removing the cylinder liner

09420-1450 CYLINDER LINER and measuring the protrusion
PULLER of the cylinder liner
09402-1290 DUST SI LINGER For pressing the dust slinger to

P�ESS crankshaft pulley
To install the front oil seal

09402-1161 PRESS sleeve
,
...-···· ··---.\
CY,LINDER LINE'ft
09480-1100 Gl:JIDE ) To install the cylinder liner
( I
\
i
,/
P,ISTON RING/
09441-1051 HOLDER
For piston installation
For front oil seal to timing

09482-1420 ,PRESS gear cover
09482-1430 .· PRESS For rear oil seal

3-1-15
09402-1220 PRESS To install rear oil seal sleeve
For injection pump drive

09420-1111 PULLER gear
09431-1010 VALVE LAPPING For valve lapping

TOOL
09819-1707 W.RENCH Tightening or retightening

injection pump coupling
For installing.the nozzle

09472-1210 NOZZLE SLEEVE sleeve
BAR
(Used with 9800-06100)
For expanding the nozzle

9800-06100 STEEL BALL sleeve
(Used with 09472-1210)
For measuring engine

COMPRESSION compression pressure
09408-1010 ADAPTER (Bolt size PF 3/8)
3-1-16
)
/
// For with drawing the nozzle
09462-11JQ/ ADAPTER holder
./· (Used with 09420-1442)
· 09472-175(Y STEM SEAL To install the valve stem seal

PRESS
.6�405-1190 ,I ENGINE HANGER For lifting the engine

,,/
..,.,.....
For pressing the oil seal of

09482-1210 PRESS water pump
For inspection of the piston

9001-24265 CONNECTOR BOLT cooling jet
(
··
l
,
For inspection of the piston
, , 09470-1090 TARGET PLATE cooling jet
·�--., - . .
09472-1620 .· .· ADJUSTER BAR To adjust the jet nozzle

3-2-1
OVERHAUL
ENGINE OVERHAUL CRITERIA
1. Factor which determine when an engine overhaul is
needed.
1) Lowered compression pressure.
NOTE:
1. Before measurement.
1I Correct the valve clearance
° °
2) Warm up engine (about 80 C, 176 Fl
3) Charge the battery fully
4) Remove the air cleaner
2. Measurement
1) Remove the six nozzle holder
Fig. 3-2-1
2) Install the gauge adapter
09408-1010
Special tool
09552-1030 REPARACION GENERAL
REPARACION GENERAL DEL MOTOR
Unit: kg/cm 2 (lb/sq.in) 1. Factores que determinan la necesidad de efectuar una
Standard Difference between reparaci6n general del motor.
Limit
value each cylinder 1) Presi6n de compresi6n insuficiente.
NOTA:
28-30 26 Less than 3 1. Antes de la medici6n
(399-426) (370) (43)
1) La holgu ra de la val vu la esta correcta
°
Engine speed (r.p.m.) 200 °
2) La temperatura del agua es de 80 C (176 F)
3) Cargue la bateria por completo
4) Remueva el filtro de aire
2. Medici6n
1) Remueva los seis portainyectores
2) Revise la revoluci6n del motor
REVISION
REVISION DU MOTEUR
1. Facteurs dont depend la prise de decision sur le
moment ou ii faut envisager la revision du moteur.
1) Baisse de la pression de compression.
N.B.:
1. Avant prise de mesure
1) Le jeu de soupape est correct
°
2) La temperature de l'eau de refroidissement est de 80 C
3) Charger la batterie pleinement
4) Deposer le filtre a air
2. Mesure
1) Deposer les six porte-injecteurs
2) Verifier le regime du moteur
2) Oil pressure decreases.

2) La presi6n de aceite disminuye.
2) La pression d'huile diminue.
Fig. 3-2-2 SM3-590

2
Service limit 0.4 kg/cm (5.7 lb/sq.in)
3-2-2
3. Other factor
a. The blow-by explacive gas in the cylinder block
will increase.
b. The engine will not start easily.
c. Engine output decrease.
d. Fuel consumption increases.
e. Engine makes a larger noise.
3. Otros factores
a. Aumento de_ las gases de "blow-by" en el bloque
de ci I i_ndros.
b. El motor no arranca con facilidad
c. La potencia del motor disminuye.
d. Aumento del consume de combustible.
e. El motor produce un ruido excesivo.
3. D'autres facteurs
a. Le gaz explosif par soufflage (blow-by) dans le
bloc-cylindres sera augmente.
b. Le moteur ne demarrera pas facilement.
c. Perte de la puissance du moteur.
d. Augmentation de la consommation en carburant.
e. Le moteur fonctionne avec un bruit plus mar
quant.
3-2-3
ENGINE COMPONENT PARTS
,44 .., PIEZAS COMPONENTES DEL MOTOR

PIECES COMPOSANT DU MOTEUR
Disassembly
Desarmado
De montage
1. Drain the water and engine oil.
NOTE: After drain the ,water and engine oil, retighten the
each drain plug.
2. Dismount the following component parts.
1) Remove the cooling fan.
2) Fuel filter
3) Engine oil level gauge
4) Remove the fuel pipes and oil pipes
5) Remove the starter
Fig. 3-2-3 03-1034
.El
6) Remove the generator
(1) Loosen the belt tension adjusting bolt,@.
(2) Remove the nut, G) .
(3) Loosen the through bolt, @.
(4) Remove the V-belt.
Fig. 3-2-4 EPIT-046
El
7) Remove the oil filter with oil cooler.
Fig. 3-2-5 SM3-1040

3-2-4
8) Remove the fuel pipes, oil pipes and fuel leakage

pipes.
9) Remove the fuel injection pipes.
Fig. 3-2� 03-2255
10) Di'sconnect the coupling

(1) Loosen the through boltG).
(2) Remove the coupling bolts and nuts.
Fig. 3-2-7 03-2261
11) Remove the injection pump.
Fig. 3-2-8 04-1322
Hino Engine Parts

Phone: 269 673 1638
3-3-1
HINO EP100 EP100T CYLINDER HEAD AND VALVE MECHANISM

CULATA DEL CILINDRO Y MECANISMO DE VALVULA CULASSE ET MECHANISME DE
SOUPAPE
HE11-087-00X01 (1320)
INTAKE AND EXHAUST MANIFOLD MULTIPLE DE ADMISION Y ESCAPE
1. Intake manifold 1. Multiple de admision

2. Intake manifold gasket 2. Junta del multiple de admision
3. Exhaust manifold 3. Multiple de escape
4. Exhaust manifold gasket 4. Junta del multiple de escape
5. Seal ring 5. Aro reten
6. Intake pipe 6. Tubo de admisi6n
7. Air hose 7. Manguera de aire
Fig. 3-3-1
Hino Engine Parts

Phone: 269 673 1638
3-3-2
HE11-087-00x01 (1000)(2/2) •
CYLINDER HEAD & RELATED CULATA DEL CILINDRO Y

PARTS PIEZAS RELACIONADAS CULASSE ET PIECES CONNEXES
1. Cylinder head cover 1. Cubierta de la culata del cilindro 1. Couvercle de culasse

2. Cylinder head cover gasket 2. Junta de la cubierta de la culata 2. Joint du couvercte de cu tasse
3. Cylinder head gasket del cilindro 3. Joint de culasse
4. Oil filler cap 3. Junta de la culata del cilindro 4. Bouchon de remptissage d"huile
5. Ventilator 4. Tapon de relleno de acei te S. v.,11tilateur
6. Cylinder head bolt 5. Ventilador 6. Bouton cJe fixation cle cutasse
7. Cylinder head bolt 6. Perno de la culata del cilindro 7. Bou Ion de fixation de culasse
8. Vent pipe 7. Perno de la culata del cilindro 8. Rer,iflard
8. Tubo de ventilacion
Fig. 3-3-2
Hino Engine Parts

email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638
3-3-3
HE11-094-00X02 (1310)•
HINO EP100
HINO EP100T
VALVE SYSTEM SISTEMA DE VALVULA MECANISME DE SOUPAPES
1. Inlet valve 1. Valvula de admisi6n 1. Soupape d'admission

2. Exhaust valve 2. Valvula de escape 2. Soupape d'echappement
3. Valve stem cap 3. Tapa del vastago de la valvula 3. Capuchon de tige de soupape
4. Valve spring lower seat 4. Asiento inferior de resorte de la 4. Siege inferieur de ressort de
5. Valve spring outer valvula soupape
6. Valve spring outer seat 5. Resorte de la valvula exterior 5. Ressort de soupape exterieur
7. Valve stem key 6. Asiento exterior de resorte de la 6. Siege exterieur de ressort de
8. Tappet valvula soupape
9. Push rod 7. Chaveta del vastago de la valvula 7. Demi-cone de soupape
10. Rocker arm support 8. Levantavalvula 8, Poussoir
11. Rocker arm 9. Varilla de empuje 9. Tige-poussoir
12. Adjusting screw 10. Soporte del brazo de balancin 10. Support de culbuteur
13. Adjusting screw nut 11. Brazo de balanci n 11. Culbuteur
14. Support bolt 12. Tornillo de ajuste 12. Vis de reglage
15. Rocker arm shaft 13. Tuerca del tornillo de ajuste 13. Ecrou de vis de reglage
14. Perno de soporte 14. Bou Ion de support
15. Eje de brazo de balancin 15. Axe de culbuteurs
Fig. 3-3-3
Hino Engine Parts

Phone: 269 673 1638
3-3-4
HE11-087-00X01 (1000)(1/2)•
CYLINDER HEAD CULATA DEL CILINDRO CULASSE

1. Cylinder head 1. Culata del cilindro 1. Culasse
2. Valve guide 2. Gu ia de valvula 2. Guide de soupape
3. Inlet valve seat 3. Asiento de la valvula de ad- 3. Siege de soupape d'admission
4. Exhaust valve seat misi6n 4. Siege de soupape d'echappe-
5, Nozzle seat (copper sleeve) 4. Asiento de la val vu la de escape ment
6. O-ring 5. Asiento de inyector (manguito 5. Siege d'injecteur (chemise en
7. Expansion plug de cobre) cuivrel
6. AnilloO 6. Joint torlque
Fig. 3-3-4
Hino Engine Parts

email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638
3-3-5
El
Disassembly
1. Cylinder head.
1) Remove the intake manifold.
Fig. 3-3-5 SM3-1048
El
2) Remove the exhaust manifold.
Fig. 3-3-6 SM3-1041
El
3) Remove the coolant pump.
El
4) Remove the thermostat case.
J:J��K�/'.:
Fig. 3-3-8 SM3-1042

3-3-6
13
5) Remove the injection nozzle.
5) Remueva el inyector.
5) Deposer les injecteurs.
-----L i,
Fig. 3.3.9 SM3-356
Special tool 09462-1130, 09420-1442
13
6) Remove the rocker arm cover.
6) Remueva la cubierta del balancin.
6) Deooser le couvre culbuteurs.
Fig. 3-3-10 03-1825
13
7) Remove the rocker arm shaft assembly.
Remove the valve stem cap.
Remove the push rod.
7) Remueva el conj unto de eje de balanci n.
Remueva la tapa del vastago de la valvula.
7) Deposer !'ensemble axe de c,iltuteurs.
Deposer le capuchon de la tige de soupape.
Fig. 3-3-11 03-1826
13
8) Loosen the cylinder head bolts.
8) Afloje los pernos de la culata del cilindro.
8) Desserrer les boulons de fixation de culasse.
Fig. 3-3-12 03-1827

3-3-7
9) Loosening sequence of cylinder head bolts.

9) Orden de aflojamiento de los pernos de la culata
de cilindro.
9) Ordre de deserrage des boulon de culasse.
Fig. 3-3-13 SM3-506
El
10) Remove the cylinder head assembly.
10) Remueva el conjunto de la culata del cilindro.
10) Deposer I 'ensemble culasse.
Fig. 3-3-14 SM3-552
1. Chisel 1. Cincel 1. Ciseau

2. Cylinder block 2. Bloque de cilindros 2. Bloc-cylindres
A Place the chisel only at this A Coloque el cincel solo en este A Placer le ciseau uniquement ace
corner angulo coin
B Hit up and down B Golpee arriba y abajo B Frapper ve,s le haut et vers le
bas
El
11) Lift the cylinder head from the block.
Fig. 3-3-15 SM13-425
Special tool 09433-1061

3-3-8
2. Remove the valve spring.

2. Remueva el resorte de valvula.
2. Deposer le ressort de soupape.
Fig. 3-3-16 SM3-824

. lves and springs arranged in the sequence
IAl"
:t��i:!:J ;:_
e
! ! ! ! !
.
3 Conserve las valvulas y los resortes dispuestos en la
IN � � .,. misma secuencia que los cilindros.
A�I ·�
:iJ i, �
�
iJ
�
·�
� 3. Disposer les soupape et les ressorts suivant l'o,·dre
11 !1 !1 !1 !11 !1
des cylindres.
EX
2 3 4 5 6
Fig. 3-3-17 SM3-598
4. Disassemble the rocker arm shaft.

4. Desarme el eje de balanci n.
4. Demonter l'axe de culhuteurs
Fig. 3-3-18 03-2034
5. Remove the valve guide.

5. Remueva la gu[a valvula.
5. Deposer la guide de soupape.
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Fig. 3-3-19 03-674website: www.HeavyEquipmentRestorationParts.com
3-3-9
O= C:1 6. If necessary, replace the valve seat.
c::.J
/1
__J_
2
Fig. 3-3-20 SM3-553
1. Valve seat 1. Asiento de val vu la 1. Siiige d,, soupaµ,i

2. Valve 2. Valvula 2. Sour,ap8
A Arc welding points A Soldadula electrica A Souuer a I ·arc
Grinding portion B Corte estas porciones Fl MP.ulez ici
7. If ne,,e,sa,y, ,epl"" the nmle "''·
, .... ,
Fig. 3-3·21 03-677

3-3-10
Inspection and repair

1. Cylinder head and valve
11 Clean the mounting surface of cylinder head.
I nspecci6n y reparaci6n
1. Culata del cilindro y valvula
1) Limpie la superficie de montaje de la culata del
cilindro.
Controle et reparation
1. Culasse et soupape
1) Nettoyer la surface de montage de la culasse.
Fig. 3-3-22 SM3-825
2) lnsepect for cracks and damage.

21 I nspecione en cuanto a grietas y dafios.
2) Controler la culasse a la recherche des felures
et de l'endommagement.
Fig. 3-3-23 SM3-832
3) Check the cylinder head surface for flatness.
Fig. 3-3-24 03-667
Standard 0-0.05 mm (0-0.0019 in)

Repair limit 0.1 mm (0.0039 in)
4) Measuring process and situation.

E' F' G' A'
B
C -f---""1-�-----+-------:;rl"'---t-C'
Fig. 3-3-25 SM3-554

3-3-11
Inspect the valve contact surfaces for contacting

r::;;]5) condition.
1:::1 If necessary, hand-lap the valve and valve seat.
NOTE: Lightly apply lapping compound to the valve face.
Install the valve with a special tool, tap and rotate
the valve against the seat.
Fig. 3-3-26 SM3-364
I Special tool 09431-1010
6) Measure the valve sink.

6) Mida el sumidero de la valvula.
6) Mesurer le fonc;:age de la soupape
Fig. 3-3-27 03-535
Fig. 3-3-28 SM3-236

A
Standard 0-0.2 mm (0-0.0078 in}
Service limit
7) Correct the valve seat.
7) Corrija el asiento de la valvula.
7) Rectifier le siege cle soupape
Fig. 3-3-29 SM3-708

° °
Inlet 30 -30 15'
Standard
Exhaust 45° -45° 15'
3-3-12
8) Correct the valve face.

8) Corrija la cara de la valvula.
8) Rectifier la face de la soupape.
Fig. 3-3-30 SM3-707
29 45'-30
° °
Inlet
Standard ° °
Exhaust 44 45'-45
u 45°
INLET EXHAUST
Fig. 3-3-31 SM3-555
9) Measure the oil clearance between valve stem and

guide.
Fig. 3-3-32 SM3-834
Fig. 3-3-33 SM3-835

3-3-13
10) Measuring position of valve guide and valve stem.

2
A B C
UNIT: MM
Fig. 3-3-34 SM3-556
1. Inlet 1. Admisi6n 1. Admission

2. Exhaust 2. Escape 2. Echappement
Standard Service limit

Inlet valve stem outside diameter 9.938-9.950 mm 9.88 mm
(0.3913-0.3917 in) (0.389 in)
Exhaust valve stem outside diameter 9.921-9.943 mm 9.88 mm
(0.3906-0.3914 in) (0.389 in)
Repair limit mm (in)

Clearance mm (in)
� A&B C
Inlet 0.040-0.077 (0.0016-0.0030) 0.12 (0.0047) 0.18 (0.0071)
Exhaust 0.057-0.094 (0.0023-0.0037) 0.14 (0.0055) 0.20 (0.0079)
Valve spring
1) Check the valve spring for straightness.
NOTE: Runout maximum should be less than 7 mm (0.275
in).
Straightness should be less than 3.5 mm (0.137 in)
Fig. 3-3-35 SM3-303

A (max.)-A (min.) � 7 mm (0.275 in)
Limit
B (max.)-B (min.) �7 mm (0.275 in)
2) Measure the free length.
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Fig. 3-3-36 SM3-557
mm(in)
Free length Service limit
77 (3.03) 7.5 (2.953)
J-3-14
3) Measure the valve spring force.

3) Mida la fuerza del resorte de la valvula_
3) Mesurer l'effort du ressort de soupape
-------
Fig. 3.3.37 03-680
Outer spring
Intake Exhaust
Setting length mm (in) 54.3 52.8
(2.136) (2.077)
Setting load kg(lb) 43.2-47.8 46.9-51.5
(95.26-105.4) (103.4-113.5)
41.8 45.5
Service limit kg (lb) (92.17) (100.3)
4) Check the valve spring seat for wear (upper and

lower).
4) I nspeccione el asiento del resorte de la valvula en
cuanto a desgaste (superior e inferior.)
4) Verifier le siege de ressort de soupape a la re
cherche d'usure. (superieur et inferieur)
Fig. 3-3-38 SM3-371
3. Rocker arm and rocker arm shaft

1) Measure inside diameter of the rocker arm.
3. Brazo de balanci n y eje del brazo de balanci n
3. Culbuteur et axe de culbuteur
Fig. 3-3-39 SM3-291

3-3-15
2) Measure outside diameter of the rocker arm shaft.
Fig. 3-3-40 03-682
3) Measuring position.
----
Fig. 3-3-41 SM3-558
Standard mm (in) Repair limit mm (in) Service limit mm (in)

Outside diameter 24.16-24.18 (0.9512-0.9519) - 24.12 (0.9496)
Inside diameter 24.21-24.26 (0.953-0.955) - 24.28 (0.9559)
Clearance 0.03-0.101 (0.0012-0.0039) 0.15 (0.0059) -
4) Inspect the valve stem contact point of the rocker

arm for wear.
4) I nspeccione el pu/lto de contacto del vastago de
la valvula del brazo de balancf n en cuanto a des
gaste.
4) Controler I 'usure de la partie de contact de la tige
� de soupape avec le culbuteur.
�
1:::::7
Fig. 3-3-42 SM3-930

3-3-16
Fig. 3-3-43 SM3-292
Service limit 0.5 mm (0.0196 in)
Check the adjusting screws and push rod for wear, or

I damage.
_.,./)
,
Fig. 3-3-44 SM3-419
Intake manifold.
1) Measure the flatness of flange face.
Fig. 3-3-45 03-1829

0.1 mm (0.004 in) 0.5 mm (0.02 in)
Exhaust manifold
1) Measure the flatness of flange face.
Fig. 3-3-46 03-1830

0.1 mm (0.004 in) 0.5 mm (0.02 in)
3-3-17
Hino EP100 EP100T Exhaust Seal Rings
2) Inspect the wear or damage of seal ring.
©OJ SEAL RING
45•
Fig. 3-3-47 SM3-943
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3-3-18
El
Assembly
1. Install the valve seat
Heat the cylinder head in boiling °water and put
the valve seat in liquid nitrogen (-196 C).
Armada
1. Montaje del asiento de la valvula
Caliente la culata del cilindro en agua hirviendo y
ponga el asiento de la valvula en nitr6geno liquido
°
(-196 C).
Remontage
1. Montage du siege de soupape
Chauffer la culasse dans l'eau bouillante et mettre
°
le
Fig. 3-3-48 SM3-826 siege de soupape dans le liquide nitrogene (-196 C).
Install the nozzle sleeve.

1) Set the O-ring into the cylinder head
Apply adhesive (Super Three Bond No. 1210 or
equivalent) to the lower part of the new copper
nozzle sleeve and carefully insert the nozzle sleeve
into the cylinder head.
NOTE: A damaged 0-ring may cause leaks and lead to over
heating or cracked heads.
Fig. 3-3-49 SM3-390

Special tool A 09472-1210
Special tool B 9800-06100
2) Measure the protrusion of nozzle from the cylind

er surface.
• CYLINDER HEAD
Fig. 3-3-50 SM3-391
Tightening torque 130-190 kg·cm (10-13 lb.ft)

Protrusion 2.75-3.25 mm (0.1083-0.1279 in)
3-3-19
2 Install the valve guide

1) Setting position of the valve guide.
B
Fig. 3-3-51 SM3-562
1. Inlet 1. Admisi6n 1. Admission

2. Exhaust 2. Escape 2. Echappement
Cylinder head upper face A Superficie superior de la culata del cilindro A Surface superieur de la culasse
Cylinder head lower face B Superficie inferior de la culata del cilindro B Surface ,nferiP.ur de la culasse
Hino Engine Parts

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E3
4. Install the valve stem seal.
4. lnstale el sello del vastago de valvula.
4. Poser I 'etanchei te de tige de soupape.
Fig. 3-3-52 SM3-984

El
5. Install the valve.
5. I nstale la valvula.
5. Poser la soupape.
Fig. 3-3-53 03 G87

3-3-20
El
6. Install the valve spring.
6. I nstale el re so rte de valvula.
6. Poser le guide de ressort rle soupape.
Fig. 3.3.54 SM3-824
PAINT MARK
CYLINDER HEAD
INTAKE EXHAUST
Fig. 3.3.55 SM3-402
El
8. Mount the cylinder head assembly.
NOTE: Replace the c"l'.linder head gasket with new one.
8. lnstale el cojunto de la culata del cilindro.
NOTA: Reemplace la junta de la culata del cilindro con otra
nueva.
8. Monter !'ensemble culasse.
N.B.: Remplacer le joint de culasse par une piece neuve.
Fig. 3-3·56 SM3-425
El
9. Install the cylinder head bolt and tighten them
temporarily.
NOTE: Applying the engine oil.
9. lnstalelos pernos de la culata del cilindro y apriete los

temporalmente.
9. Poser les boulons de fixation de culasse et serrer les
temp ore I lement.
Fig. 3.3.57 03-689

3-3-21
10. Install the valve push rod.

0 NOTE: Applying engine oil.
�10. I nstale el empujador de la valvula.
NOTA:
10. Poser la tige-poussoir.
N.B.:
Fig. 3-3-58
B
11. Install the stem cap.
11. lnstale la tapa del vastago de valvula.
11. Poser le capuchen de la tige de soupape.
Fig. 3-3-59 03-690
12. Assemble the rocker arm.

12. Arme el balanci6n.
··•:.\l.·.. 1 I .I
t::rit:a:sr:irif
p:
. ,. .
I
i . . 1:; .;;;;;;..;:c;;
12. Ensemble le culbuteur.
Fig. 3-3-60 03·664
m
1£=.1
13. Make sure that the rocker arm shaft is installed with
the "UP" mark the shaft upward.
NOTE: Lubricate the rocker arm shaft and arm bush.
UP
� Hino Engine Parts
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TIMING-+
GEAR SIDE Phone: 269 673 1638
Fig. 3-3-61 SM3-938 SM3-357 website: www.HeavyEquipmentRestorationParts.com
3-3-22
El
14. Install the rocker arm shaft assembly.
14. lnstale el conjunto del eje de balancin.
14. Poser l'ensemtJle axe de c:ulln1teurs.
Fig. 3·3·62 03-1826
El
Tightening sequence of rocker arm support.
,s.
NOTE: Tightening sequence 3-4·5·2· 1 ·6
Fig. 3·3·63 03-322
1, 100-1,200 kg-cm (80-86 lb.ft)

Tighting torque
2,400-2,600 kg-cm (174-188 lb.ft)
El
16. Tighten the cylinder head bolt and rocker arm
support bolt.
Fig. 3.3.54 03-1831
17. Tightening sequence of Hino EP100 Hino

EP100T cylinder head bolts.
17. Orden de apriete de los pernos de la culata de cilindro.
17. OrcJre de serrage des I.Joulons de r:t1lassri.
INTAKE
Fig. 3.3.55 SM3-506

Outside diameter Hino EP100 T Tightening torque
16 1.1m 3,300-3,500 i<g•cm (239-253 lb.ft)
10 mm 650-750 kg-cm (47-54 lb.ft)
3-3-23
18. Install the injection nozzle.

18. lnstale la tobera del inyector.
18. Remettre l'injecteur en place.
Fig. 3-3-66 03-2159
I Tightening torque I 130-190kg.cm(10-13Ib.ft)
Adjust the valve clearance.
[BJ'"·
1) Set the each piston at top dead center of the
compression stroke and adjust the valve clear
ance. Firing order: 1-4-2-6-3-5
19. Ajuste la holgura de la valvula.
1) Coloque cada piston en el punto muerto superior
de la carrera de compresion y ajuste la holgura
de la valliula. Orden de encendido: 1-4-2-6-3-5
19. Regler le jeu de soupape.
1) Regler chaque piston au point mort haut de la
phase de compression et regler le jeu de soupape.
Ordre d'allumage 1-4-2-6-3-5
Fig. 3-3-67 SM3-519
Valve Inlet 0.40 mm (0.157 in)
clearance Exhaust 0.50 mm (0.0197 in)
2) 2-time adjustment
Set the No.1 piston to top dead center of com
pression stroke, adjust the valve clearance and set
the No.6 piston to top dead center, adjust the
other valves.
2) Ajuste de 2-tiempos
Coloque el piston N °, 1 en el punto muerto
superior de la carrera de compresion y ajuste la
holgura de la valvula, luego coloque el piston
N °, 6 en el punto muerto superior y ajuste las
demas valvulas.
2) Reglage en deux reprises
Fig. 3-3-68 Regler le piston N ° 1 au point mort haut de la
phase de compression et regler le jeu de soupape
et regler le piston N ° 6 au point mort haut et
regler d'autres soupapes.
Cylinder No. 1 2 3 4 5 6
I E I E I E I E I E I E
Valve arrangement
1 2 3 4 5 6 7 8 9 10 11 12
Hino Engine Parts
With No. 1 piston at
T.D.C. on compres- • • • • • • email:
sion stroke
With No. 6 piston at Phone: 269 673 1638
0 0 0 0 0 0
T.D.C. on compres-
sion stroke
3-4-1
HINO EP100 EP100T TIMING GEAR AND CAMSHAFT

ENGRANAJE DE LA DISTRIBUCION Y ARBOL DE LEVAS
PIGNO NS DE DISTRIBUTION ET ARBRE A CAM ES
HE11-094-00X01 (1110)
1. Timing gear cover 1. Cubierta de! engranaje de la 1. Couvercle du carter de

2. Timing gear cover gasket distribuci6n distribution
3. Oil seal 2. Junta de la cubierta del 2. Joint du couvercle du carter
4. 0-ring engrenaje de la distribuci6n de distribution
5. Seal plate 3. Sella de aceite 3. Rondelle de retenue d'huile
6. Timing gear plate 4. Anillo-O 4. Joint torqieu
5. Placa retenadora 5. Plaque d'etancheite
Fig. 3-4-1
Hino Engine Parts

Phone: 269 673 1638
3-4-2
4
5
SM3-593
HINO EP100 EP100T GEAR TRAIN GREN DE ENGRANAJES PIGNONS DE DISTRIBUTION

1. Crankshaft gear 1. Engranaje del cigi.ienal 1. Pignon du vilebrcquin
2. Idler gear 2. Engranaje loco 2 Pignon intermediaire de distribution
3. Camshaft gear 3. E ngranaje del arbol de levas 3. Pignon de I 'arbrn a carnes
4. Injection pump drive gear 4. Engranaje impulsor de la bomba 4. Pignon d'entrainement de la pompe
5. Oil pump drive gear de inyeccion a injection
6. Coolant pump gear 5. Engranaje impulsor de la bomba 5. Pignon d'entrainement de la
7. Match mark de aceite 6. Pignon de pompe a eau
6. Engranaje de bomba del 7. Marques d'appariement
enfriador
7. Marcas de Alimeati6n
Fig. 3-4-2
Hino Engine Parts

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3-4-3
HE11-087-00X01 (1300)
1. Camshaft 1. Arbol de levas 1. Arbre a cames

2. Camshaft gear 2. Engranaje del arbol de levas 2. Pignon dentrainement de
3. Idler gear 3. Engranaje loco a
l'arbre cames
4. Injection pump drive gear 4. Engranaje impulsor de la bomba 3. Pignon intermediaire de
5. Spacer de i nyecci6n distribution
6. Thrust plate 5. Espaciador 4. Arbre d'entrainement de la
7. Plain washer 6. Placa de empuje pompe d'injection
8. Idler gear shaft 7. Arandela plana 5. Cale d' epaisseur
9. Bushing 8. Ene del engranaje loco 6. Plaque de butee
10. Thrust plate 9. Casquillo 7. Rondelle plate
10. Placa de empuje 8. E'.nsemble axe de pignon
intermediaire de distribution
9. Bague
10. Plaque de butee
Fig. 3-4-3
Hino Engine Parts

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3-4-4
Disassembly
1. Remove the crankshaft pulley.
1. Remueva la polea del ciguefial.
1. Deposer la poulie d'arbre a cames.
Fig. 3-4-4 SM3-935
2. R•mo,o th, 0;1 pan.
,.... ,
Fig. 3-4-5 03-1835
t;;I �:
Remove the timing gear cover.
c:J
Remueva la cubierta del engranaje de la distribuci6n.
3. Deposer le couvercle de pignons de distribution.
Fig. 3-4-o 03-1836
Fig. 3-4-7 03-2058

3-4-5
El
5. Remove the idler gear.
5. Remueva el engranaje intermedio.
5. Deposer le pignon intermediaire.
Fig. 3-4-8 03-571
I Special tool 09420-1442, 09462-1410
•· Remove the ;n;,ct;on pump dd,e .,., and ,halt.
,...... ,
Fig. 3-4-9 03-1840 03-1841
Remove the camshaft.

1) Remove the valve lifter (tappetI chamber cover.
El
2) Install the tapper holder and remove the camshaft.
3) Using a special tool, lift up the tappets and sus
pend them above the camshaft.
4) Lubricate all journals of the camshaft and insert
the camshaft assembly into the cylinder block.
NOTE: 0 Insert the camshaft, slowly turning while insert
ing so that the bearing will not be damaged.
Fig. 3-4-11 SM3-952 SM3-839

3-4-6
E3
5) Remove the tappets
(1) Remove the special tool (stopper).
(2) Remove the tappets.
NOTE: Be sure to arrange the tappets in correct order.
Fig. 3-4-12 03-2066
8. If nooo,,a,y, ,omo,o tho oam,hoft d,;,. goa,.

, ... ,
.
..
Fig. 3-4-13 03-1845

•· Romo" tho ;n;,ct;on pump d,;,. ,hoft boa,;ng.
..
, ... ,
Fig. 3-4-14 03-1846 03-1847

Hino Engine Parts

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3-4-7

1. Measure the clearance between the idler gear shaft
and the idler gear bushing.
Fig. 3-4-15 03-1848
Fig. 3-4-16 03-1849

Standard 0.030-0.090 mm (0.0012-0.0035 in)
2. Measure the idler gear end play.

2. Mida el juego longitudinal del engranaje intermedio.
2. Measurer le jeu en bout du pignon intermediaire.
Fig. 3-4-17 03-578
··
Standard 0.049-0.140 mm (0.0019-0.0055)
Repair limit 0.30 mm C0.0118 in)
lu 1
MeHure th• cam h,;ght.
Fig. 3-4-18 SM3-347 SM3-563

Camheight 54.85 mm (2.1594 in)
3-4-8
l!tl
Measure the clearance between the camshaft journal
4.
and the bearing. (Refer the table of page 3-118,
3-119).
Fig. 3-4-19 03-574 03-575

0.03-0.12 mm (0.0012-0.0047 in)
0.3 mm (0.0118 in)
I
0. Mea'"'eth, <amshaft ,un out.
ltJ
Fig. 3-4-20 03-573
g-
6. Measure the camshaft end play.
6. Mida el juego longitudinal del arbol de levas.
G Mes11rtcr le jeu en 110111 de l'arhre a ra111es.
Fig. 3-4-21 03-576
0.10-0.23 mm (0.004-0.009 in)

0.30 mm (0.0118 in)
7. ln,peot th• ;njoot;on pump d,;,.,haft beadng.
I® I
Fig. 3-4-22 03-1850

3-4-9
8. Measure the clearance between the tappet and' the

tappet guide.
lg:]
��
,�irF.,
•/' /.'.o• ... ,,
0)
, I .
-..:2./' '\.. ' l
....___,"--2.,,_,'...'
'..___
/
Fig. 3-4-23 SM3-325 SM3-420

Standard 0.020-0.066 mm (0.0008-0.0025 in)
Hino Engine Parts

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3-4-10
El
Assembly
1. Install the injection pump drive shaft and bearing.
NOTE: Adjust the bearing pre-load using the shims.
Fig. 3-4-24 03-1852
I Pre-road 4-12 kg-cm (0.29-0.86 lb-ft)
l. Install tho timing goa, plat•.
,....,
Fig. 3-4-25 03-1853
I Tightening torque 190-270 kg·cm (14-19 lb-ft)
J. Install tho injoction p"mp boa,ing holdo,.
,....,
Fig. 3-4-26 03-2083

3-4-11
4. Install tho ;nject'•o� pump drive gear

. .
1) Align the m1ect1on pump drive gear matching mark
with the camshaft ·,di er gear.
, ....., NO TE.. Incorrect installation can resu Its in engi ne d amage
or lowering of 8ngine • performance b V causing
• . .
improper inJection timing.
Fig. 3-4-27 SM3-575
5. Install the tappet.
El
6. Install th e camshaft and tighten the bolts of thrust
plate.
03-1856
'·
Special tool 0 9451-1040
l••.,I
ln,tall tho 0;1 pump.
03-1857
1 , 100 1, 200 kg·cm (1 00 -861b.ft)
Tightening torque .
450 5oo kg·cm (33-36Ib.ft)
3-4-12
8. Install th• ;do, ,,.,.
,.....,
Fig. 3-4-31 03-1858
Be sure that matching marks of the crankshaft gear,

camshaft gear, injection pump drive gear, and idle gear
aligned correctly.
I
L--
Fig. 3-4-32 SM3-593
9. Hghtoo tho ;o;,ct;oo pump d,;,. ,.., out.
IJ rl
Fig. 3-4-33 03-1859
J Tightening torque 2,000-2,200 kg•cm (145-159 lb-ft)
El
10. Tighten the idle gear bolt.
Fig. 3-4-34 03-1860
J Tightening torque 1,800-2,000 kg·cm (130-144 lb.ft)

"·
3-4-13
lu I
M,asure the tim;ngg,.. backla,h.
Backlash Unit: mm (in) 12. Standard gear backlash and service limit.
Assembly Service
� A
,C.,,. ,
Gears
allowance
�
limit
0.08 - 0.23
Crank gear - idle gear
(0.0032-0.0090)
Camshaft drive gear 0.08 - 0.23 0.30

- Idle gear (0.0032-0.0090) (0.0118)
Idle gear - Injection 0.08 - 0.23

pump drive gear (0.0032-0.0090)
Camshaft drive gear

0.14 - 0.32 0.35
- Oil pump drive
(0.0055-0.0125) (0.0138)
gear
Fig. 3-4-36 03-2058
200-250 kg·cm ( 15-18 lb.ft)
El
13. Install the timing gear cover oil seal.
Hino Engine Parts

email:
Phone: 269 673 1638
Fig. 3-4-37 03-587 website: www.HeavyEquipmentRestorationParts.com
I Special toi;,I 09482-1180

3-4-14
Fig. 3-4-38 03-1862
••· Install tno oH pan.
1•••1
-=-----
�I
Fig. 3-4-39 SM3-393
'"·
1•·•1
Install tho o,ank,haft pulley.
Fig. 3-4-40 03-2259

5,500-7,000 kg•cm
Tightening torque
(398-506 lb.ft)
3-5-1
HINO EP100 EP100T CYLINDER BLOCK, PISTON AND CRANKSHAFT

BLOOUE .DE Cl LIND ROS, PISTON Y SIGUEl'JAL
BLOC-CYLINDRES, PISTON ET VILEBREOUIN
HE11-087-00X01 ( 1100) (2/2)
1. Cylinder block 1. Bl oque de ci Ii ndros 1. Bloc-cylindres

2. Oil level gauge guide 2. Gu ia del indicador de 2. Guide de jauge a huile
3. Oil level gauge nivel de aceite 3. Jauge d'huile
4. Valve push rod cover 3. lndicador del nivel de aceite 4. Couvercle de la tige-poussoir
5. Gasket 4. Cubierta de la varilla de r·0. Joint
6. Oil pan empuje de la valvula 6. Carter d'huile
7. Gasket 5. Junta 7. Joint
8. Drain plug 6. Colector de aceite 8. Bouchon
9. Gasket 7. Junta 9 Joint
8. Tap6n
9. Junta
Fig. 3-5-1
Hino Engine Parts

Phone: 269 673 1638
3-5-2
LE17-094-00X05X06X07 (1100) (1/2)
CYLINDER BLOCK BLOOUE DE CILINDROS BLOCCYLINDRES

1. Hino EP100 EP100T Cylinder liner 1. Camisa del cilindro 1. Chemise de cylindre
2. Cylinder block 2. Bloque de cilindros 2. Bloc-cylindres
3. Bearing cap 3. Tapa del cojinete 3. Chapea,J de palier
4. Bearing cap bolt 4. Perno de la tapa del cojinete 4. Boulon de fixation du chapeau
5. Strai ght pin 5. Pasador recto de paliP.r
6. Camshaft bearing 6_ Cojinete del arbol de levas !:°L GoupillP.
7. Oil jet 7. Injector de aciete 6. Pdli,•r r1"arbre a cames
7. Gicleur d'huile
Fig. 3-5-2
Hino Engine Parts

Phone: 269 673 1638
3-5-3
HE11-087-00X01 (1200)
2!;}
16 17��,.
15
From Engine No. EP100T 00012570

2
HINO EP100 SM3-1043

HINO EP100T
CRANKSHAFT AND CIGUENAL Y PIEZAS RELACION VILEBREOUIN ET PIECES CON
RELATED PARTS ADAS NEXES
1. Crankshaft 1. Cigi.ieiial 1. Vilebrequin
2. Crankshaft gear 2. Engranaje del cigi.ieiial 2. Pignon de vilebrequin
3. O-ring 3. Anillo 0 3. Joint torique
4. Crankshaft sleeve, front 4. Mangu ito del cigi.ieiial, delantero 4. Manchon de vilebrequin, AV
5. Dust slinger 5. Deflector de polvo C,. deflecteur de poussiere
6. Crankshaft pulley center 6. Centro de la polea del cigi.ieiial 6. Cone epaule de poulie de
7. Pulley 7. Polea vilebrequin
8. Bolt 8. Perno 7. Poulie
9. Collar 9. Collar in 8. Boulon
10. O-ring 10. Anillo 0 9. Collier
11. Bolt 11. Perno 10. Joint torique
12. Key 12. Chaveta 11. Boulorr
13. O-ring 13. Anillo 0 12. Clavette
14. Crankshaft sleeve 14. Manguito del cigi.ieiial 13. Joint torique
15. Oil seal 15. Selle de aceite 14. Manchon de vilebrequ in
16. Gasket 16. Junta 15. Rone.Jelle de retenue d'huil<,
17. Retainer 17. Retenedor 16. Joint
18. Flywheel dust cover 18. Cuvierta de contra del volante 17. Support de joint
19. Crankshaft bearing set 19. Juego de cojinete del cigi.ieiial 18. Couvercle pare-poussiere de volan t
20. Thrust bearing set 20. Juego de cojinete de empuje 19. Jeu de coussi,1ets
21. Piston 21. Piston 20. Jeu de flasques
22. Piston ring 22. Arcs de piston 21. Piston
23. Piston pin 23. Pasador de piston 22. Segment de piston
24. Retainer ring 24. Anillo retenedor 23. Ax,; de pisto11
25. Connecting rod assembly 25. Cojunto de biela 24. Circlip
26. Piston pin bushing 26. Casquillo del pasador de piston 25. Ensemble biellP.
27. Connecting rod bolt 27. Perno de la,biela 26. Bague de l'axe de piston
28. Ring gear 28. Engranaje angular 27. Boulorr r:le fixation de bielle
29. Flywheel 29. Volante 28. Couronne de volant
29. Vol11nt
Fig. 3-5-3
3-5-4
E1
Disassembly
1. Remove the flywheel assembly.
Desarmado
1. Remueva el conj unto de volante.
Demontage
1 Deposer. I 'ensemble vol ant.
Fig. 3-5-4 03-2169
E1
2. Remove the flywheel housing.
2. Remueva el carter del volante.
2. Deposer le carter de volant.
Fig. 3-5-5 03-1865
E1
3. Remove the oil seal retainer.
3. Remueva el retenedor de sello de aceite.
3. Deposer la rondelle de retenue d'huile.
Fig. 3-5-6 03-1866
E1
4. Remove the piston with connecting rod.
4. Remueva el piston con la biela.
4. Deposer le piston avec la bielle.
Fig. 3-5-7 03-727 03-1867

3-5-5
5. Remove the crankshaft.
E) 5. Remueva el ciguenal.
5. Deposer le vilelJreqLJin.
Fig. 3-5-8 03-556
6. Remove the connecting rod.
E) 6. Remueva la biela.
6. Deposer la bielle.
Fig. 3-5-9 SM3-294
El
7. Remove the piston rings.
7. Remueva los aros de piston.
7. Deposer les segments de piston.
Fig. 3-5-10 SM3-295
Remove the cylinder liner.

NOTE: Put the line-up marks on the cylinder block and
I iner flange.
Remueva la camisa del cilindro.
NOTA: Ponga les marca de coincidencial bloque de cilindros
y el reborde de la camisa del cilindro.
Deposer la chemise de cyl incJre.
N.B. · Faire les marques d'alliance sur le bloc-cylindres et la col
lerette de la chemise de cylindre.
Fig. 3-5-11 SM3-851

3-5-6
a. Romo,e tho oyhndo, 1;no,.
,......,
Fig. 3-5-12 03-539


1. Measure the clearance between the small end bushing
and the piston pin.
Fig. 3-5-13 SM3-296 SM3-297

Pin diameter 47.0 mm ( 1.850 in) I Service limit 46.95 mm ( 1.8485 in)
Clearance
Standard I 0.025-0.043 mm (0.0010-0.0016 in)
Repair limit I 0.10 mm (0.0039 in)
Measure the spread dimension of the connecting rod
bearing.
Mida la dimension de la amplitud del cojinete de pie
de biela.
2. Mesurer la dimension d'ecartement du conssinet de
hielle.
Fig. 3-5-14 SM3-298

I Standard 80.75-81.75 mm (3.1792-3.2184 in)
3-5-7
3. Measurement of oil clearance between connecting

rod and crank pin.
1) Measure the connecting rod inside diameter.
3. Medici6n de la holgura de aceite entre la biela y el
codo de cigueiial.
1) Mida el diametro interior de la biela.
3. Prise cJe rnesure du jeu de passa[.)e cJ'huile entre hielle
et rnaneton de vilehrequin.
1) Mesurer le diarnetre interieur de la bielle.
Fig. 3-5-15 SM3-564 SM3-300

Tightening torque 2,200-2,400 kg·cm (160-173 lb.ft)
Oil clearance 0.041-0.092 mm (0.0017-0.0036 in)
2) Measure the crank pin outside diameter.
2) Mida el diametro exterior de\ codo de cigueiial.
2) Mesurer le c.Jiametre exterieur c.Ju maneton c.Je
vilebreljuin.
Fig. 3-5-16 SM3-430 03-739

Standard 74.95-74.97 mm (2.9508-2.9515 in)
3) Check to ensure that this hole is not clogged up,
by blowing air through it or inserting a piece of
wire into it.
Fig. 3-5-17 SM3-424
4. Measure the connecting rod end play.

4. Mida el juego longitudinal de la bila.
4. Mesurer le jeu en bout c.Je la bielle.
Fig. 3-5-18 SM3-576

Tightening torque 2,200-2,400 kg·cm (159-174 lb-ft) I
End play 0.15-0.32 mm (0.0059-0.013 in) I
Service limit 0.6 mm (0.0236 in) I
··
3-5-8
lu 1
M .. , ... th, connooting rnd maightn,...
Fig. 3-5-19 SM3-330
··
I Service limit 0.1 mm (0.0039 in) for each 200 mm (7.87 in)
lu 1
Mea,u .. th, connooting rnd twist.
Fig. 3-5-20
I Service limit 0.1 mm (0.0039 in) for each 200 mm (7.87 in)
Measurement of the clearance between cylinder liner
I![)
and piston.
1) Measure the cylinder liner inside diameter.
7.
7. Medici6n de la holgura entre la camisa del cilindro y
el piston.
(;}��
1) Mida el diametro interior de la camisa del cilindro.
7. Prise de mesure du jeu entre chemise et piston.
�� 1) Mesurer le diametre interieur de la chemise de
_____l
lf----41----·__J_� cylindre.
Fig. 3-5-21 SM3-313 SM3-432

Standard 120 mm (4.724 in)
2) Measure the piston outside diameter.

2) Mida el diametro exterior del piston.
2) Mesurer le diametre exterieur du piston.
Fig. 3-5-22 SM3-433

I Clearance 0.134-0.166 mm (0.0053-0.0065 in)
3-5-9
Measure the clearance between the piston pin hole

and the piston pin.
Fig. 3-5-23 SM3-585 SM3-297
Outside diameter Standard 47 mm ( 1.850 in)

Standard 0.002-0.016 mm
(0.00008-0.00063 in)
Clearance Service
limit 0.05 mm (0.0020 in)
Hino Engine Parts

Phone: 269 673 1638
Measure the clearance between the piston ring groove

and the piston ring.
--
Fig. 3-5-24 SM3-301
Clearance Service limit

Top ring, 2nd ring - -
3rd ring 0.04-0.08 mm (0.0016-0.0031 in) 0.2 mm (0.0079 in)
Oil ring 0.02-0.06 mm.(0.0008-0.0023 in} 0.1 mm (0.0039 in}
'"·
3-5-10
lu I
M, ..... th, p;,ton ,;ng •nd """""·
--
Fig. 3-5-25
Top ring
2nd ring
3rd ring
Clearance
SM3-302
0.35-0.50 mm (0.0138-0.0196 in)

0.35-0.47 mm (0.0138-0.0185 in)
0.35-0.47 mm (0.0138-0.0185 in)
Service limit
1.5 mm (0.0590 in)
1.2 mm (0.0472 in)
1.2 mm (0.0472 in)
Oil ring 0.35-0.55 mm (0.0138-0.0217 in) 1.0 mm (0.0393 in)
"·
lu I
Meamoth, c,ank,hofnunout.
Fig. 3-5-26 SM3-577

12. Measure the spread dimension of the main bearing.

✓
----
12. Mida la dimension de la amplitud del cojinete prin
cipal.
12. Mesu rer la dimension d 'ecartemen t du coussinet
principal.
Fig. 3-5-27 SM3-298

Standard 96.75-98.00 mm (3.8091-3.8582 in)
3-5-11
l!tl
Measure the oil clearance between crankshaft jour
nal and main bearing.
1) Measure the crankshaft journal outside diameter.
y 0 13.
,$, y
JOURNAL'
/
Fig. 3-5-28 SM3-431

Standard 89.91-89 .93 mm (3.5398-3.5405 in)
Repair limit -0.2 mm (-0.0079 in)
B
Service limit -1.2 mm (-0.0472 in)
2) Measure the main bearing inside diameter.
If the oil clearance is larger than repair limit,
regrind or replace the crankshaft.
rll 1{
Fig. 3-5-29
00 00
- � ,\
- H
.
.- •- t --
I
SM3-440
Tightening torque 2,700-2,900 kg-cm (196-209 lb.ft)
Oil clearance 0.050-0.106 mm (0.0020-0.0041 in)
Machining dimension of crankshaft
Under size bearing Crank pin outside Journal outside

diameter diameter
0.25 mm (0.0098 in) 74.69-74.71 mm 89.69-89.71 mm

(2.9405-2.9413 in) (3.5310-3.5319 in)
0.50 mm (0.0197 in) 74.44-74.46 mm 89.44-89.46 mm

(2.9307-2.9315 in) (3.5212-3.5220 in)
0.75 mm (0.0295 in) 74.19-74.21 mm 89.19-89.21 mm

(2.9208-2.9216 in) (3.5114-3.5122 in)
1.00 mm (0.0394 in) 73.94-73.96 mm 88.96-89.94 mm

(2.9110-2.9118 in) (3.5024-3.5409)
Standard 74.950-74.970 mm 89.910-89.930 mm

(2.9508-2.9515 in) (3.5398-3.5405 in)
Hino Engine Parts

Phone: 269 673 1638
3-5-12
3) Method of the crankshaft regrinding for fillet R.
�·J��.
:::--.�
CORRECT
I I
WRONG
Fig. 3-5-30 SM3-441
Dimension of C_ra_n_k_:;p_in_+-_4 _.5_-_5_.0_m_m 0( _._17_7_-_0_._196_in l

� �
fillet R Journal 4.5-5.0 mm (0.177-0.196� in).,... ----l
14. Measure the cylinder block surface evenness.

14. Mida la superificie del bloque de cilindros para
comprobar su uniformidad.
14. Verifier la regularite de la surface du bloc-cylindres.
Fig. 3-5-31 SM3-578
15. Measure the crankshaft end play.

15. Mida el juego longitudinal del cigueiial.
15. Mesurer le jeu en bout du vilebrequih.
Fig_ 3-5-32 SfVl3-362

Standard 0.110-0.240 mm (0.0043-0.0094 in)
1) Measure the distortion of flywheel friction surface.

1) Mida la distorsi6n de la superficie de fricci6n del
volanete.
1) Mesurer la distorsion de la surface de friction du
volant.
Fig. 3-5-33 03-858

3-5-13

1. Inspect the piston cooling jet positioning
1) Remove the piston cooling jet connector bolt and
install a special tool.
Fig. 3-5-34 03-2092

2) Use a commercially available oil pump [pressure

about 2 kg/cm2 , flow rate about 2.5Q/min (0.66
US.gal)].
3) Prepare new engine oil.
4) Connect the oil lines.
Connect the oil pump outlet to a special tool (con
A nector bolt).
B
Fig. 3-5-35 SM3-579

A. Coling jet
B. Bolt for inspection
C. Oil hose for inspection
5) Install a special tool on the cylinder block with

locating pins.
6) Operate the oil pump, and with pressure at about
2 kg/cm2 (28.44 lb/sq.in), pump new oil from the
jet, and perform a spray test. Conditions are nor
mal if the center of stream hits a target plate of
cj>10mm (0.39 in).
SPECIAL TOOL
COOLING
JET
Fig. 3-5-36 SM3-942
j Special tool 09470-1090

3-5-14
2. Adjust the direction of oil jet stream

1) Inspect the hitting position of oil spout on the
target plate.
NOTE: Operate the oil pump, and with pressure at about 2
kg/cm 2 (28.44 lb/sq.in), pump new oil from the jet,
and perform a spray test. Conditions are normal if
TARGET the center of stream hits a target plate of ¢10 mm
(0.39 in).
WARNING
Diesel oil is flamable.
This spray test should be done in a well ventilated
room and away from any open flames or electric
sparks.
SPRAY
-$- $ ®-
� '--v--'
-E!(TARGET ¢10
ABNORMAL NORMAL
Fig. 3-5-37 SM3-923 SM3-581
2) Adjust the nozzle direction using a special tool,

if the spray of the cooling jet messes the circle on
the target plate.
Fig. 3-5-38 SM3-953

SPRAY PATTERN
3) Inspect the spray pattern
( 1) When inspecting the piston cooling jet posi
lll
tioning, check that the spray is dispersed as
VSPRAY
shown in (a) and not as in (b), (c), or (d) in
the illustration at left.
(2) Check that the spray is not a thin muddy
�OLINGJET
color.
NOTE: If the tip of the jet is damaged so that the spray
pattern is bad, replace the jet wfth a new one.
When replacing the cooling jet, always inspect the
new piston cooling jet's positioning.
NORMAL
(d) (cl (b) (a)
ABNORMAL
'------,.v-----
Fig. 3.5.39 SM3-582

3-5-15
4) After inspecting the piston cooling jet positioning.

Remove the special tool (connector bolt), then
install the cooling jet on the cylinder block using
the correct mounting bolt.
5) After installing the piston, make sure that there is
no interference between the cooling jet and the
piston when the piston is at bottom dead center.
NOTE: Do not remove the cooling jet except when per
forming overhauls or when otherwise necessary.
In the event that the cooling jet is removed, be sure
to replace it on the cylinder.
Fig. 3-5-40 03-2092

200-250 kg·cm
Tightening torque
(15-18 lb.ft)
3. Inspect the pilot bearing.

3. lnspeccione el cojinete piloto.
3. Controler le roulement-guide.
Fig. 3-5-41 03-756
Inspect the crankshaft sleeve for wear.

SPECIAL TOOL If excessive worn, replace its.
SPECIAL TOOL Replacement of crankshaft sleeve.
1) Remove the crankshaft sleeve (Front and rear).
(FRONT SIDE) (REAR SIDE)
Fig. 3-5-42 SM3-565 SM3-566

09420-1560
Special tool
09420-1570
E1
4.9-5.1 mm 2) Install the crankshaft sleeve (Front and rear).
NOTE: To prevent the oil seal lip from-dropping off, drive in
the sleeve to a distance of 4.9 to 5.1 mm from the
edge of the pulley center.
(REAR SIDE)
SPECIAL TOOL
Fig. 3-5-43 SM3-985 SM3-568

09402-1161
I Special tool
09402-1220
3-5-16
EJ
5. Replacement of oil seal and dust slinger
1 I Front oil seal
SPECIAL TOOL
5. Reemplazo del sello de aceite y del deflector de polvo
1) Sella de aceite delantero
5. Remplacement cle la rondelle de retenue cfhuile et le
deflecteur cJ'huile
TIMING 1) Rondelle cJe retenue cJ'huile AV.
GEAR CASE
Fig. 3-5-44 SM3-569

EJ
2) Front dust slinger.
SPECIAL TOOL 2) Deflector de polvo delantero.
2) Detlecteur cl'huile AV.
PULLEY
Fig. 3-5-45 SM3-570

I Special tool 09402-1290, 964507-435
EJ
3) Rear oil seal.
3) Sella de aceite trasero.
3) Rone.Jelle de retenue cJ'huile AR.
Fig. 3-5-46 SM3-966
E3
4) If necessary, remove the ring gear.
a. Heat the ring gear with a blow torch in a uniform
° °
manner [Approx. 100 C (212 F)).
b. Strike all around the ring gear in a uniform manner
and remove it.
4) Si es necesario, remueva la corona dentada.
a. Caliente la corona dentada con un soplete oxi °
acetilenio
°
etc., de manera uniforme [Aprox. 100 C
(212 F)].
b. Golpee de manera uniforme alrededor de la corona
dentada y remuevala.
Fig. 3-5-47 SM3-787

3-5-17
a Assembly and adjustment

1. Install the cylinder liner.
Apply engine oil to the liner.
Armado y ajuste
1. I nstale la camisa del cilindro.
Aplique aceite de motor en la camisa.
Remontage et reglage
1. Remonter la chemise de cylindre.
Enduire la chemise de cylindre d'huile pour moteur.
Fig. 3-5-48
I Spacial tool 09480-1110
NOTE: When install the cylinder liner to be fit the same

make with cylinder block (A or Bl.
IA
A or B
I
A or B
'I
Fig. 3-5-49 SM3-583
2. Align the line-up marks of cylinder liner and block.

2. Alinee las marcas de coincidencia de la camisa del
cilindro y el bloque.
2. Faire aligner les marques d'alliance sur la chemise
et le bloc-cylindres.
Fig. 3-5-50 SM3-851

3-5-18
3. Measure the protrusion of the cylinder liner flange.

3. Mida la saliente de la brida de la camisa del cilindro.
3. Mesurer la protrusion de la collerette de la chem,se
de cylindre.
Fig. 3-5-51 03-546

Tightening torque 100 kg•cm (7.23 lb.ft)
Protrusion 0.04-0.10 mm (0.0016-0.0039 in)
PRESSURE: 500kg (1,100 lb)
Fig. 3-5-52 SM3-572
rrr Mounting the crankshaft

1) Apply engine oil to the bearing.
NOTE: Do not forget to install the thrust bearing.
4. Montaje del ciguefial
1) Aplique aceite de motor en el cojinete.
NOTA: No olvide de instalar el cojinete de empuje.
4. Remontage du vilebrequin
1) Enduire le coussinet d'huile pour moteur.
N.8.: Ne pas oublier de remonter les flasques.
Fig. 3-5-53 03-762
El
2) Install the crankshaft.
2) lnstale el ciguefial.
2) Remonter le vilebrequin.
Fig. 3-5-54 03-556

3-5-19
El
3) Install the bearing cap and thrust bearing.
ARROW
MARK
TIMING GEAR
SIDE
Fig. 3-5-55 SM3-855
El
4) Tightening the main bearing cap bolt.
NOTE: Make sure that crankshaft rotates smoothly.
Tightening sequence: 4-3-5-2-6-1-7
Fig. 3-5-56 03-564
2,700-2,900 kg-cm
Tightening torque (195-209 lb.ft)
El
5.- Assembling the piston and connecting rod.
1) Assemble the piston and connecting rod.
5. · Armado del piston y la biela.
1) Arme el piston y la biela.
5. Assemblage du piston et de la biel le.
1) Assembler le piston et la bielle.
Fig. 3.5.57 03-214
m 2) Piston and connecting rod fitting position.
l=:I
INJECTION
PUMP SIDE
Fig. 3-5-58 SM3-407

3-5-20
3) Position of ring gap seen from piston top.

OMARK RING 3) Posicion de la holgura del aro vista de la parte
UPPER superior del piston.
FACE
3) Position de la fente du segment vue au dessus du
piston.
IDENTIFI
CATION NO.
Fig. 3-5-59 SM3-573
El
6. Install the piston assembly
1) Lubricate the piston and cylinder liner.
6. I nstale el conjunto del piston
1) Lubrique el piston y la camisa del cilindro.
6. Monter !'ensemble piston
1) Graisser le piston et la chemise de cylindre.
Fig. 3-5-60 SM3-383 03-857

PISTON O-MARK
IDENTIFICATION
MARKS OF
m
�
2) Direction of the piston head.
NOTE: When installing the piston and connecting rod
assembly, be careful that the cooling jet is not struck
by the connecting rod.
LINER AND
BLOCK
Fig. 3-5-61 SM3-967
El
7. Tightening the connecting rod bolt.
7. Apriete las biela perno.
7. Serrer les l>ielle IJoulon.
Fig. 3-5-62 03-547

2,200-2,400 kg-cm
3-5-21
El
8. Install the oil seal retainer.
8. Instate el retenedor de sello de aceite.
8. Monter la rondelle de retenue d'huile.
Fig. 3-5-63 03-1868
Tightening torque 190-260 kg•cm

(14-18 lb.ft)
B
9. Install the flywheel housing.
9. Instate el carter del volante.
9. Monter le carter de volant.
Fig. 3-5-64
Tightening torque 1,000-1,300 kg-cm

(73-93 lb.ft)
B
10. Install the flywheel.
10. Instate el voltante.
10. Monter le vol ant.
Fig. 3-5-65 03-2169
Tightening torque 2,600-2,900 kg·cm

(189-209 lb.ft)
Hino Engine Parts

Phone: 269 673 1638
MEMO
3-6-1
HINO EP100 HINO EP100T
LUBRICATING SYSTEM
SISTEME DE LUBRICACION
SYSTEME OE REFROIOISSEMENT
�1
, a : 2
"
24 3
26
25
21
+----23
SM3-1044
LUBRICATING SYSTEM
1. Piston 14. Oil filter (Full-flow)
2. Cooling jet 15. Oil filter (By-pass)
3. Sub oil hole 16. Low cut off valve
4. Crankshaft 17. Oil cooler
5. Main hole 18. Safety valve
6. Camshaft 19. Regulator valve
7. Injection pump 20. Safety valve
8. Fuel injection pump drive gear 21. Oil pump
9. Turbocharger 22. Oil strainer
10. Check valve 23. Oil pan
11. Pressure gauge (OPT.) 24. Check valve
12. Safety valve 25. To valve system
13. Oil filter warning switch 26. To jet
Fig. 3-6-1
Hino Engine Parts
Phone: 269 673 1638
3-6-2
HE11-094-00X00 (1400)
1. Oil pump 1. Bomba de aceite 1. Pompe a huile

2. O-ring 2. AnilloO 2. Joint torique
3. Suction strainer 3. Colador de aspiraci6n 3. Crepine d'aspiration
4. Oil cooler 4. Enfriador de aceite 4. Refroidisseur d'huilf.
Fig. 3-6-2
Hino Engine Parts

Phone: 269 673 1638
3-6-3
1420D
I-NO.20
4 �
.1·
��
i�
L/
7
L_/
10
""
� 6
6
1. Oil cooler case 1. Caja de enfriador de aceite 1. Carter de refroidisseur a huile

2. Regulator valve 2. Valvula de regulaje 2. Soupape de regulatrice
3. Safety valve 3. Valvula de seguridad 3. Soupape de securite
5. Element 5. Elemento 5. Cartouche de filtre
6. Cover 6. Cubierta 6. Couvercle
7. Bolt 7. Perno 7. Bou Ion
8. co·ver 8. Cubierta 8. Couvercle
10. Element 10. Elemento 10. Cartouche de fi ltre
Fig. 3-6-3
Hino Engine Parts

Phone: 269 673 1638
3-6-4
1458S
I-N0.21
HINO EP100
HINO EP100T
Engine Oil Pump
1. Oil pump body 1. Caja de bomba de aceite 1. Corps de pompe a huile

2. Oil pump cover 2. Cubierta de bomba de aceite 2. Couvercle de pompe a huile
3. Driven gear 3. Engranaje impulsado 3. Piynon entraine
4. Drive gear 4. Engranaje impulsor 4. Pignon d"entraine,nent
5. Drive shaft 5. Eje impulsor 5. Arure d"entrainernent
6. Bushing 6. Casquillo 6. Bague
7. Drive gear 7. Engranaje impulsor 7. Pignon d'entrairiement
Fig. 3-6-4
Hino Engine Parts

Phone: 269 673 1638
3-6-5

1. Oil pump and oil cooler
1) Measure the clearance between the pump case and
gear teeth.
Fig. 3-6-5 03-581

Standard 0.033-0.10 mm (0.0013-0.0039 in)
2) Measure the end play of the driven gear.

2) Mida el juego longitudinal de! engranaje impul
sado.
2) Mesurer le ieu en liout du pignon entraine.
Fig. 3-6-6 SM3-927

Standard 0.040-0.092 mm (0.0016-0.0036 in)
3) Measure the oil clearance between the drive gear

shaft and the inside diameter of pump cover.
Fig. 3-6-7 SM3-929
Standard 0.04-0.083 mm (0.0016-0.0032 in)

4) Mesure the gear backlash.

4) Mida el contragolpe de los engranajes.
4) Mesurer le batternenr des engrenages.
Fig. 3-6-8 03-584

Standard 0.15-0.28 mm (0.006-0.011 in)_
3-6-6
2. Oil cooler
�. Inspect the oil cooler for cracks and any other
� damage.
2. Enfriador de aceite
lnspeccione el enfriador de aceite en cuanto a grietas
y cualquier otro dafio.
2. Refroidisseur d'huile
Controler le refroidisseur d'huile a lil rH:herche cJe
fissures et ci'autres deteriorations
Fig. 3-6-9 03-597

Cooler-element 150-250 kg·cm ( 11-18 lb.ft)
Tightening torque t--------+-----=----------l
Cooler assembly 130-180 kg•cm (10-13 lb.ft)
�r
Oil filter
1) Inspect the safety valve, regulator valve and springs
for wear and any other damage.
3. Filtro de aceite
1) I nspeccione la val vu la de seguridad, valvula de
regulaje y el resorte en cuanto a desgaste y cual
quier otro dafio.
3. Filtreahuile
1) C:ontroler la soupape cJe sec:urite, soupapc cJc
regulatrice et le ressort a la recherche cl'usure et
cJ'autre deterioration
Fig. 3-6-10 03-595

Regulator valve 300-400 kg·cm (22-28 lb.ft)
Tightening torque t-=--c------+-----=---'----'---'-....:....--1
Safety valve 250-350 kg•cm (19-25 lb.ft)
2) Inspect the oil filter element and • 0' -ring for

clog and any other damage.
Fig. 3-6-11 03-591
3) Wash the element in clean diesel fuel to allow no

foreign matter to enter.
3) Lave el elemento el combustible diesel limpio a
fin de impedir la infiltracion de cuerpos extrafios.
3) Laver la cartouche dans le combustible diesel
propre afin de ne pas permettre !'introduction des
substances etrangeres.
Fig. 3-6-12 03 776

3-7-1
HINO EP100 HINO EP100T COOLING SYSTEM

SISTEME DE ENFRIAMIENTO SYSTEME DE REFROIDISSEMENT
HE11-094-00X01 (1600)
1. Coolant pump out let pipe 1. Tuba de salida de la bomba 1. Canalisation de debouche de
2. Coolant pump del enfriador pompe eau a
3. Hose 2. Bomba del enfriador a
2. Pompe eau
4. Thermostat case cover 3. Manguera 3. Du rite
5. Thermostat case 4. Cubierta de la caja del 4. Couvercle de la cage de thermostat
6. Thermostat thermostato 5. Cage de thermostat
7. Gasket 5. Caja del termostato 6. Thermostat
8. Cooling fan 6. Termostato 7. Joint
7. Junta 8. Ventilateur
8. Ventilador del radiador
Fig. 3-7-1
Hino Engine Parts

Phone: 269 673 1638
3-7-2
1659J
I-N0.21
COOLANT PUMP BOMBA DEL ENFIADOR POMPE A EAU
1. Case 1. Caja 1. Carter

2. Shaft 2. Eje 2. Arbre
3. Vane 3. Paleta 3. Ailette
0
4. Coolant seal 4. Sello del enfriador 4. Bague d etancheite
5. Spacer 5. Espaciador 5. EntretoisP.
6. Plate 6. Placa 6. Plaque de fermeture
Fig. 3-7·2
3-7-3
El
Coolant pump
Disassembly
1. Remove the plate and vane.
Bomba de enfriador
Desarmado
1. Reml)eva la placa y el alabe.
Pompe a eau
Demontage
1. Deposer la plaque de fermeture el l'ailette.
Fig. 3-7-3 SM3-954

El
2. Remove the retainer ring.
2. Remueva el anillo retenedor.
2. Deposer le circlip
Fig. 3-7-4 SM3-964
3. Remo,e the d,;., shaft, wam seal aad oH seal.
, .... ,
Fig. 3-7-5 SM3-994

1. Inspect the disassembled parts for wear, cracks and
any other damage.
I nspecci6n y reparaci6n
1. I nspeccione las piezas desarmadas en c_uanto a des
gaste, grietas, y cualquier otro dano.
Controle et reparation
1. ConIroler 1es pieces desassernblees a la recherche
cl'usure, de felures et d'autres deteriorations.
Fig. 3-7-6 03-1876

3-7-4
r=1 2. Clean the water drain hole.
L:J
Fig. 3-7-7 SM3-932
El
Assembly
1. Install the oil seal, water seal, and drive shaft.
Fig. 3-7-8 SM3-963
El
2. Install the retainer ring.
2. lnstale el anillo retenedor.
2. Remonter le circlip
Fig. 3-7-9 SM3-964
El
3. Install the vane to the shaft.
3. lnstale la paleta en el eje.
3. Remonter l'ailette sur l'arbre.
Fig. 3-7-10 SM3-954

Tightening torque 1,150-1,250 kg•cm (83-90Ib.ft)
3-7-5
B
Thermostat
1. Disassembly
1) Loosen the 4 bolts attaching the thermostart cover
and case, then remove the thermostat from within
the case.
Fig. 3-7-11 SM3-366
Inspection
1) Inspect the thermostat case.
Check to see whether there is deterioration or
damage to the thermostat attachment section.
Replace any worn or damaged parts.
Fig. 3-7-12 SM3-370

3-7-6
a Assembly
1. Replace the gasket without fail if it is corroded,
damaged or flattened.
2. Before installing the thermostat, apply sealing com
pound to the thermostat gasket and the hose installa
tion portion of the thermostat case cover.
Armado
1. Reemplace sin falta la junta en caso que este corroida,
danada o aplastada.
2. Antes de instalar el termostato, aplique empaque•
tadura liquida en la junta del termostato, y en la
porci6n de instalaci6n de la manguera en la cubierta
del termostato.
Fig. 3-7-13 SM3-791
1. Gasket 1. Junta
2. Plate 2. Placa
3. Cover 3. Cubierta
4. Thermostat 4. Termostato
5. Case 5. Caja
El
3. Tighten up the clamp bolts of the case and thermo
stat cover.
3. Apriete los pernos de fijaci6n de la caja y de la
cubierta del termostato.
Fig. 3-7-14 SM3-807

I Tightening torque 190-270 kg.cm (14-19 lb.ft)
3-7-7
2) Check the valve lift in hot water.

°
Valve opening temperature: 76.5 C
Maximum valve lift: 10.0 mm
2) lnspeccione el alzado de la valvula en agua caliente.
°
Temperatura de apertura de la valvula: 76,5 C
Alzado maximo de la valvula: 10,0 mm
2) Verifier la levee de la soupape dans l'eau chaude.
°
Temperature d'ouverture de la soupape: 76,5 C
Levee maxi. de soupape: 10,0 mm
Fig. 3-7-15 SM3-805
10 MM
t
A
° ° I
0 C f--10 C•--; I
° °
76.5 C 90 C
Fig. 3-7-16 SM3-638
1. Stirring rod 1. Varilla de mezcla 1. Agitateur

2. Thermometer 2. Term6metro 2. Thermometre
3. Thermostat 3. Term6stato 3. Thermostat
4. Heater 4. Calentador 4. Chau ff age
A. Lift A. Alzado A. ·Levee
B. Temperature B. Temperatura B. Temperature
3-7-8
El
Radiator
1. Inspect the radiator cap pressure.
Fig. 3-7-17 03-793

2
Pressure 0.4-0.6 kg/cm (5.64-8.53 lb.sq.in)
2. Inspect the radiator for crack and clogging of tube.

2. lnspeccione el radiador en cuanto a grietas y obtura
ci6n el tubo.
2. Contr61er le racliiiteur ;'1 lil reclierche cle fissures r.t de
IHlLICiicll.jP cill tllytltJ
Fig. 3-7-18 03-794

3-8-1
HINO EP100 HINO EP100T FUEL SYSTEM

SISTEMA DE COMBUSTIBLE SYS TEME DE COMBUSTIBLr
- -
(Automatic timer is optional)

t
5
SM3-595
HINO EP100
HINO EP100T
FUEL SYSTEM SISTEMA DE COMBUSTIBLE SYSTEME DE COMBUSTIBLE
1. Fuel f ilter (seocndary) 1. Filtro de combustible (secundario) 1. Filre a carburant lsecondaire)

2. Injector 2. Portainyector 2. Porte-injecteur
3. Feed pump 3. Bomba de alimentaci6n 3. Pompe d'alimentation
4. Water separator 4. Separador de agua 4. Separateur d'eau
5. Fuel tank 5. Tanque de combustible 5. Reservoir de carburant
Fig, 3-8-1
Hino Engine Parts

Phone: 269 673 1638
3-8-2
HE11-087-00X01 (1500)
HINO EP100
HINO EP100T
RELATED PARTS OF FUEL PIEZAS RELACIONADAS CON EL PIECES CONNEXES AU SYSTEME
SYSTEM D'ALIMENTATION EN COMBU-
STIBLE
1. Fuel injection pump assembly 1. Conjunto de la bomba de inyec- 1. a

Ensemble pompe injection
2. Fuel feed pump ci6n del combustible 2, Pompe d'alimentation de
3. Automatic timer (OPT.) 2. Bomba de alimentaci6n del carburant
4. Coupling combustible 3. Dispositif d'avance automatique
5. Fuel injection pump drive gear 3. Dispositivo de avance auto- (sur demande)
6. Nozzle holder matico (OPC.) 4, Accouplement
7. Fuel filter 4. Acoplamiento 5, Pignon d'entrainement de la
8. High pressure pipe 5. Engranaje impulsor de la bomba a
pompe injection
9. Fuel pipe (inlet) de inyecci6n del combustible 6. Porte-i njecteu r
10. Fuel pipe (return) 6. Portainyector 7. a
Filtre carburant
11. Fuel pipe (return) 7. Filtro de combustible 8. Tuyau a haute pression
8. Tubo de alta presi6n 9. Tuyau de carburant (admission)
9. Tubo de combustible (admisi6n) 10. Tuyau de carburant (retour)
10. Tubo de combustible (retorno) 11. Tuyau de carburant (retour)
11. Tubo de combustible (retorno)
Fig. 3-8-2
Hino Engine Parts
Phone: 269 673 1638
3-8-3
1530R
I-NO.20
� 10
6 9
8
4
\+ �
7
3---'
HINO EP100 INJECTOR

HINO EP100T INJECTOR PORT Al NY ECTOR PORTE-INJECTION
1. Nozzle holder assembly 1. Conjunto de portainyector 1. Ensemble porte-injecteur
3. Inlet connector 3. Conector de admision 3. Connecteur d'admission
4. Nozzle holder press pin 4. Pasador de presion del portain- 4. Tige de pression du porte-
5. Pressure spring yector injecteur
6. Adjusting screw 5. Resorte de presion 5. Ressort depression
7. Gasket 6. Tornillo de ajuste 6. Vis de reglage
8. Retaining nut 7. Junta 7. Joint
9. Gasket 8. Tuerca retenedora 8. Ecrou de retenue
10. Joint bolt 9. Junta 9. Joint
11. Nozzle holder cap nut 10. Perno de union 10. Bou Ion d'articu lat ion
11. Tuerca de combrerete del 11. Ecrou a chapeau de porte-
po rta in yector injecteur
Fig. 3-8-3
Hino Engine Parts

Phone: 269 673 1638
3-8-4
1518M
I-N0.22
-2
�-10
'----11
FUEL FILTER FILTRO DE COMBUSTIBLE Fl L TRE A CAR BU RANT
1. Body 1. Cuerpo 1. Corps

2. Center bolt 2. Perno central 2. Bou Ion central
4. Element spring 4. Resorte del elemento 4. Ressort de cartouche
5. Element spring seat 5. Asiento del resorte del elemento 5. Siege de ressort de canouche
6. Element kit 6. Juego de elemento 6. Ensemble cartouche
8. Body cover 8. Cubierta del cuerpo 8. Couvercle de corps
9. Bleeder plug 9. Tap6n de purga 9. Bouchon de trop-plein
11. Drain plug 11. Tap6n de vaciado 11. Bouchon de vidange
Fig. 3-8-4
3-8-5
1571 B
I-NO.20
4-0
3 �· �--··---7
0------------
6
�
SEDIMENTER SEDIMENTADOR SEDIMENTEUR

1. Cover 1. Cubierta 1. Couvercle
2. Body 2. Cuerpo 2. Corps
3. Float 3. Flotador 3. Flotteur
5. Nut 5. Tuerca 5. Ecrou
6. Drain plug 6. Tap6n de vaciado 6. Bouchon de vidange
8. Bolt 8. Perno 8. Bou Ion
Fig. 3-8-5
3-8-6
Disassembly
1. Disassemble the injection nozzle.
Fig. 3-8-6 03-786
Inspection and adjustment

1. Inspect the injection pump coupling for cracks and
any other damage.
lnspecci6n y ajuste
1. I nspeccione el acoplamiento de la bomba de inyec
ci6n en cuanto a grietas y cualqu ier otro daii o.
Controle et reglage
Controler l'accouplernent de la pompe a injection a
la recherche de felure et d'autres deteriorations.
Fig. 3-8-7 03-796
2. Inspect the nozzle for wear and damage.

2. lnspeccione el inyector en cuanto a desgaste y daiios.
2. Controler l'injecteur a la recherche de l'usure et de
la deterioration.
Fig. 3-8-8 03-797
3. Adjusting the injection pressure.

1) Assemble the injection nozzle.
3. Ajuste la presi6n de inyecci6n.
1} Arme la tobera de inyecci6n.
3. Reglage de la pression d'injection.
1) Assembler l'injecteur
Fig. 3-8-9 03-798
I Tightening torque I 600 ~ 800 kg.cm (44 ~ 57 lb.ft)

3-8-7
2) Adjust the injection pressure.

2) Adjuste la presion de inyeccion.
2) Regler la pression d'injection
Fig. 3-8-10 03-799
Injection pressure I 220 kg/cm l (3,128 lb/sq .in)
3) Checking the spray profile.

4) In the spray profile is unsatisfactory, clean or
r 1 replace the nozzle.
GOOD DEFECTIVE DEFECTIVE DEFECTIVE
Fig. 3-8-11 SM3-450
ASSEMBLY
Adjusting the injection timing °
1. Rotate the crankshaft clockwise to a position 16
_,.
CLOCK
WISE before top dead center of the compression stroke
of the No.1 cylinder as seen in the inspection hole of
the flywheel housing.
C)
___ 16___
Fig. 3-8-12 SM3-1047
2. Match the injection timing marks on the pump body

side and the coupling side.
Fig. 3-8-13 EP1T-037

3-8-8
3. Check the rocker arms on No.1 cylinder are loose and

rockers on No.6 are tight.
NOTE: If not, turn the crankshaft one complete revolution
and align marks as above.
Fig. 3-8-14 SM3-338
Match the injection timing marks on the automatic

timer.
NOTE: Align the timing marks by turning the automatic
timer to clockwise by hand.
The automatic timer is optional.
Fig. 3-8-15 SM3-339
Fig. 3-8-16 SM3-340
Tighten the coupling bolt.

NOTE: There should not be any gap between the laminated
plates or by any deformation of the flange due to
pressure the laminated plates.
Hino Engine Parts

Phone: 269 673 1638
Fig. 3-8-17 SM3-336 website: www.HeavyEquipmentRestorationParts.com
3-9-1
AIR CLEANER
FILTRO DE AIRE
FILTRE A AIR
2502E
I-N0.23
J·
- �--�
/((\� /
AIR CLEANER FILTRO DE AIRE FILTREAAIR
1. Air cleaner body sub-assembly 1. Sub-conjunto del cuerpo del 1. a

Sous-ensemble corps de filtre air
2. Hook bolt filtro de aire 2. Boulon-crochet
3. Air cleaner cover sub-assembly 2. Perno de gancho 3. Sous-ensemble couvercle du
4. Dust pan sub-assembly 3. Cubierta del filtro de aire a
filtre air
5. Filter element 4. Sub-conjunto del colector de 4. Sous-ensemble carter de poussiere
6. Gasket polvo 5. Cartouche de filtre
7. Wing nut 5. Elemento del filtro 6. Joint
8. Dust indicator 6. Junta 7. Ecrou a oreilles
7. Tuerca de aletas 8. lndicateur de poussieres
8. I ndicador de polvo
Fig. 3-9-1
3-9-2
Inspection
•
·1· 1. Inspect the rubber packing for damage .
. . lnspecci6n
1. 1 nspeccione la empaquetadura de goma en cuanto a
.
dai'ios
'
Cont role
1 Controler le joint caoutchouc a la recherche de sa
deterioration.
Fig. 3-9-2 03-802
2. Element
E]
1) Clean the element with compressed air.
2. Elemento
1) Limpie el elemento con a ire comprimido.
2. Cartouche
1) Net toyer la cartouche avec d'air comprime.
Fig. 3-9-3 E024
Washing the element (only primary element) which
E]
is dirty with soot and oil.
2) Wash the element by soaking it in a non-sudsing
detergent solution for about 30 minutes.
Rinse it with clean water.
Fig. 3-9-4 E025
Air dry the element completely. Do not apply fire

or compressed air.
Fig. 3-9-5 03-808

3-9-3
4. Inspection
Check the element for rupture or pin holes by plac
ing a light inside the element after cleaning. Check
for a damaged gasket. Replace if necessary.
Fig. 3-9-6 E087

3-9-4
13
ENGINE COMPONENT PARTS
PIEZAS COMPONENTES DEL MOTOR
PIECES COMPOSANT DU MOTEUR
Assembly
Armada
Remontage
1. Installment of component parts
Installment should be done in the opposite order of
disassembly. Pay attention to the following points.
1) Install the inspection pump.
Fig. 3-9-7 04-1322 NOTE: Adjust the injection timing refer to fuel system
380-500 kg·cm page 3-8-7.
Tightening torque
(28-36 lb.ft)
2. Install the intake manifold.
, ....,
Fig. 3-9-8 SM3-1046

HINO EP100 EP100T 190-270 kg•cm
3. ln,tall the exhau>t manifold.
, ....,
Hino Engine Parts

Phone: 269 673 1638
Fig. 3-9-9 SM3-1041

HINO EP100 EP100T 450-500 kg·cm
3-9-5
•·
1•••1
ln'1all th, oH coolo, (w;th on tut,,>.
Fig. 3·9-10 03-2258

1•·•1
J. Install tho ooolant pomp and tho,momt '"'·
Fig. 3-9-11 03-1886

Hino Engine Parts

Phone: 269 673 1638
3-10-1
TUNING THE ENGINE

PUESTA .A PUMTO DEL MOTOR
GONFLAGE DE MOTEUR
El
1. Set the engine assembly on the test bench.
1. Coloque el conjunto del motor sabre un banco de
pruebas.
Fig. 3-10-1 SM3-810
OJ
2. Fill the engine oil, power steering oil and coolant.
2. Rellene refrigerante, aceite de motor y de direcci6n
de potencia.
Fig. 3-10-2 SM3-414

3-10-2
m 3. Bleeding the air from the fuel filter (Secondary
l:=I
filter).
1) Loosen the bleeder plus of the fuel filter.
2) Loosen the priming pump handle.
3) Operate the priming pump handle and bleed the
air from the filter until no air comes out through
the bleeding plug.
4) Insert the priming pump handle, turn it to the
right, and lock it.
5) Tighten the bleeder plug.
3. Purgue el aire del filtro de combutible
(Filtro secundario).
1) Afloje el tap6n de purga del filtro de combustible.
Fig. 3-10-3 SM3-475
2) Afloje la manivela de la bomba de cebado.
3) Opere la manivela de la bomba de cebado y prugue
el filtro hasta que deje de aslir aire a traves del
tap6n de purga.
m 4) lnserte la manivela de la bomba de cebado, girela
l:=I
hacia la derecha y enclavela.
5) Apriete el tap6n de purga.
Fig. 3-10-4 03-2260
j Tightening torque 40-60 kg.cm (3-4 lb.ft)
A
Turn the engine stop lever to the engine stop position
and crank the engine till the oil flows to each parts.
4. Gire la paranca de parada del motor al posici6n de
"�4.
parada y dar vueltas al cigi..iefial hasta que el aceite
circula hacia cada partes.
Fig. 3-10-5 03-2255

3-10-3
5. Start the engine.

1) Check the oil feed to rocker arms.
Within one minute after starting the engine, oil
should flow to the head ( Face A) of all push rods
B and the head ( Face B) of all valves.
2) Check the contact of the rocker arm and valve
stem caps. After running the engine, contact of
7 to 11 mm (0.276 to 0.433 in) should be obtain
ed at the cap contact face of the rocker arm.
3) Operate the engine for 30 to 40 minutes so that
the cylinder head gasket is warmed and stabilized
in dimension.
NOTE: Check for water and gas leaks, and noise.
Fig. 3-10-6 SM3-399 5. Arranque el motor
A: Face A A: Cara A 1) Revise de un minuto despues de poner en marcha
B: Face B B: Cara B el motor, el aceite circulara hacia la cabeza (cara
A) de todos los empujadores, y la cabeza (cara B)
de todas las val vu\as.
2) Revise el contacto de las tapas de\ balancin y de\
vastago de la valvula. Despues de arrancar el
motor, se debe obtener un cojntacto de 7 a 11 mm
(0,276 a 0,433 pul.) en la cara de contacto de la
tapa de! balanci n.
3) Opere el motor durante 30 a 40 minutos, de
manera tal que se caliente la junta de la culata del
cilindro, y se estabilicen sus dimensiones.
NOTA: Revise si hay ruidos o perdidas de agua o gas.
6. Check the injection timing

°
1) Rotate the crankshaft clockwise to a pos1t1on 15
before top dead center of the compression stroke
of the No.1 cylinder as seen in the inspection hole of
the flywheel housing.
At the same time, check that the timing marks of the
injection pump are aligned.
Fig. 3-10-7 SM3-413, SM3-1047

3-10-4
7. Adjust the valve clearance

1) Set each piston in firing order at top dead center of
the compression stroke and adjust the valve clearance.
Firing order: 1-4-2-6-3-5
--
Fig, 3-10-8
Inlet
Exhaust
Valve clearance, when cold
0.40 mm (0.0157 in)
0.50 mm (0.0197 in)
03-1526
Set the No.1 piston to top dead center of compres

sion stroke and adjust the valve clearance of the
valves indicated in the table below.
Then set the No.6 piston to top dead center and
adjust the remaining valves.
Firing order:· 1-4-2-6-3-5

Valve clearance, when cold;
Inlet: 0.40 mm (0.0157 in)
Outlet: 0.50 mm (0.0196 in)
Fig. 3-10-9 SM3-519
Cylinder 1 2 3 4 5 6
Valve arrangement I E I E I E I E I E I E
With No. 1 piston at T.O.C.
on compression stroke
• • • • • •
With No. 6 piston at T.D.C. 0 () 0 () () ()
on compression stroke
Hino Engine Parts

Phone: 269 673 1638
3-11-1
TROUBLESHOOTING
RECHERCHE DES PANNES
1. ENGINE OVER HEATING

1. RECALENTAMIENTO DEL MOTOR
1. SURCHAUFFE DU MOTEUR
OPERATION
OPERACION 1----- Over load
FONCTIONNEMENT Sobrecarga
Surcharge
Loosening or slipping fan belt

Flomedad o patinaje de la correa del ventilador
Courroie de ventilateur desserree ou glissante
Insufficient coolant water

I nsuficiencia de agua de enfriamiento
Eau de refroidissement insuffisante
COOLING SYSTEM Clogged radiator

SISTEMA DE ENFRIAMIENTO Radiador obstruido
SYSTEME DE REFROIDISSEMENT Radiateur bouche
Defective thermostat
Termostato defectuoso
Thermostat defectueux
Damaged coolant pump impeller

Rotor de la bomba de! refrigerante danado
Turbine de pompe a eau de refroidissement endommagee
Engine oil level too low

N ivel de aceite de motor demasiado bajo
Niveau d'huile de moteur trop bas
Engine oil deteriorated

Aceite de motor deteriorado
LUBRICATING SYSTEM Huile de moteur deterioree
SYSTEME DE LUBRIFICATION Defective oil cooler
Enfriador de aceite defectuoso
Radiateur d'huile defectueux
Defective oil pump

Bomba de aceite defectuosa
Pompe a huile defectueuse
3-11-2
Improper injection pump timing

Reglaje inadecuado de la bomba de inyeccion
Reglage de la pompe d'injection incorrecte
Defective nozzle injection

I nyeccion defectuosa
lnJection d'injecteur defectueuse
ABNORMAL COMBUSTION Injection pressure deteriorated

COMBUSTION ANORMAL Presion de inyeccion deteriorada
COMBUSTION ANORMALE Pression d'in1ection deterioree
Excessive fuel volume

Volumen de combustibole excesivo
Volume de combustible excessif
Poor quality fuel

Combustible de calidad deficiente
Combustible de mauvaise qualite
3-11-3
2. EXCESSIVE OIL CONSUMPTION

2. CONSUMO EXCESIVO DE ACEITE
2. CONSOMMATION D'HUI LE EXCESSIVE
Oil leakage from head cover

Fuga de aceite de la cubierta de la culata
Fuite d'huile du couvercle de culasse
Oil leakage from oil filter

Fuga de aceite del filtro de aceite
Fuite d'huile du filtre a huile
OIL LEAKAGE Oil leakage fro� oil cooler

FUGAS DE ACEITE Fuga de aceite del enfriador de aceite
FUITE: O'HUI Le Fuite d'huile du radiateur d'huile
Oil leakage from front oil seal

Fuga de aceite de! sello de aceite delantero
Fuite d'huile de la bague d'etancheite avant
Oil leakage from rear oil seal
Fuga de aceite de! sello de ace\te trasero
Fuite d'huile de la bauge d'etancheite arriere
Excessive oil flow on rocker arm

Flujo de aceite excesivo sobre el balanci n
Debit excessif d'huile sur le culbuteur
Valve guide worn

Guia de la valvula gastada
VALVE, VALVE GUIDE
VALVULA, GUIA DE LA VALVULA Guide de soupape use
SOUPAPE, GUIDE. DE SOUPAPE
Valve stem worn
Vastago de la valvula gastado
Tige de soupape usee
Valve seat worn

Aciento de la valvula gastado
Siege de soupape use
Piston, liner and ring worn

Piston, c·amisam y aros gastados
Piston, chemise et segment uses
Shortage ring expanding
Expansion deficiente del aro
PISTON, LINER, RING Dilatation d'insuffisance de segment
PISTON, CAMISA, AROS
PISTON, CHEMISE, SEGMENT Damaged orsticked ring
Aro danado o adherido
Anneau endommage ou colle
Incorrectly assembled ring

Aros ensamblados incorrectamente
Segment assemble incorrectement
3-11-4
3. BURNT OUT OF PISTON

3. OUEMADURA DEL PISTON
3. BRULURE DE PISTON
Operating under non cooling water

Operaci6n sin agua de enframiento
Fonctionnement sous eau non refrigerante
OPERATION
OPERACION Sudden engine stop
FONCTIONNEMENT Parada repentina del motor
Arret brusque de moteur
�Overload
Sobrecarga
Surcharge
Insufficient cooling water

Agua de enfriamiento insuficiente
� Clogged radiator
Radiador obstruido
Radiateur bouche
COOLING SYSTEM Defective radiator cap

SISTEMA DE ENFRIAMIENTO Tapa del radiador defectuosa
SYSTEME DE REFROIDISSEMENT Bouchon de radiateur defectueux
Dirty water
Agua sucia
Eau souillee
Defective thermostat
Termostato defectuoso
Thermostat souille
Insufficient oil
I nsuficiencia de aceite
Huile insuffisante
Decrease oil pressure

Disminuci6n de la presi6n de aceite
OIL SYSTEM Pression d'huile diminuee
SYSTEME D'HUI LE Dirty oil
Aceite sucio
Huile sou ii lee
Poor quality oil

Aceite de calidad deficiente
Huile de mauvaise qualite
3-11-5
Improper injection timing

Reglaje de la inyeccion inadecuada
Calage d'injection incorrecte
ABNORMAL COMBUSTION Excessive fuel injection
COMBUSTION ANORMAL I nyeccion de combustible excesiva
COMBUSTION ANROMALE Injection de combustible excessi f
Poor quality fuel

Ring broken
Rotura del aro
Segment
Intrusion carbon to ring groove

Adhesion de carbonilla en la ranura del aro
PISTON, LINER, RING Penetration de carbone dans la gorge de segment
PISTON, FORRO, ARO
PISTON, CHEMISE, SEGMENT Defective rubber ring
Aro de goma defectuoso
Joint torique defectueux
Improper assembly piston pin

Pasador del piston incorrectamente ensamblado
Axe de piston assemble incorrectement
3-11-6
4. ENGINE LACKS POWER

4. EL MOTOR PIERDE FUERZA
4. LE MOTEUR MANOUE DE PUISSANCE
Draw air
Aspiraci6n aire
Air de tirage
Clogged fuel filter

Filtro de combustible obturado
FUEL SYSTEM Filtre de combustible bouche
SYSTEME DE COMBUSTIBLE Worn and burn nozzle
I nyector gastado y quemado
I njecteur use et brule
Poor quality fuel

Improper adjustment for control lever

Ajuste incorrecto de la palanca de control
Reglage incorrect de levier de commande

Reglaje de la inyecci6n defectuoso
INJECTION PUMP Calage d'injection incorrecte
BOMBA DE INYECCION
POMPE D'I NJECTION Clogged feed pump strainer
Colador de la bomba de alimentaci6n obturado
Crepine de pompe d'alimentation bouchee
Uneven fuel volume

Volumen de combustible irregular
Volume inegal de combustible
Improper valve clearance

Holgura de la valvula inadecuada
Jeu de soupape incorrect
Incorrect valve seat contact

Contacto incorrecto del asiento de la valvula
Contact de siege de soupape incorrect
ENGINE Perished valve spring

MOTOR Resorte de la valvula defectuoso
MOTEUR Ressort de soupape endommage
Worn piston and liner

Piston y forro gastados
Piston et chemise uses

3-11-7

Engine oil deteriorated

Aceite de motor deteriorado
OVER HEAT Huile de moteur deterioree
RECA LENTAM IE NTO
SURCHAUFFE Abnormal combustion
Combustion anormal
Combustion anormale
Worn water pump

Bomba de agua gastada
Pompe d'eau usee
3-11-8
5. BLOW OUT OF CYLINDER HEAD GASKET

5. ESTALLIDO DE LA JUNTA DE LA CULATA DEL CILINDRO
5. RUPTURE DE JOINT D'ETANCHEITE DE CULASSE
Incorrect tightening torque

Par de apriete incorrecto
Couple de serrage incorrect
HEAD BOLT Incorrect" tightening sequence

PERNO DE LA CULATA Secuencia de apriete incorrecto
BOULON OE CULASSE Ordre de serrage incorrect
Poor retightening
Deficiencia de reapriete
Resserrage mediocre
� Using wrong parts
-
CYLINDER HEAD GASKET Empleo de piezas erroneas
JUNTA DE LA CULATA DEL Usage de pieces errones
CILINDRO
JOINT O'ET ANCHE ITE OE � Reuse
CULASSE Reuso
Reusage
Cracked cylinder block and cylinder head

Bloque y culata de cilindro agrietados
Bloc-cylindre et culasse feles
CYLINDER BLOCK AND CYLINDER
HEAD >-- Distortion block top face or cracked cylinder head
BLOOUE DE CILINDROS Y CULATA .__ Superficie superior del bloque deformado o culata del
DEL CILINDRO cilindro agrietada
BLOC-CYLINDRE ET CULASSE Face superieure de bloc deformee et culasse felee
Shortage liner protrusion

Protusion deficiente de la camisa
Saillie de chemise insuffisante

Reglaje de la inyeccion inadecuada
Calage d'injection incorrecte
Incorrect injection pressure

Presion de inyeccion incorrecta
ABNORMAL COMBUSTION Pression d'iniection incorrecte
COMBUSTION ANORMAL
COMBUSTION ANORMALE Incorrect nozzle spray
Pulverizacion incorrecta del inyector
Jet d'injecteur incorrecte
Over heat
Recalentamiento
Surchauffe
3-12-1
HINO EP100 HINO EP100T ENGINE PARTS SPECIFICATIONS

Unit: mm (inch)
Item Nominal Assembly standard Repair Service Corrective

dimensions or clearance limit limit method
..
-c Flatness - 0-0.05
(0-0.0019)
0.10
(0.0039)
Regrind or replace
.s::
ai
-c
Regrinding limit 104
(4.09)
- - 103.7
(4.083)
.!:
>-
u Protrusion of nozzle - 2.75-3.25 - - Replace gasket or
(0.1083-0.1279 I nozzle
..... - -
., .,"'.,
0 0 0
Valve seat angle 30 30 - 30 15'
..:
.,._
.. >
C "' Valve face angle 30
0 °
29 45' - 30
0
- - 0
...� .....&I
- > Regri1,1d with 30
or 45 cutter and
Valve seat angle 45 °
0
45 - 45 15'
0
- - finish by lapping
"'.,
.s:: >
x-
w � Valve face angle 45
° °
44 45' - 45
°
- -
..:
C Intake valve - 0-0.2
( o .000-0.0078 I
- 0.70
(0.0276)
.,>
"iii Replace valve and
valve seat
io
> Exhaust valve - 0-0.2
Io .000-0 .0078 I
- 0.70
(0.0276)
Rocker arm shaft 24.2 24.16-24.18 - 24.12
....
outside diameter (0.953) (0.9512-0.9519) (0.9496) Replace shaft
E
.,..: Bushing inside 24.2 24.21-24.26 - 24.28 Replace bushing
"
0
diameter (0.953) (0.9532-0.9551) (0.9559)
a:
Clearance - 0.03-0.101
(0.0012-0.0039)
0.15
(0.0059)
- Replace shaft and/
or bushing
Pushrod bend - - 0.50

(0.0196)
- Repair by pressing
or replace
10 10.000-10.015 - -
..
E"' Valve guide inside diameter
(0.39) (0.3938-0.3942)
·c
.,"E
.s::
., Valve stem out- 10 9.938-9.960 - 9.88 Replace valve
:-2 ., ., side diameter (0.39) (0.3913-0.3921 I (0.3890)
.,> .,"'>
::,
...-="'-"'>
..: >
Clearance - 0.040-0.077 0.12 - Replace valve guide

io (0.0016-0.0030) and/or valve
> (0.0047)
.. ..... .,,.
>
-c
C Valve stem out- 10 9.921-9.943 - 9.88 Replace valve
.,> "'
::, side diameter (0.39) (0.3906-0.3914) (0.3890)
io .s;;iij
> w
)( ,.
Clearance - 0.057-0.094
(0.0023-0.0037)
0.14
(0.0055)
- Replace valve guide
and/or valve
Free length 77
(3.03)
- - 75
(2.953)
In 54.25 (2.1358) - - -
"'
.!:
Setting length
Ex - - -
Replace spring
seat
..
52.75 (2.0768)
a.
"' 45.5 In 43.2-47.8 - 41.8 kg
....,::, Setting load kg (lb)
In
(100.3) (95.3-105.3) (92.1 lbl
0
Ex 49.2 Ex 48.9-51.5 - 45.5 kg
Replace spring
(108.5) (103.4-113.5) (100.3 lb)
Straightness - - - 3.5
(0.137)
Tappet guide inside
diameter
20.0
(0.787)
20.000-20.021
(0.7874-0.7882)
- 20.10
(0.7914)
Tappet outside
diameter
20.0
(0.787)
19.995-19.980
(0.7857-0. 7866)
- - Replace tappet
Clearance - 0.020-0.066
(0.0008-0.0025)
0.10
(0.0039)
-
Hino Engine Parts
Phone: 269 673 1638
3-12-2
Nominal Assembly standard Repair Service Corrective

Item dimensions or clearance limit limit method
II>
Intake - 0.40
(0.0157)
±0.15
(±0.0059)
-
g? � Adjust at cold
ti � engine
>: Exhaust - 0.50
(0.0197)
±0.15
(±0.0059)
-
Top ring - 0.35-0.50
(0.0138-0.0196)
- 1.5
(0.059)
...
=c:
.. -c
0. II>
o,::
2nd ring
- 0.35-0.47 1.2 Replace piston
·-rx: "C:
C: >
3rd ring
(0.0138-0.0185) (0.047) ring
Oil ring - 0.35-0.55

I0.0138-0.0216)
- 1.0
(0.039)
Ring groove
thickness
- - - -
-� Ring breadth
3.3 3.29-3.30 - - Replace piston
0. (0.1300) (0.1 296-0.1299) and/or piston ring
Clearance - - - -
Ring groove - 2.53-2.55 - -
= thickness (0.0997-0.1003)
C:
·5. = ·E
-c Ring breadth 2.8 2.79-2.80 - - Replace piston
C: ...
C:
C:
(0.1102) (0.1098-0.1102) and/or piston ring
-
0 N
-
C
t: 0 -
Clearance
.. ..
·5. t:
-c ·5.
-c Ring gropve 2.5 2.53-2.55 - -
·E ..
C
thickness (0.0984) (0.0996-0.1003)
..
C
.[ -
0
C:
0
C: Ring breadth
2 .5
(0.0984)
2.47-2.49
(0.0974-0.0980)
- Replace piston
and/or piston ring
"E
c:'
·5. M
0 Clearance - 0.04-0.08
(0.0016-0.0031)
- 0.20
(0.0079)
Ring groove
thickness
5.0
(0.1968)
5.01-5.03
(0.1973-0.1980)
- -
-� Ring breadth
5.0
(0.1968)
4.97-4.99
(0.1957-0.1964)
- - Replace piston
and/or piston ring
0
(0.0008-0.0023)
- 0.10
(0.0039)
Piston pin hole inside
diameter
47
(1.850)
47.002-47.008
( 1.8505-1.8507)
- -
Piston pin outside 47 46.992-47.000 46.95 Replace piston an
diameter (1.850) (1.8501-1.8503) (1.8485) and piston pin
C
'ii
C: Clearance between
piston pin hole and pin
- 0.002-0.016
(0.00008-0.00063)
0.05
(0.0020)
Connecting rod bushing

inside diameter
47
(1.850)
47.025-47.035
(1.8514-1.8517) - -
Replace bushing
Clearance between
piston pin and bashing
- 0.025-0.043
(0.0010-0.0016)
0.10
(0.0039)
- and/or piston pin
Connecting rod big end

width
42.85
(1.687)
42.78-42.85
(1.6843-1.6870)
-
- -
.....
..... -ce.,.
-c -c Crankshaft crank pin 43.0 43.0-43.1 Replace connecting
C: 0 width (1,693) (1.693-1.696) rod
... C:
CD•-
-5 ti
.:.:•
C C
..
...."
C
C
(0.0059-0.013)
- 0.6
(0.0236)
-
ID C C
u"
... 0 0
u Straightness - - 0.1
(0.0039)
Repair or replace
Twist - - - for each
200 (7.87)
3-12-3
Item Nominal Assembly standard Repair Service Corrective

dimensions or clearance limit limit method
Connecting rod big

end inner diameter
80.0
(3.150)
80.015-80.030
(3.1502-3.1507)
- -
"'
C
Crank pin outside
diameter
75.0
(2.953)
74.95-74.97
(2.9508-2.9515)
74.80
(2.9447)
73.80
(2.9056)
Regrind undersize
or replace
·;:::
Q)
C:
Clearance - 0.041-0.092 0.30 -
e"' (0.0017-0.0036)
-0 C:
0 (0.0118)
(.)
·;:::
Connecting rod
bearing spread
80.75-81.75
(3.1792-3.2184)
- - -
C:
C
0
Journal outside, 90.0 89.91-89.93 89.8 88.8 Regrind undersize
..
CJ diameter (3,543) (3.5398-3.5405) (3,535) (3.496) or replace
-0
.. -
C oi
,t'.
E::, Clearance - 0.050-0.106 0.30 Replace bearing
(0.0020-0.0041) (0.0118)
.s::U) 0
-,
..ll:
�
C
Main bearing
spread
96.75-98.00
(3.8091-3.8582)
- - - Replace bearing
-
(.)
Width of thrust
face
46.00-46.025
(1.8110-1.8120)
- -
End play - 0.110-0.240
(0.0043-0.0094)
0.50
(0.0197)
- Replace oversize
thrust bearing
Crankshaft runout - - - 0.09

(0.0035)
Regrind or replace
oi
Q)
Depth of friction face (OPT.) 48.00
(1.890)
47.9-48.1
(1.8859-1.8937)
- 50.00
(1.96)
.s::
:::> Replace or regrind
u:: Face alignment - 0-0.2 - 0.3
.....
(0-0.0078) (0.0118)
-0..i,:
C CJ
:: 0
Distortion at the top of the
cylinder
- 0- 0.05
(0 - 0.0019)
0.10
(0.0039)
- Regrind
>-
(.) JJ
... Liner, inside diameter 120.0

(4.724)
- - 120.15
(4,730)
Q)
.!:
·>-=
-0
;
(.)
Piston clearance
Height (protrusion)
- 0.134-0.166
(0.0053-0.0065)
0.04-0.10
-
-
-
0.03
Replace cylinder liner
(0.0016-0.0039) (0.0012)
No.1 65.00
(2.5591)
65.00-65.07
(2.5591-2.5618)
- 65.15
(2.5649)
No. 2 64.60 64.60-64.67 - 64.75
..�..
(2.5433) (2.5433-2.5460) (2.5492)
No. 3 64.20 64.20-64.27 64.35

E (2.5276) (2.5276-2.5303) (2.5334)
., 63.80 63.80-63.87 - 63.95
....
-0 No. 4 Replace bearing
·.; (2.5118) (2.5119-2.5145) (2.5177)
.!:
"' -
,._ -�.. No. 5 63.40
(1.4961)
63.40-63.47
(2.4961-2.4988)
63.55
(2.5017)
..
.s::
Ill
E Ill
u No.6 63.00
(2.4803)
63.00-63.07
(2.4804-2.4830)
- 63.15
(2.4862)
No. 7 62.60
(2.4646)
62.60-62.67
(2.4646-2.4673)
- 62.75
(2.4704)
No. 1 65.00 64.95-64.97 64.85

(2.5591) (2.5571-2.5578) (2.5531)
No.2 64.60 64.55-64.57 64.45

(2.5433) (2.5413-2.5421) (2.5374)
No. 3 64.20
(2.5276)
64.15-64.17
(2.5256-2.5263)
- 64,05
(2.5217)
3-12-4

..;., No.4 63.80

(2.5118)
63.75-64.77
(2.5099-2.5500)
- 63.65
(2.5059)
.,
E
'ii
"C
No. 5
63.40
(2.4961)
63.35-63.37
(2.4941-2.5342)
- 63.25
"iii (2.4902)
...., No. 6 63.00

(2.4803)
62.95-62.97
(2.4784-2.4791)
- 62.85
(2.4744)
......, .,E No. 7 62.60 62.55-62.57 - 62.45

CJ (2.4646) (2.4626-2.4633) (2.4587)
"'
.,E Clearance - 0.03-0.12
(0.0012-0.0047)
0.30
(0.0118)
- Replace camshaft
and/or bearing
(J
Camshaft end play - 0.10-0.23

(0.0040-0.0090)
0.30
(0.0118)
- Replace cam thrust
bearing
..
:!: Intake 7.85
(0.3091)
- - 7.05
(0.2775)
Replace camshaft
.,E
CJ Exhaust 7.85 - - 7.05
(0.3091) (0.2775)
Runout - - 0.10
(0.0039)
- Repair or replace
Crankshaft gear to
idle gear
.."
"'
J:.
:i
Idle gear to
camshaft gear
0.08-0.23
(0.0032-0.0090)
- 0.30
(0.0118)
Replace gear
Idle gear to injection
pump drive gear
Camshaft gear to oil - 0.14-0.32 - 0.35
..
pump drive gear (0.0055-0.0125) (0.0138)
Idle gear shaft outside
diameter
55.0
(2.165)
54.94-54.97
(2.1630-2.1641)
- -
"' Replace shaft
·i=e -
C
Idle gear bushing
inside diameter
55.0
(2.165)
55.00-55.03
(2.1654-2.'l 665)
- Replace shaft
.. Clearance - 0.03-0.09
(0.0012-0.0035)
0.20
(0.0079)
-
;
'c
Length of idle gear
shaft
44.0
(1.733)
44.009-44.034
(1.7326-1.7336)
- -
Breadth of idler
gear
43.9
(1.729)
43.894-43.960
(1.7282-1.7307)
- Replace idler gear
bushing
End play - 0.049-0.140

(0.0019-0.0055)
0.30
(0.0118)
-
Gear outside
diameter
51.4
(2.024)
51.22-51.25
(2.0165-2.0177)
-
- Replace gear and/
or case
.,
Gear to gear case
clearance
- 0.033-0.100
(0.0013-0.0039)
0.13
(0.0051)
....
0
Depth of gear case - 38.040-38.067
(1.4977-1.4987)
- -
Q.
E
CJ
Width of gear - 37.975-38.000
(1.4951-1.4960)
- - Replace gear and/
or case
::s
Q.
0 End play - 0.040-0.092

(0.0016-0.0036)
0.15
(0.0059)
-
Gear backlash - 0.15-0.28 0.40 - Replace gear ass'y
..
(0.0060-0.0110) (0.0157)
Case bushing - 18.034-18.061 - -
"'., inside diameter (0.7100-0.7110)
Replace bushing
.::
c Shaft outside
diameter
- 17 .976-17 .994
(0.8078-0. 7084)
- -
3-12-5

.,
> � Clearance - 0.040-0.090 0.15 - Replace bushing
·;:
Cl ""
� (0.0016-0.0035) (0.0059)
E
::,
Gear inside - 18.122-18.147 - -
Cl. �., diameter (0.7135-0.7144)
0 .,,
., Shaft outside
diameter
- 18.064-18.082
(0.7112-0.7119)
- - Replace bushing
.?!
0
Clearance - 0.040-0.083 0.15 -
(0.0016-0.0032) (0.0059)
.., Deflection between crank
-.; - 15-22 - - Apply force
>
.0 shaft pulley to generator (33.1-48.51 10 kg (22 lb)
pulley
C
0
'Bl .,
Compression pressure
kg/cm 2 (lb/sq.in)
- 28-30 (399-426)
at 200 rpm
26 -
.,� ::,� (370)
Engine overhaul
ECl. i� Differences between cylinders - Within ±3 (±43) - -
8 C. kg/cm 2 (lb/sq.in)
.,-
.:,:.0
co� Flatness of flange face - 0.1 - 0.5
., C (0.004) (0.02)
-e
C c,:,
Repair or replace
,,,_
.., -c
::, 0
fO :it:
.t::. C Flatness of flange face - 0.1
(0.004)
- 0.5
(0.02)
X c,:,
WE
Hino Engine Parts

Phone: 269 673 1638
3-12-6
HINO EP100 HINO EP100T ENGINE BOLTS TIGHTENING TORQUE
Tightening position Size kg•cm lb.ft

Mounting bracket fitting bolts (Front) M12 P1.75 650-900 47-65
Flywheel housing fitting bolts M14 P2.0 1,000-1,300 73-94
Main bearing cap bolts M16 P2.0 • 2,700-2,900 • 196-209
Oil pump safety valve M30 P1.5 800-900 58-65
M14 P2.0 1,100-1,200 80-86
Oil pump assembly fitting bolts
M10 P1.5 450-500 33-36
Connecting rod cap bolts M15 P1.5 @ 2,200-2,400 @ 160-173
Cooling jet nozzle fitting bolts M12 P1.5 • 200-250 • 15-18
Oil strainer fitting bolts MS P1.25 200-250 15-18
Oil filter regulator valve M22 P1.5 300-400 22-28
Oil filter safety valve M22 P1.5 250-350 19-25
Oil filter center bolt M16 P2.0 400-500 29-36
Oil filter assembly fitting bolts M10 P1.5 350-400 26-28
Oil cooler element fitting nuts MS P1.25 150-250 11-18
M20 P1.5 200-300 15-21
Oil cooler plug
M36 P1.5 350-450 25-32
Oil cooler various plug MS P1.25 190-260 14-18
Oil cooler fitting bolts MS P1.25 130-180 10-13
M17 P2.0 • 3,300-3,500 239-253
Cylinder head bolts
M10 P1.5 • 650-750 • 47-54
Camshaft thrust plate fitting bolts MS P1.25 190-280 14-18
Injection pump drive shaft fitting bolts MS P1.25 • 190-260 • 14-18
Idle gear shaft fitting bolts M14 P2.0 • 1,800-2,000 • 131-144
Camshaft drive gear fitting bolt M22 P1.5 • 2,000-2,200 • 145-159
Injection pump drive gear fitting nut M24 P1.5 2,000-2,200 145-159
Timing gear plate fitting bolts MS P1.25 190-260 14-18
Oil pan fitting bolts MS P1.25 190-270 14-19
Flywheel fitting bolts M16 P1.5 @ 2,600-2,900 @ 189-209
Coolant pump vane fitting nut M10 P1.5 1,150-1,250 83-90
Coolant pump cover fitting bolts MB P1.25 180-230 14-16
Coolant pump assembly fitting bolts M10 P1.5 350-500 26-36
Nozzle holder fitting nuts MS P1.25 130-190 10-13
Rocker arm support bolts M12 P1.75 • 1,100-1,200 • 80-86
Rocker shaft fitting bolts at both end MS P1.25 190-260 14-18
Rocker arm adjust screw nuts M10 P1.0 400-500 29-36
Rocker arm cover fitting bolts MS P1.25 190-260 14-18
Tappet chamber cover MS P1.25 190-260 14-18
Injection pump bracket fitting bolts M10 P1.5 450-500 33-36
Injection pump mounting bolts MS P1.25 380-500 28-36
Injection pump through bolt at coupling M10 P1.5 600-650 44-47
Intake manifold MS P1.25 190-270 14-19
Thermostat case cover MS P1.25 190-270 14-19
Air intake heater fitting nuts M22 P1.5 230-330 17-23
Fuel filter center bolt M16 P2.0 400-450 29-32
Fuel filter bleeder plug MS P1.25 50-100 3.7-7.2
End nipples of injection pump M14 P1.5 300-400 22-28
3-12-7
Tightening position Size kg·cm lb.ft

Holding clip of injection pipe MB P1.25 50-100 3.7-7.2
Starter fitting nuts M14 P2.0 1,100-1,500 80-108
Exhaust manifold MlO Pl.5 450-500 33-36
Crankshaft pulley fitting nut M22 Pl.5 • �O='t;860"
,., •1 ·- 1' • ,.. " • ---1,��'t
Coolant pump pulley nut M18 P1.5 (800-2,400 131-173
Turbocharger fitting nuts M10 P1.5 450-500 33-36
Intake pipe (Turbo. t intake manifold) M10 P1.5 350-500 25-36
M10 P1.0
Joint bolts of fuel pipe 200-250 15-18
M10 Pl.5
M12 P1.5
Joint bolts of fuel pipe 250-300 18-21
M12 Pl.75
M14 P1.5
Joint bo Its of fuel pipe 250-300 18-21
M14 P2.0
Joint bolts of fuel pipe M16 P1.5 300-350 22-25
Flare nut (for the pipe of 6.35 mm dia.) M12 P1.0 200-220 14.5-15.9
Flare nut (for the pipe of 10 mm dia.) M16 P1.5 400-500 29-36
Flare nut (for the pipe of 12 mm dia.) M20 P1.5 650-700 47-50
Generator supporting bolt & fitting nut M14 P1.5 1,300-1,400 94-101
Cooling fan fitting bolts M14 P1.5 350-500 26-36
Engine mounting fitting nuts (Front & Rear) M16 P1.5 1,400-1, 600 102-115
NOTE: 1. • mark means that it is needed to apply a light coat of clean engine oil to the thread of bolt.
2. @ mark means that it is needed to apply a light coat of clean engine oil to the thread of bolts or nuts and further .more
to tighten the nuts or bolts to the specified torque and loosen each one, and then tighten its to the specified torque again
in the sequence order.
Hino Engine Parts

Phone: 269 673 1638
(K.P.)
FUEL INJECTION PUMP IP-1
IP-100E-01
CHAPTER IP
HINO EP100 FUEL INJECTION PUMP
HINO EP100T FUEL INJECTION PUMP
DESCRIPTION ....................................... IP- 2
TROUBLESHOOTING ................................. IP- 3
SPECIAL TOOLS ..................................... IP- 6
INJECTION PUMP .................................... IP- 8
FEED PUMP ......................................... IP-17
ADJUSTMENT ....................................... IP-19
Hino Engine Parts

Phone: 269 673 1638
IP-2 FUEL INJECTION PUMP
DESCRIPTION
10
11
12
13
14
JIIL---+--- 15
tr��:!_�,�.� 16
17
18
19
HINO EP100
SM4-342
HINO EP100T
FUEL INJECTION PUMP
1. Nut 11. Delivery valve gasket
2. Washer 12. Adjusting shim
3. 0-ring 13. Delivery valve
4. Deflector 14. Flange sleeve
5. Snap ring 15. Plunger barrel
6. 0-ring 16. Plunger
7. Camshaft 17. Control rack
8. Bearing 18. Control sleeve
9. Cover 19. Tappet
10. Delivery valve holder
Hino Engine Parts

Phone: 269 673 1638
TROUBLESHOOTING
Symptom Possible cause Remedy /Prevention
Engine does not start -----"""T""--1 Fuel not reaching injection pump
• Fuel lines clogged or damaged . . . . . . . . . . . . Clean or replace fuel lines.
• Fuel filter clogged . . . . . . . . . . . . . . . . . . . . Clean or replace the filter element.
• Air in fuel caused by improper . . . . . . . . . . . Repair connections.

connections of fuel I ine between
fuel tank and feed pump
• Filter incorporated in inlet side Remove foreign material.

of feed pump clogged
• Faulty feed pump check valve . . . . . . . . . . . . Repair or replace it.
• Feed pump piston spring broken . . . . . . . . . . Replace it.
• Feed pump push rod or tappet sticking . . . . . . Repair or replace it.
Fuel reaching injection pump
• Faulty connection of accelerator Repair connection.

wire to pump adjusting lever.
• Control rack faulty or sticking Repair it.
• Damaged camshaft bearing . . . . . . . . . . . . . . Repair it.
• Plunger worn or sticking . . . . . . . . . . . . . . . Correct or replace it.
• Faulty connection of engine . . . . . . . . . . . . . Repair it.

stop wire to pump stop lever.
Nozzle faulty
• Fuel leakage caused by loosened Inspect and tighten it.

nozzle holder.
• Low opening pressure of nozzle . . . . . . . . . . . Adjust it.
• Nozzle pressure spring broken . . . . . . . . . . . . Replace it.
• Nozzle needle sticking to nozzle body . . . . . . Correct or replace it.
Pump out of timing
• Improperly retarded injection timing Correct injection timing.
• Incorrect timing caused by improper Check engine timing and correct

Installation of pump. it.
• Woodruff key for pump camshaft Replace it.

cut off.
• Improper pre-stroke adjustment Correct it to obtain specified

injection timing.
Excessive smoke---------- Black smoke
• Excessive fuel delivery caused by ......... . Adjust fuel delivery on test

incorrect adjustment of fuel load stand.
stopper screw.
• Excessively advanced injection Correct it.

timing.
• Large spread in fuel delivery Adjust it.
• Bad nozzle fuel spray characteristics . . . . . . . . Check and correct them.
White smoke
• Improperly retarded injection Advance injection timing.

timing.
• Water in fuel Check and clean fuel lines.
Low idle speed--------�- Improper adjustment of idle button . . . . . . . . Correct it.

irregular
Bad fuel spray characteristic of Check and repair them.
nozzles.
Incorrect injection timing. . . . . . . . . . . . . . . Correct it.
Incorrect initial tension setting of Adjust or replace it.

idling spring or the spring broken.
Control rack not smoothly move . . . . . . . . . . Disassemble pump and repair it.
Large spread in fuel delivery . .. . . . . . . . . . . Adjust it.
Plunger worn . . . . . . . . . . . . . . . .. ... . . . Replace it.
Governor linkage not smoothly Correct it.

move.
Defective feed pump . . . . . . . . . . . .. . . . . . Disassemble and repair it.
Engine always runs------�- Accelerator cable sticking . . . . . . . . . . . . . . . Check and correct it.
at hig speed
Governor linkage sticking. . . . . . . . . . . . . . . Disassemble and repair the
governor.
Control rack sticking . . . . . . . . . . . . . . . . . . Check and correct it.
Engine starts and stops-----� - Fuel lines clogged ................... . Clean or replace fuel lines.
[
Air in fuel caused by damaged ........... Repair fuel lines or replace fuel
fuel lines or improper connection of lines and gaskets.
fuel lines.
Engine has low power -----,----1 Pump out of timing
• Excessive advanced timing, . . . . . . . . . . . . . . Check and correct it.

resulting in loud knocking.
• Excessively retarded timing Check and correct it.

resulting in black smoke.
• Defective injection pump overflow. . . . . . . . . Repair or replace it.

valve.
• Feed pressure too low Repair the feed pump.
• lnproper accelerator cable adjustment . . . . . . Adjust it.
Nozzle faulty
• Fuel leakage from nozzle holder Check and repair nozzle holder.
• Bad nozzle spray characteristic . . . . . . . . . . . Repair or replace it.
• Loosened adjusting screw in nozzle . . . . . . . . Adjust it.

holder, resulting in low opening pressure.
• Nozzle pressure spring broken . . . . . . . . . . . . Replace it.
Pump faulty
• Fuel leakage from delivery valve Retighten the delivery valve

holder. holder if it is loosened or replace
O-ring if the O-ring is defective.
• Defective seat of delivery valve Repair or replace it.

assembly.
• Delivery valve spring broken Replace the spring.
• Plunger worn . . . . . . . . . . . . . . . . . . . . . . . Replace it.
• Large spread in fuel delivery . . . . . . . . . . . . . Adjust it.
• Wear of tappet roller . . . . . . . . . . . . . . . . . . Replace the roller.
• Camshaft bearing worn or broken Replace it.
• Improper adjustment of governor Adjust it.

fuel load stopper screw.
Bad fuel nozzle spray pattern Check and correct it.

after-dribble.
High nozzle opening pressure Adjust the opening pressure.
Incorrect fuel deliveries to Readjust the fuel deliveries.

some nozzles.
SPECIAL TOOL
Prior to starting a fuel injection pump overhaul, it is necessary to have these special tools.
BEARING REMOVER MEASURING DEVICE MEASURING PLATE
09500-1160 09500-1310 09511-1300
SOCKET WRENCH WRENCH BRACKET
09511-1340 09511-1350 09511-1380
OUTER RACE PULLER EXTRACTOR MOUNTING DEVICE
09511-1700 09511-1800
CLAMP PLATE EXTRACTOR 0-RING INSERT
09511-1820 09511-1830 09511-1850

TAPPET HOLDER
09511-2040
HINO EP100 INJECTION PUMP PARTS

HINO EP100T INJECTION PUMP PARTS
P-TYPE PUMP
i-------�
'
I
T = 1, 100-1,200
(80-86) 2 I
3
4
5 T = 200-300
6 (15-21)
T = 120-150
(9-10)
21
20
�1T�•,.:�1.soo1�-1os1
14
I
for equipped with industrial engine. SM4-341
T = Tightening torque kg-cm (lb.ft)
1. Plunger block assembly 11. Deflector 21. Cam shaft

2. 0-ring 12. Snap ring 22. Control sleeve
3. Delivery valve spring 13. 0-ring 23. Upper plunger spring seat
4. Gasket 14. Coupling 24. Plunger spring
5. Delivery valve 15. Sleeve 25. Lower plunger spring seat
6. Plunger barrel 16. Oil seal 26. Tappet
7. Plunger 17. Bearing cover 27. Center bearing
8. Shim 18. Shim 28. Taper roller bearing
9. Collar 19. 0-ring 29. Bearing holder
10. 0-ring 20. Taper roller bearing 30. Shim
Hino Engine Parts

Phone: 269 673 1638
IMPORTANT POINT (S) - DIASSEMBL Y
WARNING
0 Breaking of the lead seals or crimp caps by anyone other
than HINO or pump manufacture authorized service
stations to make these adjustment will void the warranty.
0 If fuel pump or governor difficulties are suspected, consult
only HINO or pump manufacture authorized service
stations, where the problem can be corrected and the injec
tion pump lead seals and crimp caps can be reinstalled as
required.
0 Measure and record the fuel delivery characteristics of the
pump before disassembling it.
0 Keep the parts for each cylinder in separate groups and in
an orderly arrangement. Parts to be replaced and parts to
be used again must be kept separately.
REMOVE THE TIMER ASSEMBLY.

Refer to "TIMER AND COUPLING".
REMOVE THE GOVERNOR.

Refer to "GOVERNOR".
REMOVE THE CAMSHAFT FROM PUMP BODY.

1. Remove the screw plug.
2. Turn the camshaft and when the tappet reaches top dead
center, insert the tappet holder into the screw plug hole.
Special tool: Tappet holder (09511-2040)
3. Remove the cover setting bolt.

4. Using a special tools, takeout the bearing cover.
Special tools: Bracket (09511-1380)
Eextractor (09511-1710)
5. Remove the center bearing bolt and pull out the camshaft
with the center bearing .
SM4-348 SM 4- 3 49
._______ _ -=-..:...:..., '-------=- _:_;_-=. _:.::.J
REMOVE THE TAPPET ASSEMBLY.

1. Set up the mounting device on bottom of the pump housing.
2. Operate the lever to push up the tappet and pull out tappet
holder.
Special tools: Mounting device (09511-1800)
REMOVE THE SPRING SEAT WITH PLUNGER.

::-i; n '-�� --- , _ ,---.... - r ,J r:.i. 3. Using small pincers, pull out lower spring seat together with
�;:),_ �� (\ plunger.
()
NOTE: Put the plunger in order in a tray containing clean diesel
fuel.
SM4-351
REMOVE THE CONTROL SLEEVE UPPER SPRING SEAT.

NOTE: To do this, it is essential to line up the sleeve ball with the
groove in the pump housing; otherwise the control sleeve
will not come out.
REMOVE THE PLUNGER BLOCK ASSEMBLY.

Fasten extractor to the delivery valve holder, and withdraw
plunger block assembly.
Special tool: Extractor (09511-1830)
NOTE: Put the plunger block assembly and adjusting shims in a
tray containing clean diesel fuel.
SM4-353
REMOVE THE CONTROL RACK

1. Use the wrench, remove the screw bush.
Special tool: Wrench (09511-1350)
2. Remove the pin from the control rack and pull out the control
rack.
DISASSEMBLY THE PLUNGER BLOCK ASSEMBLY.

1. Remove the delivery valve holder fit the clamp plate in vise
and place the plunger block assembly on it.
Special tool: Clamp plate (09511-1820)
REMOVE THE TAPER BEARING FROM THE CAMSHAFT.

1. Remove the taper bearing from the drive end of the camshaft.
Special tool: Bearing remover (09500-1160)
2. Use the guide to remove the bearing at the governor side.
SM4-125
REMOVE THE OUTER RACE FROM THE BEARING COVER.
t:J
OUTER RACE /
PU LLER --------=
r---.._---;---___ Use the outer race puller, to tap out the outer race in the
bearing cover.
Special tool: Outer race puller (09511-1700)
IMPORTANT POINT (S) - ASSEMBLY

WARNING
0 Wash all parts with clean diesel fuel before installing them,
and any defective or damaged parts must be replaced.
0 Do not allow dust or other foreign matter to enter the
pump during assembly.
0 Apply grease to O-rings and oil seals before installing them.
0 Assemble the parts in correct order and to correct tighten
ing torques, assembled dimensions etc.
0 Assembly takes place in the reverse order of disassembly.
ASSEMBLING THE PLUNGER BLOCK

1. Before install the plunger ba rrel should be inspect the plunger
barrel and plungers for wear, scratches, or discoloration.
°
2. Tilt the plunger to about 60 . Pull the plunger out approxi
mately 10 to 15 mm (0.39-0.59 in) and release it to see if it
slides down smoothly from its own weight.
SM4-257
3. Assemble the plunger barrel into the flange sleeve.

NOTE: Be sure that the knock pin of the flange sleeve is fitted into
the guide groove on the plunger barrel.
SM4-357
4. Install the delivery valve, delivery valve gasket, delivery spring

and delivery valve holder on the flange sleeve in this order.
NOTE: Before install the delivery valves, inspect the delivery valves
for scratches on the valve seat or the piston sections.
SM4-258
5. Tighten the delivery valve holder.

NOTE: O-ring should first be assembled in the delivery valve
holder. In doing this, be sure that O-ring is coated with
grease to prevent it from being damaged.
SM4-356
6. Install the collar, O-ring, deflector, ring and O-ring.

NOTE: The deflector should not be installed upside down with the
COLLAR hole near to its lower edge.
0-RING
PLUNGER BARREL
SM4-358
7. Install the small O-ring in the housing by with the inserter.

Special tool: O-Ring inserter (09611-1850)
SM4-359
INSTALL THE PLUNGER BLOCK ASSEMBLY TO THE PUMP

BODY.
1. Tighten the delivery valve holder using a socket wrench and
a torque wrench.
Special tool: Socket wrench (09511-1340)
NOTE: Tightening should be made in three steps in the order of
1,200 ➔ 0 ➔ 1,200 ➔ 0 ➔ 1,200 kg-cm
(87) (87) (87) lb.ft
SM4-360
Hino Engine Parts

Phone: 269 673 1638
INSTALL THE CONTROL RACK AND THE CONTROL SLEEVE.

Assemble the control sleeve, inserting it until the ball on the
sleeve is parfectly fitted in the notch of the control rod.
NOTE: Make sure that the ball of the control sleeve is well fitted
in the groove on the control rack; otherwise the ball section
of the control sleeve will be bent when the next associated
parts are assembled.
INSTALL THE UPPER SPRINC. SEAT, THE PLUNGER SPRING

AND.THE PLUNGER.
Insert the plunger in the barrel. Make sure that the aligning
mark on the plunger vane is pointing toward the front of the
pump housing. Install the lower spring seat on the plunger.
NOTE: Do not interchange plungers with barrels.
INSTALL THE TAPPET.

Using the mounting device to press in the tappet and hold it
in with the tappet holder.
Special tool: Mounting device (09511-1800)
Tappet holder (09511-2040)
INSTALL THE CAMSHAFT.

Place the center bearing on the camshaft and insert the cam
shaft into the pump housing.
MEASURE THE PROTRUDING LENGTH OF THE CAMSHAFT.

1. Measure the distance from the surface of the end of the pump
housing to the surface of the end of the measuring plate
(where the tapered section of the cam-shaft starts).
Special tool: Measuring plate (09511-1300)
Standard length: 13.3-14.3 mm (0.524-0.563 in)
2. If the specification is not met, use appropriate shim plates at

the governor end of camshaft until the specification is met.
GOVERNOR
HOUSING
(GOVERNOR END) SM4-365
Ml:ASURE THE CAMSHAFT END PLAY.

1. Attach the special tool onto the camshaft drive end and
measure the thrust clearance of the camshaft with a dial
gauge.
Special tool: Camshaft end play gauge (09500-1310)
Standard end play: 0.02-0.06 mm (0.0008-0.0023 in)
2. If the specification is not met, use appropriate shim plates

at the drive end of camshaft until the specification is met.
BEARING COVER
SHIM
(DRIVE END) SM4-367
MEASURE THE SLIDING RESISTANCE OF THE CONTROL

RACK.
After the pump body has been assembled, attach a spring
scale to the control rack and check that the control rack
slides smoothly through its entire stroke.
Assembly standard: Less than 130 g (4.59 oz)
INSTALL THE TIMER ASSEMBLY.

Refer to "TIMER".
INSTALL THE GOVERNOR.

Refer to "GOVERNOR".
INSPECTION AND REPAIR
Inspection Item Standard Limit Remedy Inspection Procedure
Tappet wear. 0.2mm Replace, tappet

(0.008 in) assembly.
TAPPET ROLLER
ROLLER BUSHING
! - ROLLER Pl N
SM4-129
Tappet surface wear. 0.2 mm Replace, tappet.
(0.008 in)
Camshaft wear Replace, cam KEY GROOVES

shaft.
OIL SEAL CONTACT SURFACE

SM4-131
Roller and center bearing Replace, if Visual check

wear, any other damage. necessary.
FEED PUMP
FP/KE-TYPE
20-----1
1. Feed pump housing 11. Pin

2. Push rod 12. Retainer ring
3. Oil seal 13. Roller
4. Piston 14. Tappet
5. Spring 15. Sliding block
6. Gasket 16. Check valve
7. Plug 17. Spring
8. Joint bolt 18. Gasket
9. Filter 19. Plug
10. Gasket 20. Priming pump
IMPORTANT POINT (S) - DISASSEMBLY

REMOVE THE PRIMING PUMP AND CHECK VALVES.
1. Unscrew the priming pump and remove the spring and inlet
check valve.
2. Remove the outlet check valve and spring.
REMOVE THE TAPPET

Remove the snap ring and pull out the tappet.
G
REMOVE THE FILTER FROM INLET PIPE JOINT.
Clean the filter with clean diesel fuel.
IMPORTANT POINT (S) - ASSEMBLY

INSTALL THE TAPPET.
INSTALL THE SNAPRING.
SM4-290
INSTALL THE PISTON.

Insert the piton and spring in the ·housing and screw on the
chamber plug with a new gasket.
SM4-291
INSTALL THE PRIMING PUMP AND CHECK VALVES.

ADJUSTMENT
PREPARATION
1. Mount the injection pump correctly on the pump tester.
2. Attach a rack measuring device to the control rack and set to

''O''.
3. Install calibration nozzles and lines of the following specifica

tions.
a) Nozzle
Nozzle holder assembly: 105780-8140
Opening pressure: 175 kg/cm (2,489 lb.ft)
b) Line
Outside diameter: 8.0 mm (0.3150 in)
Inner diameter: 3.0 mm (0.1181 in)
SM4-370
Length: 600 mm (23.6 in)
4. Calibration oil
a) Calibration oil: SAE J967C
° °
b) Oil temperature: 40-45 C (104-113 F)
ADJUSTING THE PRE-STROKE OF N0.1 PLUNGER.

HOLDER
1. Remove the 1st cylinder delivery valve holder, spring delivery
SPRING valve and gasket.
GASKET
2. Install the plunger stroke measuring gauge to the flange
sleeve by turning it as far as it will go.
DELIVERY
VALVE 3. Bring the tappet of the first cylinder to its bottom dead
center, and set the dial indial indicator zero.
SM4-371
4. Measure the pre-stroke

OVERFLOW a) Set the control rack at full-load position.
PIPE
b) Loosen the overflow screw of each nozzle holder.
HIGH PRESSURE c) Operate the high-pressure pump of the pump tester and let
0
fuel run out of the overflow line.
SM4-372
d) Move the angle dial to set the first cylinder of the pump to
bottom dead center and adjust the pre-stroke gauge to zero.
SM4-373
OVERFLOW e) Turn the camshaft clockwise with the angle dial and read
PIPE the dial gauge when the fuel stops running out of the over
flow line. This reading is the pre-stroke value of the pump.
Pre-stroke: 2.94-3.30 mm (0.1158-0.1299 in)
PLUNGER
BARREL
SM4-374
f) If the pre-stroke value is not within specification, adjust by

changing the adjusting shim.
The shims can be replaced by pulling up the plunger block
slightly.
ADJUST THE INJECTION INTERVAL.

1. Using the No.1 cylinder injection starting point as a base,
inspect and adjust the injection interval in the order of injec
tion.
6-cylinder
° °
Injection interval: 59 45' -60 15'
Injection order: 1-4-2-6-3-5
2. If the injection intervals are not within specification, adjust

by using the same procedure as for pre-stroke adjustment.
3. Set the No.1 cylinder at the injection starting point, and check
that the marks on the timerr or coupling and the marks on the
pump body are aligned.
If the timing marks are not aligned, make a new mark on the
timer or coupling and erase the old mark.
MEASURING AND ADJUSTING THE INJECTION VOLUME.

1. Measure the injection volume for each control rack position
and pump speed.
Injection volume: Refer to "CALIBRATION chart."
SM4-378
2. To adjust the injection volume, loose the flare nut of injection

pipe and the lock nut of the plunger block assembly and turn
to left or right the plunger block assembly.
SM4-379
GOVERNOR GV-1
GV-06E-01
CHAPTER GV
HINO EP100
HINO EP100T
INJECTION PUMP GOVERNOR
(MODEL: RSV)
DESCRIPTION •.....•...•....•....................... GV-2
GOVERNOR ...•....•................................ GV-3
SPECIAL TOOL .......•..•...•.••.....•.............•. GV-4
Hino Engine Parts

Phone: 269 673 1638
GV-2 GOVERNOR
DESCRIPTION
[MODEL: RSV]
1
12
1. Governor spring 11. Sleeve

2. Control rod 12. Link
3. Knuckle 13. Start spring
4. Swivel lever 14. Guide lever
5. Maximum speed stopper bolt 15. Tension lever
6. Camshaft 16. Idle sub spring
7. Control lever 17. Full load stopper bolt
8. Stop lever 18. Idle spring
9. Supporting lever 19. Floating lever
10. Flyweight
Hino Engine Parts

Phone: 269 673 1638
GOVERNOR GV-3
GOVERNOR
18
8
---.. �
��@--
13 f -- 14
' 15
�)
11
23 r�l�"�
J '@'� -{}
. �I 2s26
i7 28 )I
-
2 2
2
4 �rP!?
: �-
�" , I
30
29
1. Governor housing 14. Idle spring 27. O-ring

2. Stopper bolt 15_ Lock nut 28. Snap ring
3. Woodruff key 16. Governor cover 29. Stop lever
4. Flyweight 17. Swivel lever 30. Cap
5. Sleeve 18. Governor spring 31. Idle stopper bolt
6. Bearing 19. Gasket 32. Idle sub spring
7. Shim 20. Pin 33. Nut
8. Guide lever assy 21. Plug 34, Cap nut
9. Link 22_ Control lever 35. Closing cover
10. Start spring 23_ Woodruff key 36. O-ring
11. Supporting lever 24. Coller 37. Cap nut
12. Tension lever 25. OHseal
13. Full load stopper 26. Bush
Hino Engine Parts

Phone: 269 673 1638
GV-4 GOVERNOR
SPECIAL TOOL
Prior to starting an injection pump governor overhaul, it is necessary to have these special tools.
FLYWEIGHT EXTRACTOR ROUND NUT WRENCH
09511-1900

WARNING
0 Breaking of the lead seals or crimp caps by anyother other
than HINO or pump manufacture authorized service
stations to make these adjustment will void the warranty.
0 If fuel pump or governor difficulties are suspected, consult
only HINO or pump manufacture authorized service
stations, where the problem can be corrected and the injec
tion pump lead seals and crimp caps can be rainstalled as
required.
DISASSEMBLY THE GOVERNOR COVER FROM PUMP BODY.

1. Disconnect the shackle from the control rack.
NOTE: When remove the governor cover fitting bolt, hold the
governor cover.
2. Disconnect the return spring.

GOVERNOR GV-5
REMOVE THE FLYWEIGHT ROUND NUT.

NOTE: Use the holding spanner to keep the camshaft from rotat
ing.
Special Tools: Round Nut Wrench (09511-1500)
SM4-384
REMOVE THE FLYWEIGHT, USING THE FLYWEIGHT EX

TRACTOR.
Special Tool: Flyweight Extractor (09511-1900)
IMPORTANT POINT (S) - Assebmly

WARNING
0 Wash all parts with clean diesel fuel before installing them,
and any defective or damaged parts must be replaced.
0 Do not allow dust or other foreign matter to enter the
pump during assembly.
0 Apply grease to O-rings and oil seals before installing them.
0 Assemble the parts in correct order and to correct tighten
ing torque, assembled dimensions etc.
0 Assembly takes place in the reverse order of disassembly.
INSTALL THE ADJUSTING LEVER

Measure the thrust clearance of the adjusting lever.
ADJUSTING
LEVER Thrust Clearance: 0.05-0.20 mm (0.002-0.0078 in)
CHECK THE GOVERNOR LINKAGE FOR SMOOTH OPERA

TION.
Hook under the guide lever, and pull upwards, using a spring
balance.
SM4-302
GV-6 GOVERNOR
INSTALL THE FLYWEIGHT TO PUMP CAMSHAFT.

Using a special tools, tighten the round nut.
Special Tools: Round Nut Wrench (09511-1500)
SM4-384
INSTALL THE GOVERNOR HOUSING TO.PUI\/IP BODY.

1. Connect the shackle to control rack.
2. Connect the return spring.
ADJUSTMENT OF THE GOVERNOR

[MODEL; RSV]
1. PREPARATION
1. Connect the rack measuring device to the control rack and
set to "O".
2. Gonnect the fuel line.
3. Refill the camshaft chamber with engine oil.
4. Install the angle gauge on the adjusting lever.
2. STEPS IN GOVERNOR ADJUSTMENT.

MAXIMUM
SPEED STOPPER Perform governor testing and adjustment in the following
BOLT sequence (For values of N. and R Refer to "CALIBRATION
SWIVEL LEVER chart"):
ADJUST SCREW
1. Adjustment of maximum speed control.
2. Adjustment of speed droop.
3. Adjustment of idling speed control.
IDLING
SCREW
FULL LOAD
STOP LEVER STOPPER BOLT
IDRING SUB
SETTING SCREW
SM4-386
GOVERNOR GV-7
1. Adjustment of maximum speed control

NOTE: The control lever should be full load position.
z a) Adjust the full load stopi:;er bolt.
0 At a pum·p speed of Na rpm, adjust the rack position to Ra
!::: Ra 1----..J"'T'----,
mm with the full load stopper bolt.
(/)
0
a.
�
u
<!
a: O .____,.N_a --- FULL LOAD
PUMP SPEED (rpm) STOPPER BOLT
SM4-386
b) Adjust the maximum speed stopper bolt.

At a pump speed of Nb rpm, adjust the rack position to Rb
mm with maximum speed stopper bolt.
z
i= r\ Rb
I NOTE: The control rack should start to be pulled.
a.
0
\
Nb
PUMP SPEED (rpm)
2. Adjust of speed droop.

At a pump speed of Ne rpm, adjust rack position to Re mm
with swivel lever adjusting screw.
z Rb
0
(/)
0
a.
l<'.
-----=--...,_
(.)
SWIVEL LEVER
a: 0 ADJUST SCREW
Nb
Ne
PUMP SPEED (rpm)
SM4-387
3. Adjusting of idling speed control

a) At a pump speed of Na rpm, adjust the rack position to Rd
mm with idling screw.
NOTE: The control lever angle, refer to CALIBURATION chart.
......=..-IDLING SUB
b) At a pump speed of Ne rpm, adjust the rack position to Re
SETTING SCREW mm with idling sub setting screw.
· SM4-386
GOVERNOR EXTERNAL LEAD SEALS AND CRIMP CAPS.

NOTE: All adjusting devices on the fuel injection pump governor,
are wired and lead sealed as a protection for the customer.
This is to prevent unauthorized readjustment which may
cause engine malfunction and/or engine failure. Periodical
ly check to insure that these seals are not broken as this
will void the warranty.
SM4-388
C-16E-01
CALIBRATION
Engine model EP1 OOT Use for generator set Adjusting Adjusting Pump speed Control rack position
item lever position Adjusting position
INJECTION Injection pump part number 22020-1951 (rpm) mm (in)
PUMP Injection pump type NP-PE6P120
SPECIFI Na: 410-430 Ra: 8.4 (0.331 I Control lever
CATION Governor type RSV
Timer type Not equipped :li Nb: Approx. Rb: should be start to pulled Maximum speed stopper bolt.
-690 control rack
z
f-
Feed pump type NP/K-P E
Test nozzle type 105780-8140 :a 0 Ne: 745-755 Re: 8.2 (0.323) Swivel lever adjusting screw
f-
Test nozzle opening pressure 175 kg/cm' (2,489 psi) Maximum
Full load Nd: 780-790 Rd: 5.5-6.0 (0.217-0.236) lndling sub spring set
Outer diameter 8.0 mm (0.31 in) speed ,E
Injection pipe Inner diameter 3.0 mm (0.12 in) a: ii Nb: Approx Rb: should be start to pulled
Maximum speed stopper bolt
TEST 0 890 control rack
CONDITION Length 600 mm (23.6 in) z
Calibration oil
Type
Oil temperature
SAE J967C
°
40 -45 C (104 - 113 F)
° § Ne: 895-905 Re: 8.2 (0.323) Swivel lever adjusting screw
Fuel feerl pressurP. 1.6 ko/cm 2 (22.8 r,i)

<.:) ,2 Nd: 930-940 Nd: 5.5-6.0 (0.217-0.236) Idling sub spring set
Overflow valve opening pressure 1.5 - 1.8 kg/cm' (21.33 - 25.59 psi) Idling speed Idle Ne: 360 Re: 5.7 (0.224) Idling screw
Rotation Clockwise viewed from drive side NOTE: Recommended setting of swivel adjusting screw: 8 clicks from bottom end.
INJECTION Injection order 1-4-2-6-3-5
TIMING Injection interval
°
60 ± 15' Governor characteristic diaphragm
Pre-stroke 3.4 - 3.5 mm (0.134 - 0.134 - 0.138 in)
□
Rack position Pump speed Measuring Injection volume Max. variation limit
mm (in) (rpm) strokes cc (cu.in) cc (cu.in)
INJECTION /Rack limiter
VOLUME 8.4 (0.33) 900 500 56.1-58,1 (3.423-3,544) 2 (0.122)
5,7 (0.22) 360 500 3,25-6,25 (0,199-0,381)
1
ADJUSTING POSITION CONTROL LEVER ANGLE /Ab
\�
Ab
Ra: B.4
MAXIMUM
SPEED STOPPER
SWIVEL LEVER
ADJUST SCA EW V.P E Ac , 8.2
1
\
BOLT
900 rpm set 0,
\ tor 750 ,pm
STOP
IDLING
� ,..-set
for 900 rpm set
�+-+-- 750 rpm set � Rd: 5.5

6.0
\_
Re: 5.7
GOVERNOR
ADJUSTMENT I\_
� ;:!_g
/ "'o
., .,
0 /"'0
"'0,
g cl;
11 0 J, 6
2 2 "' � �
0 "'0
0 0
... 4 ±5
0, "'"'
"'
o, 0, M
"'0,
.0 • 'C .0 • 'C
z z z z z
° °
2 ... 32 ±3
° °
3 ... 16 ±5
rt,5'
4 ... , Pump speed (rpm) -
, Lever angle "V.P"
STOP LEVER FULL LOAD means. Vertical position
STOPPER BOLT
IK.P.I
21-0BESF-01E
GENERATOR
GENERADOR
GENERATRICE
SYMBOL MARKS
SIMBOLOS
SYMBOLES ............................................ 21- 1

LEXIQUE DES TERMES TECHNIQUES ....................... 21- 2
DATA & SPECIFICATION
□ATOS Y ESPECIFICACIONES
DATA & CARACTERISTIQUES ............................. 21- 3
DESCRIPTION
DESCRIPCION
DESCRIPTION 21- 4
OVERHAUL
REPARACION GENERAL
REVISION ............................................. 21- 5
TROUBLESHOOTING
RECHERCHE DES CAUSES D'ENNUI ET REMEDE .............. 21-20
REPAIR SPECIFICATIONS
ESPECIFICACIONES DE REPARACION
CARACTERISTIQUES DE REPARATION ...................... 21-21
21-1-
SYMBOL MARKS
SIMBOLOS
Se han adoptado los siguientes si'mbolos para simplidad y facil comprensi6n.
SYMBOLES
Les symboles suivants ont ete adoptes afin de simplifier et de faciliter la comprehension
ASSEMBLY TIGHTENING
la\tl ARMADO
ASSEMBLAGE El APRIETE
SERRAGE
8
DISASSEMBLY
l}�I
CLEAN
DESARMADO LIMPIEZA
DESASSEMBLAGE NETTOYAGE
Iii
INSTALLATION
El
IMPORTANT
INSTALACION IMPORTANTE
MISE EN PLACE IMPORTANT
B
REMOVAL ADJUSTMENT
El
REMOCION AJUSTE
DEPOSE REGLAGE
IT]
CONTROLE GRAISSAGE
�
Im
MEASUREMENT
MEDICION
Ml:SURE
21-2

GLASARIO DE TERMINOS TECNICOS
LEXIOUE DES TERMS TECHNIQUES
ENGLISH ESPANOL FRANCAIS

1. About 1. Alrededor de 1. Environ
2. Ammeter 2. Amperimetro 2. Amperem6tre
3. And 3. y 3. ET
4. At 4. A 4. A
5. Bad 5. Malo 5. Mauvais
6. Good 6. Bueno 6. Bon
7. Capacity 7. Capacidad 7. Capacitl�
8. Insulation resistance 8. Resistencia de aislamiento 8. Resistance d'isole111ent
9. In 9. Pul. 9. Pouce
10. Limit 10. Lfmite 10. Lirnite
11. Less than 11. Menos de 11. I nferieur(e) a
12. More than 12. Mas de 12. Depasse
13. Resistance 13. Resistencia 13. Resistance
14. Service limit 14. Lfmite de servicio 14. Lirnite d'utilisation
15. Standard 15. Estandard 15. Nol mal (e)
16. Tightening torque 16. Par de apriete 16. Couple de serrage
17. Voltage meter 17. I ndicadora de tenci6n 17. Compteur de tension
21-3
GENERATOR
DATA AND SPECIFICATIONS
GENERATOR
Type . . . . . ... . . . . . . . . . . . . . . . . . . . Alternator
Output power . . . . . . . . . . . . . . ... . . . . 24 V, 20A
Normal voltage . . . . . . . . . . . . . . . . . . . . . 24V
Charging rotation and voltage . . . . . . . . ... 900 r.p.m., 27V
Direction of rotation ................. Right (From the pulley side)
Allowable max. speed . . . . ... . . . . . . . . . . 7,200 r.p.m.
Power and rotating speed .............. 28V, 20A, at 5,000 r.p.m.
21-4
DESCRIPTION
2 3
\ I
I
SM21-073
GENERATOR
1. Brush
2. I.C. Regulator
3. Stator
4. Rotor
5. Pulley
Fig. 21-1
21-5
OVERHAUL
1824E
1-NO. 20
;1«
I
I
I
I______ 7
20
t_ ______ ..J
DETAIL "A"
221
'21 1
I
I 7
10
15--
1. Rotor
2. Stator
3. Bearing retainer
4. Rear bearing
5. Felt cover
6. Felt
7. Front bracket
8. Collar
9. Fan
10. Pulley
11. Front bearing
12. Terminal insulation
13. Heat sink with rectifier
14. Condenser
15. Connector
16. O-ring
17. Rear bracket
18. Regulator
19. Cover
20. Brush holder
21. Brush
22. Brush spring
Fig. 21-2
21-6
El
ALTERNATOR
Dismounting
1. Disconnect the battery 8 terminal.
Fig. 21-3 21-0218
L. o;,connect the B and E mm;n,1.
,....,
Fig. 21-4 W04-046
Remove the alternator set bolts and alternator

assembly.
Fig. 21-5 W04-046

21-7
DISASSEMBLY
1. Disassemble the regulator and brush.
1). Remove the brush cover.
Fig. 21-6 21-0250
El
2) Remove the regulator.
Fig. 21-7 21-0251
El
3) Remove the brush holder set screws.
Fig. 21-8 21-0252
Disassemble the rotor.

1) Remove the through bolts.
Fig. 21-9 21-0253

21-8
13
2) Remove the front bracket assembly.
Fig. 21-10 21-0254
13
3) Remove the pulley, fan and collar.
Fig_ 21-11 21-0255
13
4) Remove the rotor by using a press.
Fig. 21-12 21-0256
13
5) Remove the bearing retainer.
Fig. 21-13 21-0257

21-9
El
6) Remove the front bearing_
Fig. 21-14 21-0258
El
7) Remove the rear bearing.
Fig.21-15 27-0259
Remove the stator assembly_

1) Unsolder the regulator lead wires.
Fig. 21-16 21-0260
2) Remove the stator coil assembly.
Fig. 21-17 21-0233

21-10
3) Remove the heat sink assembly.
Fig. 21-18 21-0261
INSPECTION
1. Brush
1) Measure the brush length.
Fig. 21-19 21-0234
Standard Limit
16 mm 7mm
2) Confirm that the brush is movable freely with the

brush holder.
Fig. 21-20 21-0235
Rotor
1) Check the conduction of the rotor coil.
Fig. 21-21 21-0262
Standard Limit
About 12.5.1'1 Less than 11.Q
21-11
2) Check the insulation between the slip ring and the

core.
Fig. 21-22 21-0263
Standard Limit
More than 1 Mn Less than 0.5 Mn
3) Measure the outside diameter of the slip ring.
Fig. 21-23 21-0264
Standard Limit
34.5 mm 33.5 mm
Stator
1) Check the conduction.
(U.V.W. terminal)
Fig. 21-24 SM21-037
N-U
N-V
N-W
Resistance About0.4 n
21-12
2) Check the insulation.
Fig. 21-25 SM21-038
Standard Limit
More than 1 M.\1 Less than 0.5 M.\1
A B
Heat sink
1) Inspect the each positive side rectifier condition.
(1) Connect the circuit tester (±) lead to the rec
tifier holder and the 0 lead to the rectifier
terminal.
1). I nspeccione la condici6n del rectificador de cada
lado positive.
( 1) Conecte el conductor C±) del pro bador de cir
cuito al portarrectificador y el conductor 0
at terminal del rectificador.
1) Verifier que chacun des redressurs cote positif
est en bonne condition.
Fig. 21-26 SM21-013A ( 1) Connecter le conducteur C±) du controleur de
circuit au porte-redresseurs et le conducteur
A: Good B: Bad 0 a la borne de redresseur.
B (2) C±) lead to the rectifier terminal and 0 lead

to the rectifier holder.
(2) El conductor 0 con el terminal del rectifica
dor y el conductor 0 con el portarrectifi
cador.
(2) Connecter le conducteur E) a
la borne de
redresseur et le conducteur 0
au porte-redres
seurs.
Fig. 21-27 SM21-013B
A: Good B: Bad
2) Inspect the each negative side rectifier condition.

A B
(1) Connect the circuit tester E) lead to the
rectifier terminal and the 0 lead to the recti
fier holder.
2) I nspeccione la condici6n del rectificador de cada
la«!Jo negative
( 1) Conecte el conductor E) del probador de
circuito con el terminal del rectificador y el
conductor 0 con el portarrectificador.
2) Verifir!r q11l1 chilc11n des redresseurs cf1tr'.! negatif est
en bonnc condition.
( 1) Connecter le conducteu1· E) cJ11 controleur de
Fig. 21-28 SM21-012A a
cirC t it la borne dl, redrnsscur r!t le conduct
r.ur 0 au porte-rec.lresseurs.
21-13
A B (2) (±) lead to the rectifier holder and 0 lead to

the rectifier terminal.
(2) El conductor (±) con el portarrectificador, y el
conductor 0 con el terminal de rectificador.
(2) Connecter le conducteur (±) au porte-redres
seurs et le conducteur 0 a la borne de redres
seur.
Fig. 21-29 SM21-012B

A: Good B : Bad
5. I.C. regulator
1) Check the resistance between each terminal.
5. Regulador I.C.
1) Revise la resistencia entre cada terminal.
5. Regulateur a circuit integral
1) Verifier la resistance entre les bornes.
L C
Fig. 21-30 SM21-035
RESISTANCE BETWEEN EACH TERMINAL

Tester Resistance Tester Resistance
+ Lead - Lead n. + Lead - Lead n.

R L About 10 L R 00
R F About 10 F R 00
R C 00 C R 00
R E About 1.5 K E R 00
L F About 10 F L About2 K
L C About 90 C L 00
L E About 100 E L About 1.5 K
F C About 10 C F 00
F E About 180 E F 00
C E About 40 E C 00
21-14
Condenser
1) Inspect the condenser function.
(1) Connect the test leads.
(2) Reverse the polarity of the test leads.
2) Measure the condenser capacity.
(Condenser tester)
Fig. 21-31 21-0242
I Capacity About 0.5 µF
Connector
1) Check the resistance between each terminal.
Fig. 21-32 SM21-074
1, R Lead
2. L Lead
3. N Lead
4. Support
RESISTANCE BETWEEN EACH TERMINAL

Tester Resistance
+ Lead - Lead n
R L 400 - 500
L Support 00
Support L 9 -12
21-15
ZQ ASSEMBLY
1. Install the stator assembly.
1) Install the heat sink assembly.
NOTE: Be careful with the each positon of two heat
sink. Install the (-) pole heat sink, which has
printed circuit, lower.
Fig. 21-33 21-0233
2) Install the O-ring into the rear bracket .
• .
'"
I:·"· , .
Fig. 21-34
.•,•"-. "'"
..
,...,.,,,,.. ,.·
,�
21-0265
3) Install the stator.
E)
Solder the lead wires of the stator to the each
terminal of the heat sink as shown in the figure .
....
Fig. 21-35 21-0260
Installation of the rotor.

1) Install the felt, bearing and the bearing retainer
into the front bracket.
Fig. 21-36 21-0270

21-16
El
2) Install the rotor into the front bracket.
Fig. 21-37 21-0266
El
3) Install the fan and pulley.
Fig.21-38 21-0267
I Tightening torque 980-1,300 kg•cm (71-94 lb.ft)
El
4) Install the through bolts.
Fig. 21-39 21-0268
Tightening torque 60-90 kg•cm (4-6.5 lb.ft)
3. Installation of the regulator and the brush holder

assembly.
1) Install the brushes into the holder.
And then solder the lead wires to the support.
NOTE: In installing the brusties, solder the wires so that

brush projection should be 16 mm.
NOTE: Suit the concave face .of the brush to the convex
face of the slip ring..
Fig. 21-40 21-0270

21-17
El
2) Install the brush holder.
Fig. 21-41 21-0252
Tightening torque 19-25 kg•cm (1.4-1.8 lb.ft)
El
3) Install the I.C. regulator.
Fig. 21-42 21-0251
Tightening torque J 19-25 kg•cm (1.4-1.8 lb.ft)
CHARGING SYSTEM CIRCUIT

- Precautions -
1. Note the battery polarity carefully so as not to make
reverse connections.
If the connections are reversed, the diodes will short
the circuit and allow large current to flow through
and damage the diodes 'and IC regulator as well as
burn up the wiring harness.
2. Use care not to make wrong connections of terminals.
3. When charging the battery with a quick charge.
.. . .... _ _J Disconnect the battery terminals .
Fig. 21-43 SM21-010B 4. Do not perform tests with high voltage insulation
resistance tester.
1. Alternator 4. Starter switch 5. When in operation, never disconnect the battery.
2. IC Regulator 5. Char11e warning lamp
3. Field coil 6. Battery
21-18
INSPECTION
1. Measure the resistance between each terminal after
assembling.
(1.5V circuit tester, x 1)
Fig. 21-44 21-0269
Tester · Tester
Resistance Resistance
+ Lead - Lead tn) + Lead - Lead (nl
B R 00 N E 7-10
B N 7-10 N B 00
'
R L 400-500 E R 00
R E 00 E L 00
L E 00 E N 00
�r Inspect the alternator performance.

1) Turn on switch SW 1 and off SW2 to increase the
rotation of the alternator slowly.
2. lnspeccione el funcionamiento del alternador.
1) Posicionar en "ON" el interruptor SW I y en
"OFF" SW2 y aumentar de a poco la rotaci6n
del alternador.
2. l11specter la µerformance cJe l'alternateur.
1) Augmenter lenternent la rotation de l'alternateur,
l'interruptem SW 1 etant mis sur la position ON et
SW 2 sur la µosition OFF.
Fig. 21-45 SM21-014A

1. Ampere-meter
2. Volt-meter
3. Load
2) When voltage reaches 28V, turn on swigch SW2
regulate load resistance. Increase the rotation of
the rotor keeping voltage at 28V.
2) Cuando el voltaje llega a 28V, posicionar en
"ON" el interruptor SW 2 para regular la restencia
de carga. Aumente la rotaci6n del rotor mante
niendo el voltaje a 28V.
a
2) Lorsquc la tension arrive 28V, 111ettrn SW 2 sur
la position ON. Auq111cntcr la rot;,tion du rotor
tout r;n rnai11tcnant la tensiona 28V par reglc1ge
rle la rt'!sistancc) c!n charqr).
Fig. 21-46 SM21-014B
Standard
Less t_han 5,000 rpm 28V, 20A
21-19
3 Inspect the IC regulator performance.

Turn on switch SW 1 and off SW 2 to increase the
rotation of rotor to 5,000 rpm.
�
3. lnspeccione el funcionamiento del regulador de IC
Posicionar el interruptor SW 1 en "ON", SW2 en OFF
y aumentar la rotaci6n del alternador a 5000 ppm.
3. lnspecter la performance du regulateur a C.I.
Porter la rotation du rotor a 5_000 tr/mn. SW1
etant missur la position ON et SW 2 sur la position
OFF.
Fig. 21-47 SM21-014A
I s.ooo rpm
=-\ Standard
28.SV - 29.5V
MOUNTING
1. Adjust the V-belt tension and tighten the set bolt.
1. Adjuste la tension de la correa en V y apriete el perno

de fijaci6n.
1. Regler la tension de la courroie trapezo·i dale et serrer

le boulon de blocage.
Fig. 21-48 W04-058
El
2. Connect the battery 0 terminal.
2. Conecte el terminal de bateriia.
2. Connecter la bcirne de batterie.
Fig. 21-49 21-081
PRECAUTIONS ON THE VEHICLE

1 _ Note the battery polarity carefully so as not to make reverse connections_
If the connections are reversed, the diodes will short the circuit and allow large current to flow through and damage
the diodes and IC regulator as well as burn up the wiring harness.
2. Do not disconnect the alternator terminals when in operation_
3. When charging the battery with a quick charge disconnect the battery terminals.
4. Do not inspect with a megger tester.
5. When in operation, never disconnect the battery_
21-20
TROUBLESHOOTING
Fuse is blown out

Poor operation of meter
Poor connecting or wiring of each terminals
When charging current is not
conducted Breaking of short-circuit of coil and wiring inside the alter
nator
Poor diode
Trouble of regulator
Poor wiring
Belt is loosened
Charging is insufficient
Poor regulating voltage of regulator
Trouble of alternator (Short-circuit of coil, poor diode)

Poor battery
Note: Charging current will be reduced when the battery's charging is

almost completed.
Poor alternator or regulator (Short-circuit of wiring, coil,

When charging current is transistor)
excessive
Regulating voltage of regulator is too high
21-21
Item Standard Service limit
Brush length mm 20 5.5

Outside diameter of slip ring mm 32.5 32.1
Stator 0.91
Resistance of coil (nl
Rotor 9.0 -
TIGHTENING TORQUE
Item kg·cm lb.ft

Pulley lock nut 980 - 1,300 71 -94
Through bolt 60-90 4-6.5
Others M5 x 0.8 19 -25 1.3 -1.8
M6x1 33-45 2.4-3.3
IK.P.i.
22-0lESF-02
STARTER
ARRANCADOR
DEMARREUR
SYMBOL MARKS
SIMBOLOS
SYMBOLES .........•..........•..........•...•...•.... 22- 1

GLOSARIO DE TERMINOS TECHNIQUES
LEXIQUES DES TERM ES TECHNIQUES ....•............•..•... 22- 2
DATA & SPECIFICATION

□ ATOS Y ESPECIFICACIONES
DATA & CARACTERISTIQUES .•.......••......•...•.....•... 22- 3
DESCRIPTION
DESCRIPCION
DESCRIPTION ................................•.•.•..••. 22- 4
OVERHAUL
REPARACION GENERAL
REVISION ..........•....•.•.••..•..••........•........ 22- 5
ESPECl FICACIONES DE REPARACION
CARACTERISTIQUES DE REPARATION ....................•...22-27
22-1
SYMBOL MARKS
SIMBOLOS
Se han adoptado los siguientes simbolos para simplidad y facil comprensi6n.
SYMBOLES
Les symboles suivants ont ete adoptes afin de simplifier et de faciliter la comprehension.
El
ASSEMBLY TIGHTENING
l"'1i..l
ARMADO APRIETE
MONTAGE SERRAGE
1
DISASSEMBLY CLEAN
l� �I E]
DESARMADO LIMPIEZA
a
DE MONTAGE NETTOYAGE
INSTALLATION IMPORTANT
INSTALACION IMPORT ANTE
MISE EN PLACE � IMPORTANT
E3
REMOVAL ADJUSTMENT
[BJ
REMOCION AJUSTE
DEPOSE REGLAGE
[I]
� CONT.ROLE GRAISSAGE
l!B
MEASUREMENT
MEDICION
MESURE
22-2

GLOSARIO DE TERMINOS TECNICQS
LEXIOUE DES TERMES TECHNIQUES
ENGLISH ESPANOL FRANCAIS

1. Ft.lb 1. lb.pie 1. Lb.
2. In 2. Puig. 2. Pouce
3. Less than 3. Menos de .. 3. lnferieura
4. More than 4. Mas de .. 4. Superieur a
5. Repair limit 5. Li mite de reparaci6n 5. Limite de reparation
6. Service limit 6. Li mite de servicio 6. Li mite d'utilisation
7. Standard 7. Estandard 7. Standard (normal)
8. Tightening torque 8. Par de apriete 8. Couple de serrage
22-3
STARTER (24V, 6.0 KW)

ARRANCADOR (24V, 6.0 KW)
DEMARREUR (24V, 6.0 KW)
DATA & SPECIFICATIONS
Model ................................. 28100-1472A (0350 602 003)

Mechanism . . . . .. . . . . . . . .. . . . . .. . . . ... . . Pinion shift type
Output ................................ 24V, 6.0 KW
Number of teeth of pinion . . . . . . . . . . . . . . . . . . . 11
Module ................................ 3.5
□ ATOS Y ESPECIFICACIONES
Modelo ................................ 28100-1472A (0350 602 003)

Mecanismo . . . .. . . . . . . . . . . . . . . . . . . . . . . . . Tipo cambio de pin6n
Salida ................................. 24V, 6.0 KW
Numero de dientes del pin6n . . . . . . . . . . . . . . . . . 11
Modulo ................................ 3,5
DATA & CARACTERISTIOUES
Modele ................................ 28100-1472A ( 0350 602 003)

Mecanisme Type a pignon d'entrainement
Puissance 24V,6.0 KW
Nombre des dents de pignon . . . . . . . . .... . . . . . . 11
Module . .. . . ................ 3,5
22-4
DESCRIPTION
DESCRIPCION
DESCRIPTION
C80-190EA
2
1
A'
STARTER ARRANCADOR DEMARREUR
1. Brush 1. Escobilla 1. Balai

2.Magnetic switch 2. Conj unto de interrupter mag- 2. Contacteur magnetique d'en-
3.Pinion shift lever netico gagement
4. Clutch and pinion 3. Palanca de cambio 3. Levier d"enclenchement
5. Pinion stopper 4. Embrague y pifi6n 4. Pignon et accouplement
6. Commutator 5. Tope del pii'i6n 5. Butee de pignon
7. Field coil 6. Colector 6. Collecteur
8. Armature 7. Bobina de campo 7. Enroulement de champs
9. Reduction gear 8. lnducido 8. Endu it
10. A-A' section 9. Engranaje de recci6n 9. Engrenages de reduction
10. Secci6n A-A' 10. Coupe A-A'
Fig. 22-1
22-5
OVERHAUL
REPARACION GENERAL
REVISION
1846T
1-NO. 22
��
i 23
22
��·-
31
24
STARTER ARRANCADOR DEMARREUR

1. Magnetic switch assembly 1. Conjunto de interrupter magnetico 1. Ensemble contacteur magnetic
2. Contactor point assembly 2. Conjunto de punto de contactor que d'engagement
3. Contactor with terminal 3. Contactor con conjunto de cubierta 2. Ensemble contacteur en point
cover assembly de terminal 3. Contacteur avec couvercle de borne
4. Terminal assembly 4. Conjunto de terminal 4. Ensemble borne
5. Shim 5. Lamina 5. Rondelle d'epaisseur
6. Pinion shift lever 6. Palanca de cambio de pii'l6n 6. Levier d'enclenchement
7. Lever set bolt 7. Tornillo de fijaci6ri de la palanca 7. Bou Ion de fixation du lever
8. Moving core 8. Nucleo m6vil 8. Noyau mobile
9. Through bolt 9. Perno pasante a
9. Bou Ion travers
10. Commutator end frame assembly 10. Conjunto de bastidor final del 10. Ensemble couvercle de collecteur
11. Brush holder assembly colector 11. Ensemble porte-balai
12. Brush spring 11. Conjunto de portaescobilla 12. Ressort de balai
13. Brush 12. Resorte de la escobilla 13. Balai
14. Band 13. Escobilla 14. Bride
15. Connecting bar 14. Banda 15. Barre de connexion
16. Field coil 15. Barra de conexi6n 16. Enroulement de champ
17. Armature assembly 16. Bobina de campo 17. Ensemble induit
18. Ball bearing 17. Cojunto de inducido a
18. Palier bille
19. Gear housing 18. Cojinete de bolas 19. Carter d 'engrenages
20. Shim 19. Caja de engranaje 20. Rondelle d'epaisseur
21. Drive shaft 20. Lamina 21. Arbre de commande
22. O-ring 21. Eje impulsor 22. Aneau 0
23. Shim 22. AnilloO 23. Rondelle d'epaisseur
24. Center bracket 23. Lamina 24. Ensemble cercle de jante
25. Center bearing 24. Mensula central 25. Palier intermediaire
26. Clutch and pinion 25. Cojinete central 26. Pignon et accouplement
27. Pinion stopper 26. Embrague y piii6n 27. Butee de pignon
28. Hook 27. Tope del piii6n 28. Crochet
29. Clip 28. Gancho 29. Bride
30. Pinion case 29. Abrazadera 30. Carter de pignon
31. Front bearing 30. Caja del pi i'l6n 31. Palier avant
31. Cojinete delantero
Fig. 22-2
22-6
E3
STARTER
Dismounting
1. Disconnect the battery terminal.
ARRANCADOR
Desmontaje
1. Desconecte el terminal de la baterf a.
DEMARREUR
De montage
1. Debrancher la borne de batterie.
Fig. 22-3 21-081
E3
2. Disconnect the cable which are connected to B and
C terminal of the starter.
2. Desconecte el cable conectado a los terminales B y
C del arrancador.
2. Deposer le cable qui est connecte a la borne B et
C du demarreur.
Fig. 22-4 22-059
E3
.-t..
3. Remove the starter set bolt .
3. Remueva el perno de sujeci6n del arrancador.
3. Deposer la vis de fixation du demarreur.
Fig. 22-5 22-060
E3
4. Dismount the starter assembly.
4. Desmonte el conjunto de arrancador.
4. Deposer !'ensemble demarreur.
Fig. 22-6 22-061

22-7
Disassembly
1. Disconnect the connecting· bar.
Desarmado
1. Desconecte la barra de conexi6n.
Desassemblage
1. Deposer la barre de connexion.
Fig. 22-7 22-062
2. Remove the magnetic switch set bolts.

2. Remueva los pernos de sujeci6n del interruptor
magnetico.
2. Deposer les vis de fixation du contacteur magneti
que.
Fig. 22-8 22-063
3. Remove the magnetic switch assembly.

3. Remueva el conjunto de interruptor magnetico.
3_ Deposer !'ensemble contacteur magnetique.
Fig. 22-9 22-064
4. Remove the moving core.

4. Remueva el nucleo m6vil.
4. Deposer le noyau mobile.
Fig. 22-10 22-065

El
22-8
5. Remove the through bolt.

..... 5. Remueva el perno pasante.
5. Deposer les boulons a travers.
Fig.22-11 22-066
El
6. Remove the pinion case.
6. Remueva la caja del pin6n.
6. Deposer le carter de pignon.
Fig. 22-12 22-067
El
7. Remove the center bracket with the pinion clutch
assembly.
7. Remueva la mensula central con conijunto de em
braque de pinion.
7. Deposer le support central ainsi que !'ensemble
embrayage de pignon comme un ensemble.
Fig. 22-13 22-126
El
8. Remove the clip.
8. Remue va el abrasadera.
8. Deposer du bride:
Fig. 22-14 22-125(8) 22-069

22-9
El
9. Separate the pinion clutch and the drive shaft.
9. Separe el embraque de pinion y el eje impulsor.
9. Separer i !embrayage de pignon et l'arbre d'entra1ne
ment.
Fig. 22-15 22-123
El
10. Remove the shim.
10. Remueva la lamina.
10. Deposer la rondelle d'epaisseur.
Fig. 22-16 22-075 22-0119
El
11. Remove the pinion shift lever set bolt.
11. Remue va el perno de. sujecion de la palanca de
. cambio de pinion.
11. Deposer la vis de fixation du levier d'enclenchement.
Fig. 22-17 22-121
El
12. Remove the band.
12. Remueva la banda.
12. Deposer la bride.
Fig. 22-18 22-076

22-10
El
13. Remove the brush set screw.
13. Remueva el tornillo de ajuste de la escobilla.
13. Deposer la vis de fixation de balai.
Fig. 22-19 22-077
El
14. Remove the brush.
14. Remueva la escobilla.
14. Deposer le balai.
Fig. 22-20 22-078
El
15. Remove the through bolt.
15. Remueva el perno pasante.
15. Deposer le bou Ion a travers.
Fig. 22-21 22-079
16. Remove the gear housing together with the armature.

16. Remueva la caja de engranaje junta con el inducido.
16. Deposer le carter d'engrenage avec l'induit.
Fig. 22-22 22-080

22-11
1��1
17. Remove the armature from the gear housing.
17. Remueva el inducido de la caja de engranaje.
17. Deposer l'induit du carter d'engrenage.
Fig. 22-23 22-081
E3
18. Remove the commutator end frame.
18. Remueva el bastidor final del colector.
18. Deposer le couvercle de collecteur.
Fig. 22-24 22-082
Inspection & repair

1. Armature
1) Shortcircuit test.
(1) Place the armature on the armature tester.
(2) Operate the tester and place the iron piece on
the armature.
* If the iron piece is not vibrated, the armature is
good.
lnspeccion y reparacion
1. lnducido
1) Prueba de cortocircuito.
( 1) Coloque el inducido sobre el probador de in
Fig. 22"-25 22-083 ducido.
(2) Opere el probador y coloque una pieza de hierro
sobre el inducido.
* Si la pieza de hierro no vibra, significa que el
inducido esta en buenas condiciones.
Controle & reparation
1. lnduit
1) Essai de court-circuit
( 1) Placer l'induit sur I 'appareil d'essai d'induit.
(2) Fonctionner l'appareil et placer une piece de fer
mince sur l'induit.
* Si la piece de fer mince n'est pas vibree, l'induit
est bon.
22-12

2) Revise el aislarniento.
2) Verifier I 'isolement.
Fig. 22-26 22-084
Standard More tha111MD
3) Measure the wave of commutator.

3) Mida la onda del colector.
3) Mesurer I 'usure du collecteur.
Fig. 22-27 22-085

Less than 0.05 mm (0.0020 in)
0.1 mm (0.0039 in)
4) Measure the outside diameter of the commutator.

4) Mida el diarnetro exterior del colector.
4) Mesurer le diametre exterieu·r du collecteur.
Fig. 22-28 22-086

Standard 40 mm ( 1.575 in)
Service limit 38 mm (1.496 in)
22-13
5) Measure the depth of under cut.

5) Mida la profundidad del rebaje.
5) Mesurer la profondeur du mica.
Fig. 22-29
1. Quantity of mica 1. Cantidad de mica 1. Ouantite du mica

2. Segment 2. Segment 2. Segment
3. Mica 3. Mica 3. Mica
Standard 0.5~0.Bmm (0.0197~0.0315 in}

Repair limit 0.2 mm (0.0079 in}
2. Field coil
1) Check the conduction between the series coil and the
yoke.
· ·� * Should be conducted.
2. Bobina de campo
1) Revise la conducci6n entre la bobina en serie y el
yugo.
* Debe haber conducci6n.
2. Enroulement de champ
1) Verifier la conduction entre l'enroulement de champ
et la culasse de demarreur.
* 11 faut elre conductible.
Fig. 22-30 22-087
EJ
(1) Remove the coil earthing screw at 2 points.
2) Revise el aislamiento.
( 1) Remueva el tornillo de puesta a tierra de la
bobina en 2 puntos.
2) Verifier l'isolement
( 1) Deposer les vis de masse d'enroulement a 2
points.
Fig. 22-31 22-088

22-14
E3
(2) Apart the end of coil from the yoke.
(2) Separe el extrema de la bobina del yugo.
(2) Separer l'extremite d'enroulement de la culasse.
Fig. 22-32 22-089
(3) Check the insulation.

(3) Revise el aislamiento.
(3) Verifier l'isolement.
Fig. 22-33 22-090
Standard More than 1 MD.
3. Drive shaft
1) Measure the d.rive shaft for bend.
3. Eje impulsor
1) Mida el eje impulsor por siesta combado.
3. Arbre de commande
1) Verifier la torsion de l'arbre de commande.
Fig. 22-34 22-091

2) Inspect the spline and internal gear for wear and

damage.
2) I nspeccione la estri a y el engranaje interno en cuanto
a dafios y desgaste.
2) Verifier l'usure et la deterioration de la cannelure
et l'engrenage interieur.
Fig. 22-35 22-092

22-15
l!tl
4. Bushing
1) Measure the inside diameter of the bushings.
(1) Front bushing
4. Buje
1) Mida el diametro interior de los bujes.
( 1) Buje delantero.
4. Bague
1) Mesurer '1e diametre interieur des bague
( 1) Bague avant.
Fig. 22-36 22-093

(2) Center bushing.

(2) Buje central.
(2) Bague central.
Fig. 22-37 22-094

5. Brush holder
1) Check the insulation between the brush holder and
the bracket.
5. Portaescobilla
1) Revise el aislamiento entre el portaescobilla y la
mensula.
5. Porte-balai
1) Verifier I 'isolement entre le porte-balai et le cou
vercle.
Fig. 22-38 22-095

I Standard More than 1MS1
2) Check the tension of the brush spring.

2) Revise la tension del resorte de la escobilla.
2) Verifier la tension du ressort de palai.
Fig. 22-39 22-096

Standard 1.4 kg (3 lb)
Service limit 1.0 kg (2 lb)
22-16
3) Measure the brush length.

3) Mida la longitud de la escobilla.
3) Mesurer la longueur de balai.
Fig. 2240 22-097

Service limit 14 mm (0.551 in)
6. Magnetic switch
1) Check the conduction between the C terminal and
the body.
* Should be conducted.
6. I nterruptor magnetico
1) Revise la conducci6n entre el terminal Cy el cuerpo.
* Debe haber conducci6n
6. Contacteur magnetique d'engagement
1) Verifier la conduction entre la borne C et le corps.
* 11 taut etre conductible.
Fig. 22-41 22-098
2) Check the conduction between the C terminal and

the coil terminal.
* Should be conducted
2) Revise la conducci6n entre el terminal Cy el terminal
de bobina.
* Debe haber conducci6n.
2) Verifier la conduction entre la borne C et la borne
d'enroulement.
* 11 taut etre conductible.
i\..
\··
Fig. 22-42 22-099
7. Pinion and clutch

1) Check the pinion teeth for damage.
7. Pifi6n y embrague
1) Revise los dientes del pifi6n en cuanto a dafios.
7. Pignon et accouplement
1) Verifier la deterioration des dents de pignon.
Fig. 22-43 22-100

22-17
2) Fix the shaft and rotate the pinion to check the

clutch.
* If it turns both side or does not turn at all, replace
it with new one.
2) Fije el eje y gire el pifi6n a fin de revisar el embrague.
* Si gira a ambos lados o no gira para nada, reemplace
par uno nuevo.
2) Fixer l'arbre et tourner le pignon afin de verifier
l'accouplement.
* Si l'accouplement se tourne toutes les deux cotes
ou ne se tourne pas du tout, remplacer-le avec un
neuf.
Fig. 22-44 22-101
OJ
Assembly
NOTE: When assembly the starter motor, apply grease at
the following points. Be sure to use the proper
kind of grease at each point.
Armada
NOTA: Al remontar el motor del arrancador, aplique grasa en
los puntos siguientes. Asgurese de utilizar la clase
adecuada de grasa en cada punto.
Remontage
N.B.: Lors du remontage du demarreur, appliquer de la
graisse aux points suivants.
S'assurer d'utiliser la graisse appropriee a chaque
Fig. 22-45 point.
Bushing (Front) 1 Buje {Delantero) Bague (Avant)

2 Bushing (Pinion gear) 2 Buje (Pinon satelite) 2 Bague (Pignon d'attaque)
3 Bushing (Center) & shim 3 Buje (Centro) y laminilla de ajuste 3 Bague (Central) a cale
4 Reduction gear & shim 4 Engranaje de reducci6n 4 Pignon de d'emultiplication et cale
5 Bearing (Center) 5 Cojinete de bolas (Centro) 5 Roulement (Central)
6 Bearing (Rear) 6 Cojinete de bolas (Tracero) 6 Roulement (Arriere)
7 Clutch 7 Embrague 7 Em bray age
8 Shaft 8 Eje 8 Arbre
9 Pinion shift lever 9 Palanca del eje pin6n 9 Levier de l'arbre de pignon
Lubrication
Characteristic of recommended lubricants BRAND
position
Pyronoc·2 (Nihon Sekiyu)

1 3 Lithium and sope based bearing grease
Multemp SRL (Kyodo Yushi)
Lithium and sope based bearing grease

2 4 7 8 9 (containing malybdenum disulfide) Multemp MS2 (Kyodo Yushi)
High film strength grease
Urea based high temperature grease

5 6 °
Operation temp. -20 C ~ ° ° °
250 C (-4 F-482 F)
22-18
Posici6n
Caracteristicas de los lubricantes recomendades Marca
de lubricaci6n
Pyronoc-2 (Nihon Sekiyu)

1 3 Grasa de cojinete a base de litio Multemp SRL (Kyodo Yushi)
Grasa de cojinete a base de litio

4 7 8 9 (con bisulfito de molibdeno) Multemp MS2 (Kyodo Yushi)
Pel icula de grasa altamente resistente
Pel icula de grasa altamente resistente

5 6 ° ° ° °
Operation temp. -20 C - 250 C (-4 F - 482 F)
Position
Caracteristiques des lubrifiants recommandes Marque
de graissage
1 3
Graisse pour roulement a la base du lithium et du Pyronoc-2 (Nihon Sekiyu)
savan Multemp SRL (Kyodo Yushi)
a
Graisse pour roulement la base du lithium et du
4 7 8 9 savon (comprenant la diusulfate de molybdene) Multemp MS2 (Kyodo Yushi)
Graisse a haute resistance de filme
Temperature de fonctionnement de la graisse pour

5 6
°
a ° ° °
a
roulement haute temperature la base de l'uree Mui temp SR L ( Kyodo Yushi)
-20 C- 250 C(-4 F- 482 F)
22-19
Assembling of the motor

1. Install the end frame to the yoke.
Armado del motor
1. I nstale el bastidor final al yugo.
Remontage du moteur
1. Remettre le couvercle a la culasse.
Fig. 22-46 22-082
El
2. Install the armature into the gear housing.
2. I nstale el inducido en la caja de engranaje.
2. Remettre l'induit dans le carter d'engrenage.
Fig. 22-47 22-102
3. Install the armature into the yoke.

3. lnstale el inducido en la horquilla.
3. Remettre l'induit dans la culasse.
Fig. 22-48 22-103
El
4. Tighten the through bolt.
4. Apriete el perno pasante.
4. Resserrer le boulon a travers.
Fig. 22-49 22-0145

Tightening torque 1140~160 kg.cm(10.2 ~ 11.Sft.lb}I
22-20
El
5. Install the brush.
5. lnstale la escobilla.
5. Remettre la balai.
Fig. 22-50 22-078
El
6. Install the band.
6. lnstale la banda.
6. Remettre la bride.
Fig. 22-51 22-076
El
7. Install the pinion shift lever.
7. I nstale la palanca de cambio de pifi6n.
7. Remettre le levier d'enclenchement.
Fig. 22-52 22-121
El
8. Installation of the drive shaft.
Install the shim into the drive shaft.
8. lnstalaci6n del eje impulsor
lnstale la lamina en el eje impulsor.
8. Remontage de I 'arbre de commande
Remettre la rondelle d'epaisseur a l'arbre de com
mande.
Fig. 22-53 22-105

22-21
El
9. Install the drive shaft.
9. lnstale el eje impulsor.
9. Remettre l'arbre de commande.
Fig. 22-54 22-074
El
10. Install the shim.
10. lnstale la lamina.
10. Remettre la rondelle d'epaisseur.
Fig. 22-55 22-073
El
11. Install the center bracket.
11. lnstale la mensula central.
11. Remettre le cercle de jante.
Fig. 22-56 22-106
12. Pretighten the through bolt and mesure the thrust

gap, move the drive shaft in and out.
12. Preajuste el perno pasante y mida la holgura de
empuje moviendo el eje de transmisi6n hacia dentro y
hacia fuera.
12. Measurer le jeu de butee en depalacant l'arbre
d'entra1nement vers l'interiour et vers l'exteriour.
Fig. 22-57 22-0118
Standard 0.1~0.3 mm (0.0039~0.0118 in)

22-22
El
13. Install the pinion clutch assembly.
13. lnstale el conjunto de embrague de pii'i6n.
13. Remettre I 'ensemble p ignon a accouplement.
Fig. 22-58 22-070
El
14. Install the pinion stopper.
14. lnstale el tope del pifi6n.
14. Remettre la butee de pignon.
Fig. 22-59 22-108
El
15. Install the hook and clip.
15. I nstale el
15. Remettre le circlip.
Fig. 22�0 22-109
El
16. Install the pinion case.
16. I nstale la caja del pii'i6n.
16. Remettre le carter de pignon.
Fig. 22�1 22-067

22-23
El
17. Tighten the through bolt.
17. Apriete el perno pasante.
17. Resserrer le boulon a travers.
Fig. 22-62
I Tightening torque \ 140~160 kg.cm (10.2~11.5 ft.lb) I
El
18. Install the moving core.
18. lnstale el nucleo m6vil.
18. Remettre le noyau mobile.
Fig. 22-63 22-065
El
19. Install the magnetic switch assembly.
19. lnstale el conjunto de interruptor magnetico.
19. Remettre I 'ensemble contacteur magnetique d'engage
ment.
Fig. 22-64 22-064
El
20. Tighten the set bolt.
20. Apriete el perno de sujeci6n.
20. Resserrer la vis de fixation.
Fig. 22-65 22-0147

Tightening torque 60~90 kg.cm (4.4~6.5 ft.lb)
22-24
El
21. Install the connecting bar.
21. Instate la barra de conexi6n.
21. Remettre la barre de connexion.
Fig. 22-66 22-0144

I Tightening torque I 165~225 kg·cm (14~17 ft.lb)
Inspection
1. Measurement of the timing gap.
1) Arrange the circuit as shown in Fig. 22-68.
2) Turn on the switches S1 and S2.
3) Open S2 alone when the pinion pops out.
lnspeccion
1. Medici6n del huelgo de sincronizaci6n
1) Disponga el circuito de la rnanera indicada en la
Fig. 22-68.
2) Gire los interruptores S1 y S2.
3) Abra solarnente S2 cuando aparezca el pifi6n.
Cont role
Fig. 22-67
1. Mesure de la course du pignon
1) Arranger le circuit comrne le montre la Fig. 22-68.
2) Ouvrir l'interrupteur S1 et S2.
3) N'ouvrir que S2 quand le pignon sort.
4) With above condition, push the end of pinion back

to measure the gap.
4) En la condici6n de arriba, presione el extremo del
pifi6n hacia atras para medir el huelgo.
4) A la condition ci-dessus, repousser l'extremite du
pignon afin de mesurer le jeu.
Fig. 22-68 22-113

Standard 0.5~1.5 mm (0.0197~0.0591 in)
22-25
2. Adjustment of the timing gap.

The timing gap can be adjusted by increasing or
decreasing the number of the shim which is installed
between the magnetic switch and the center bracket.
2. Ajuste del huelgo de sincronizaci6n.
El huelgo de sincronizaci6n puede ajustarse aumen
tando o disminuyendo el numero de laminas in
staladas entre el interuptor magnetico y la mensula
central.
2. Reglage de la course du pignon
Le reglage peut etre accompli en augmentant ou
diminuant le nombre des rondelles d'epaisseur qui
Fig. 22-69 22-114 sont mises entre le contacteur magne.tique et le
cercle de jante.
El
Mounting
1. Mount the starter assembly.
Montaje
1. Monte el conj unto de arrancador.
Installation
1. Installer !'ensemble demarreur.
Fig. 22-70 22-061
El
2. Tighten the set bolts.
2. Apriete los pernos de sujeci6n.
2. Resserrer les vis de fixation.
Fig. 22-71 22-060

I Tightening torque I 650~870 kg.cm (47~62 ft.lb)
El
3. Connect the cables.
3. Conecte los cables.
3. Connecter les cables.
Fig. 22-72 22-059

22-26
El
4. Connect the battery terminal.
4. Conecte el terminal de la bateri a.
4. Connecter la borne de batterie.
Fig. 22-73 21-081

22-27
SERVICE STANDARD
Unit: mm (in)
Item Nominal size Repair limit Service limit Measure
Front 19 (0.748) 19.2 (0.756) Replacement
Bushing inside
diameter
Center 28 (1.102 ) 28.2 (1.110) Replacement
Outside diameter 40 (1.575 ) 38 (1.496 ) Replacement
Less than 0.05 More than 0.1

Commutator Wave (0.0020) (0.0039) Repair
0.5 ~ 0.8 Less than 0.2

Under cut Repair
(0.0197 ~ 0.0315) (0.0079)
Brush length 20 (0.787) 14 (0.0551) Replacement
Tension of brush spring 1.4 kg (3 lb) 1.0 kg (2 lb) Replacement

Bend 0.05 (0.0020) More than 0.1 Replacement
(0.0039)
Drive shaft
Thrust play 0.1 ~ 0.3
Adjustment
(0.0039 ~ 0.0118)
Insulating resistance More than 1 MS°2 Less than 0.5MS°2 Replacement
TIGHTENING TORQUE
Item kg.cm lb.ft

M terminal 165 ~ 225 12 ~ 16
Through bolt 140 ~ 160 10.2~11.5
Magnetic switch set bolt 60 ~ 90 4.4 ~ 6.5
Starter set bolt 650 ~ 870 47 ~ 62
22-28
ESPECIFICACIONES, DE REPARACION
NORMAS DE SERVICIO
Unidad: mm (pull
Li mite de Li mite de
Item Tamafio nominal Contramedida
reparaci6n servicio
Diametro interior Delantero 19 (0,748) 19,2 (0,756) Ree mplace

del buje
Centro 28 (1,102 ) 28 ,2 (1 , 110) Reemplace
Diametro exterior 40 (1,575 ) 38 (1,496) Reemplace
Menos de O,05 Mas de 0,1 Reparaci6n

Colector Onda (0,0020) (0,0039)
0,5 ~ 0,8 Menos de 0,2

Rebaje
(0,0197 ~ 0,0315) (0,0079)
Reparaci6n
Longitud de la escobilla 20 (0,787) 14 (0,551) Reemplace
Tension del resorte de la escobilla 1,4 kg (3 lb) 1 ,0 kg (2 lb) Reemplace
Mas de 0,1
Camba 0,05 (0,0020) Reemplace
(0,004)
Eje impulsor
0,1 ~ 0,3
Juego de empuje
(0,0039 ~ 0,0118) Ajuste
Resistencia de aislamiento Mas de 1Mil Menos de 0,5Mil Reemplace
PARES DE APRIETE
Item kg.cm lb.pie
Terminal M 165 ~ 225 12 ~ 16

Perno pasante 140 ~ 160 10.2 ~ 11.5
Perno de sujeci6n del interrupter magnetico 60 ~ 90 4,4 ~ 6,5
Perno de sujeci6n del arrancador 650 ~ 870 47 ~ 62

22-29
CARACTERISTIOUES DE REPARATION
NORME D'UTILISATION
Unite: mm
Dimension Li mite de Limite

Designation Remede
nominale reparation d'utilisation
Diametre Avant 19 19,2 Remplacement

interieur
du bajue Central 28 28,2 Remplacement
Diametre exterieur 40 38 Rem placement
Collecteur Usu re Mains du 0,05 Plus de 0,1 Reparation
Profondeur du
o,5a0,8 Mains du 0,2 Reparation
mica
Longueur de balai 20 14 Remplacement
Tension de ressort de balai 1.4 kg 1,0 kg Remplacement
Arbre de Torsion 0,05 Plus du 0, 1 Remplacement

commande
Jeu de cannelure 0,1 a o,3 Reglage
Resistance d'isolement Plus du 1MS1 Mains du 0,5MS1 Rem placement
COUPLE DE SER RAGE

Designation kg.cm
Borne M 165 a 225
Bou I on a travers 140 a 150

Vis de fixation du contacteur magnetique 60 a 90
d'engagement
Vis de fixation du demarreur 550 a 870

22-30
0350 602 003

0
>
w X
I- E
e- E
> z y
Cl
lLQ _,,
....J
<1: o-
I-
a: :J w 1-
� :J :J
W....J
mo aa: o_
1- CHARACTERISTIC CURVE
2> :J
::iw 0 0
I-
w
z a:
z I- o_ l /
"
1/T
p
V
6
I/
12
I'---r--..E
24 6
20 5 10 5
I
"' I
" '
J '""
\ I/
/
v
I )"
16 4 8 4 /
7 "-. -.\
" '-....
" "L/I/ /
\
12 3 6 3
\)
\ I'---
\
8 2 4 2 '
I v-......
\
--
/ ..........____
4 2 1
V ............
�
-- \
0 0 0
r--...\
0 200 400 600 800 1000 1200 1400
CURRENT I (A)
Fig. 22-74 SM-22-015
Combination of 0350 602 003
STARTER SWITCH
TO ALTERNATOR (N) TERMINAL
BATTERY SWITCH
BLOCK RELAY e
BATTERY
SM-22-014
Fig. 22-75
22-31
0350 602 003
<!
� i
w !E
en
..I
w wo
=
0 0-
w "·
..,
<!
0 (.)
a:
wo 3 Cl
GUAVA CARACTERISTICA
0
�>
:) w
a:
<!
> z a: a.. (/J
I
w z f- 0..
/
p
VT
"J\
/
V
12
V
24
I'---,-..._E
6 6
� 7 \ V
V
20 5 10
I'I'-..
I .._I'-- /
I
16 4 8 4
,,v) I"-.�\
12 3 6 3
\
\/ V "'
7' I/
�
8 2 4 2
7
7 "/ ........
\ 1"----I'-...'
\
/ r------......
4 2
V r----.�
V �
r----r--. \
,I
0 0 0
0 200 400 600 800 1000 1200 1400
CORRIENTE (A)
Fig. 22-76 SM-22-015
Combinacion de 0350 602 003
BOTON DEL· ARRANCADOR HACIA EL TERMINAL DEL

ALTERNADOR
CONMUTADOR DE LA BATERIA
BLOQUE DEL RELE EB

MOTOR DELARRANCADOR
B ATERIA
SM-22-014
Fig. 22-77
22-32
0350 602 003
2: C: w
w E
----- l
z a:
a: 0
co 0 Cf)
E w
y 0
w
<l'. u
z w z
w .J <l'.
Q 2 (l_ Cf)
::J Cf) COURBE DE CARACTERISTIOUE
z 0 ::J
w u (l_
a:
(l_
w z I-
/
""'\
VT
- p
" IV
12
I"-.. ......._E V
24 6 6
20 5 10
�
" r---... 'V
V
- J -., '---.. / \
I
16 4 8 4
)
.Iv �\
"�I "'
�
V i
12 3 6 3
\)
I/ \ 1"----r--....
\
8 2 4 2 '
/.....
4
I / r--,.... .._
2
V
' .I �
-r----
0 0 0
V r--._\
0 200 400 600 800 1000 1200 1400
COURANT IA)
Fig. 22-78 SM-22-015
Combinasion du 0350 602 003
CLE DE CONTACT VERS LA BORNE DE

L'ALTERNATEUR
INTERRUPTEUR DE BATTERIE
e
B
DEMARREUR
RELAIS EN BLOC e
BATTER IE
SM-22-014
FilJ. 22-79
TURBOCHARGER TC-1
TC-SE-01
CHAPTER TC
HINO EP100T
TURBOCHARGER
DATA AND SPECIFICATIONS .......................... TC-2
DESCRIPTION ....................................... TC-2
TROUBLESHOOTING ................................. TC-3
OVERHAUL CRITERIA ............................... TC-4
SPECIAL TOOL ...................................... TC-5
TURBOCHARGER .................................... TC-6

TC-2 TURBOCHARGER
DATA AND SPECIFICATIONS
Type ................................. RHC 7

External dimensions {Length x Width x Height) ...... 229 mm x 215 mm x 215 mm
Turbine type . . . . . . . . . . . . . . ..... . . . . . . . . . Radial flow type
Blower type . . . . . . . . . ... . .. . . . . . . . . . . . . . . Centrifugal type
Lubricating mettiod ... . . ... . . . . . .. . . .. . . . . External lubrication type
Bearing type .... . . . . • . . . . .. . .......... . . Full floating type
Maximum allowable continuous revolution . . . . . . . . 132.000 rpm
Direction of rotation .......•............... Counterclockwise as seen from the turbine side
°
Maximum allowable continuous inlet ............ 730 C
termperature
DESCRIPTION
1881J 1
1-No. 20
J 9
��--,.?d_ 13
14
15
18
1. Oil inlet 7. Gas outlet

13. Turbine rotor assembly
2. Air outlet 8. Gas inlet
14. Seal plate
3. Bearing case 9. Blower case
15. Thrust spacer
4. Heat protector 10. Blower impeller
16. Journal bearing
5. Turbine case 11. Air inlet
17. Oil outlet
6. Turbine rotor 12. Seal ring on blower side
18. Journal bearing
TURBOCHARGER TC-3
TROUBLESHOOTING
Dense black smoke-

, ------.--- Insufficient air intake
• Air cleaner is choked with dust, ............ Disassemble and clean or replace
causing greater intake air resistance. the air cleaner element.
• Air inlet is choked . . ... . .... . . . ... . ... Repair.
• Air is leaking from intake menifold . ... . .... Repair.
Turbocharger does not rotate smoothly.
• Engine oil impurities deposited on Overhaul and clean turbocharger

rotor, resulting in heavy rotation and/or change engine oil.
or sticking.
Bearing sticking
• Insufficient lubrication or blockalge . .... . ... Check lubricating oil system,

of lubricating oil lines. and/or repair.
• Abnormal wear or damage of seal Repair.
ring caused by wear of journal bearing,
due to insufficient lubrication.
• Temperature of lubricating oil too high ....... Check cooling system.
• Unbalanced rotating parts ............... Change rotating parts.
• Incomplete warming-up, failure ............ Operate vehicle properly.
to idle before stopping engine, or
jack rabbit starts.
1-----1 Loose or damaged turbine rotor or blower impeller.
• Over-rotation . .......... . .... . . .. .. . . Check and adjust the engine.

• Temperature of exhaust gas too high ........ Check and adjust the engine.
• Foreign matter present ..... . ... . . ... . . . Remove foreign material.
Inspect the air cleaner and air
intake manifold.
Repair if necessary.
• Worn thrust bearing . . . .. . . . . . . . ..... .. Overhaul and repair.
• Incomplete assembly . . ... . .. . . ... . ... .. Reassembly.
High volume exhaust-----.- --Exhaust gas leaking before turbocharger, ....... Check and repair connections.
like noise. L therefore insufficient revolution.
Deformed or blocked exhaust gas lines ........ . Repair.
therefore insufficient revolution.
White smoke---------.--Choking defects, or deformation of ............ Repair and replace the lines.
oil return lines so that oil leaks around
blower or turbine sides.
L Seal ring may be broken or worn due . . . . ..... . Replace the thrust washer.
to abnormal wear of thrust washer.
TC-4 TURBOCHARGER
--Gas leakage from exhaust system ............ . Repair.

Loss of power-------""T
Air leakage from air manifold .............. . Repair.
�
Clogged air cleaner element ............... . Clean or replace.
Turbocharger dirty or damaged ............. . Repair or replace.
Poor response of------...--Carbon accumulation on the turbine .......... Change engine oil, clean
turbocharger L side seal ring and heavy rotation. turbocharger.
Poor combustion ...................... . Check fuel system and improve
combustion.
High pitched noise-------.-----1 Noise

and vibration • So called "surging" Overhaul and clean turbocharger.
Surging sometimes occurs when the gas
passage at the nozzle of the turbine
housing is choked or when compressed
air does not flow in proper responses to
acceleration.
• Loosen rotating parts . .. . . .. . . . . . . . . . . . Replace.
Vibration
• Joints loose between turbocharger .......... Check the mounting and repair.
and intake, exhaust manifold or
oil lines.
• Damaged bearing, loose rotating parts, . . . . ... Repair.
imbalanced rotating parts, etc.
OVERHAUL CRITERIA
CONDITIONS WHICH DETERMINE WHEN A TURBOCHARGER

OVERAHUL MAY BE NEEDED.
THE ENGINE LACKS POWER OR ENGINE EXHAUST EMITS
BLACK SMOKE.
BOOST PRESSURE IS BELOW THE NORMAL VALUE.

Inspect the turbocharger boost pressure according to the
following procedures.
NOTE: Before measurement
°
o Coolant temperature should approximately 80 C.
o Air cleaner element should be clean.
WARNING
When making a pressure test, be sure that personnel are adequate
ly protected against any stream of pressurized air that might be
released by a leak or the rupture of a hose.
TURBOCHARGER . TC-5
1. Remove the blind plug on the intake pipe and install the hose
and pressure gauge (special tools).
Special Tools: Pressure Gauge (09444-1250)
Hose ( 17108-1040)
2. Disengage the clutch and run the engine at maximum rpm.
Do
Boost pressure hose

SM51-001
3. Read boost pressure.

It the boost pressure is below the normal value, turbocharger
overhaul is needed.
Boost Pressure: Less than 0.16 kg/cm 2
OTHER FACTORS
1. Noisy of excessive vibration of the turbocharger.
2. Excessive engine oil consumption.
3. Gas leakage at the turbine end or blower end.
SM51-016
4. Oil leakage from the turbocharger.
SPECIAL TOOL
Prior to starting an turbocharger overhaul, it is necessary to have these special tools.
ATTACHMENT FOR MEASURING

TURBINE SHAFT RADIAL PLAY BOOST PRESSURE GAUGE BOOST PRESSURE GAUGE HOSE
09444-1230 09444-1250 17108-1040

TC-6 TURBOCHARGER
TURBOCHARGER
1881J
1-No. 20
16
T = Tightening torque: kg-cm (lb.ft)
1. Retainer ring 7. Journal bearing 13. Turbine rotor assembly

2. Oil thrower 8. Thrust spacer 14. Heat protector
3. Seal ring 9. Thrust bearing 15. Bearing case
4. Seal plate 10. Blower impeller 16. Plate
5. Lock plate 11. Lock nut
6. Blower case 12. Turbine case
IMPORTANT POINT (S) - BEFORE DISASSEMBLY
1. Rotate the blower impeller by hand to see if it turns smoothly.

If it does not turn smoothly, clean and inspect the bearing and
turbine rotor.
SM51-002A
2. Check the turbine rotor for axial play (A).

If the axial play is greater than the service limit, replace the
thrust bearing and/or thrust spacer.
Axial Play: 0.06 - 0.09 mm (0.0023 - 0.0035 in)
Service Limit: 0.11 mm (0.0043 in)
SM51-002
TURBOCHARGER TC-7
3. Check the turbine rotor for radial play using a special tool.
If the radial play is greater than the service limit; replace the
bearings and/or turbine rotor.
Special Tool: 09444-1230
Radial Play: 0.11 - 0.18 mm (0.004 - 0.007 ii'!)
Service Limit: 0.215 mm (0.0085 in)
SM51-002A
REMOVE THE BLOWER CASING.

NOTE: o Make matching marks on the blower case and bearing
case to aid alignment during reassembly.
o If the blower casing cannot easily be removed by hand,
tap it carefully all around using a plastic hammer and
carefully remove it.
o Be careful not to damage the blower impeller.
REMOVE THE BLOWER IMPELLER.

1. Remove the blower impeller fitting nut.
NOTE: Turn the lock nut clockwise to loosen the nut (left-hand
threads).
2. Remove the blower impeller by hand.
SM51-018
REMOVE THE TURBINE CASING.

NOTE: o Make matching marks on the turbine case and bearing
case to aid alignment during reassembly.
o Because the bolts on the turbine side are exposed to high
temperature, if they have seized, do no apply an
unreasonable force to remove them because they may
break. Spray a lubricant onto them, then wait for about
15 minutes and loosen them.
o Be careful not to damage the turbine blades.
o If the turbine casing cannot easily be removed by hand,
tap it carefully all round using a plastic hammer and
carefully remove it.
REMOVE THE TURBINE ROTOR WITH HEATER PROTECTOR.
REMOVE THE BEARINGS.
1. Remove the holding plate.
NOTE: Mark one side of the holding plate so that it can be replaced
in the proper direction during assembly.
SM51-020
TC-8 TURBOCHARGER
2. Remove the seal plate.

Pull out the seal plate using the attachment and a sliding
hammer.
3. Remove the oil thrower from the seal plate.
4. Remove the thrust bearing and thrust spacer.

Loosen the bolt, then remove the thrust bushing using a
10 dia. copper rod.
NOTE: When removing the thrust bearing and thrust spacer, be
careful not to damage the thrust bearing hole in the bearing
case.
5. Remove the retainer rings of each bearing.

NOTE: When removing the retainer ring, be careful not to damage
the front face of the hole in the bearing case.
6. Remove the bearings.
REMOVE THE SEAL RINGS.

NOTE: When removing the seal ring, be very careful not to damage
the groove of the seal ring.
SM51-025
IMPORTANT POINT (S) -ASSEMBLY
CLEAN ALL PARTS.

1. Before cleaning, the disassembled parts should be visually
inspected to check for burning, abrasion, carbon deposits,
gas and oil leakage.
2. Thoroughly clean all the parts with diesel fuel, using a soft
brush, and dry with compressed air.
NOTE: o Never use a caustic cleaning solution, as it may attack
aluminum.
o Never use a wire brush.
TURBOCHARGER TC-9
OIL INLET ASSEMBLE THE JOURNAL BEARINGS.

0
1. Install the first retainer ring in the bearing casing.
NOTE: o Bevelled edge of the retainer ring should be towards the
bearing.
o Make sure that the retainer ring is securely fitted in the
groove.
o Install the retainer ring with the gap facing as shown in
the drawing.
2. Install the bearing in the bearing case.

NOTE: Apply clean engine oil.
3. Install the other retainer ring.
NOTE: The only nearest turbine side of the retainer ring should
OIL OUTLET
be installed according to the figure on the left.
4. Repeat step 1) through 4) to install the second bearing.
OIL INLET
�VIEWFROM
TURBINE ROTOR
�
SM51-026
ASSEMBLE THE THRUST BEARING;

2
1. Install the thrust spacer on the turbine shaft.
NOTE: Lubricate thrust spacer surface.
2. Coat the thrust bearing with clean engine oil and install the
thrust bearing.
NOTE: Always use new screws and lock washers.
SM51-027
--'
BEAR ING CASE ASSEMBLE THE TURBINE ROTOR.
1. Install a new seal ring in the seal ring groove of the turbine
shaft.
SEALRIN -;Ji- _
-�
Q
� 2. Install the holding plate.
_\-{:) il ,· W--- Ll 3. Position the heat protector on the bearing case.
-�
'"'<>J" \
\ ��,� _("\ _::J \
HOLDING PLATE
HEAT PROTECTOR
TURBINE SHAFT
4. Coat the journals of the turbine rotor with clean engine oil
and install the turbine rotor in the bearing case.
NOTE: o The gap in the seal ring of the turbine shaft must face
towards the oil inlet.
o Insert the seal ring concentric with the turbine shaft. If
it is inserted with unreasonable force, it may be
damaged.
o When inserting the turbine shaft, be very careful not to
damage the journal bearing.
SEAL RING GAP
SM51-029
TC-10 TURBOCHARGER
INSTALL THE SEAL PLATE.

1. Insert two new seal rings on the oil thrower.
2. Install the oil thrower in the seal plate.
NOTE: The openings of seal rings should be positioned as shown.
SM51-024 SM51-005A
3. Install the seal plate in the bearing case.

NOTE: o The oil return hole should face the oil outlet side.
Apply silicone R.T.V. sealer to the flanged surface of
the seal plate.
o Take care that the silicone sealer does not protrude from
the flange.
4. Tighten the four screws with lock washers.
NOTE: Always use new screws and washers.
SM51-030
FIT THE BLOWER IMPELLER ON THE TURBINE ROTOR AND

TIGHTEN THE LOCK NUT.
NOTE: Remember that this nut has left-hand threads.
SM51-031
INSTALL THE TURBINE CASE TO THE BEARING CASE, BEING

SURE TO ALIGN THE MATCHING MARKS.
NOTE: Always use new lock plates.
ASSEMBLE THE BLOWER CASE.

1. Install the blower case to the bearing case referring to the
matching marks.
NOTE: Coat the flange face of the blower case with silicone R.T.V.
sealant.
SM51-032
2. Tighten the six fitting bolts.
ASSEMBLY TEST
1. Rotate the blower impeller by hand to see if it turns smoothly.
Refer to page TC-6.
2. Check the turbine rotor for axial play (A).
Refer to page TC-6.
3. Check the turbine rotor for radial play using a special tool.
Refer to page TC-7.
TURBOCHARGER TC-11

Unit: mm (in)
Turbine Shaft Diameter 12.28 Replace

(0.4835)
Turbine Shaft Bend 0.011 Replace

(0.0004)
Seal Ring Groove Width 1.63 Replace shaft

of Turbine Shaft (0.0642) assembly.
Bearing Case Inside A: Replace

Diameter 18.55
(0.7303)
B:
17.11
(0.6736)
Journal Bearing Inside 12.36 Replace

Diameter (0.4866)
Journal Bearing Outside 16.98 Replace

Diameter (0.6685)
Thrust Spacer Height 4.68 Replace

(0.1843)
SM51-007
Seal Ring Groove Width G1: Replace G1 G2

of Oil Thrower 1.75
(0.0689)
G2:
1.52
(0.0598)
SM51-006A
TC-12 TURBOCHARGER

Unit: mm (in)
Thrust Bearing Thickness 4.48 Replace

(0.1764)
SM51-038
Sealing Bore of Seal Plate H1: Replace H1
16.05
(0.6319)
H2:
14.05
H2
(0.5531)
SM51-006B
Hino Engine Parts

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HIND

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Hino Engine Parts

mm (in), m (ft), km (mile)

GENERAL INSTRUCTIONS ................................... 1-1

CHASSIS & ENGINE SERIAL NUMBERS .......................... 1-2

BOLT TIGHTENING ........................................ 1-7

Fig. 1-1 03-2252

ENGINE SERIAL NUMBER

HIND EPlOOT 8.821 liters, 4-cycle,

APPLICATION: ELECTRICAL GENERATORS, WATER PUMPS, AIR COMPRESSORS, HYDRAULIC

e PERFORMANCE & PERFORMANCE CURVE (STD. specs.)

Ambient conditions: SAE DIN

NOTE: 1 i These specifications are subject to change without notice.

HIND MOTORS, LTD. TOKYO, JAPAN

Cast iron or aluminium tightening

Tightening area having black coarse

Even tightening area. Bolt nut, coating,

Cast iron or aluminium tightening

Tightening area having black coarse

0 Even tightening area. Bolt nut, coating,

COOLANT PUMP Marfak

GENERATOR & STARTER Generator Bearing RPM Grease --- ---

INJECTION PUMP Mar1ak

ENGINE OVERHAUL CRITERIA

CYLINDER BLOCK, PISTON AND CRANKSHAFT

TUNING THE ENGINE

A GLOSSARY OF TECHNICAL TERMS

ENGLISH ESPANOL FRANCA IS

44. Inner spring 42. lncorrecto 42. lncorrect(e)

ENGINE {Model EP100T)

The terms adopted in this Workshop Manual are defined as follows.

DATA & SPECIFICATIONS

CYLINDER BLOCK, CYLINDER LINER AND CAMSHAFT

Hino Engine Parts

CONNECTING ROD AND PISTON

CRANKSHAFT AND CRANKSHAFT BEARING

PERFORMANCE & PERFORMANCE CURVE

NOTE: Outputs are converted to SAE J1349 standard ambient conditions;

Barometric pressure 100 KPa

600 450 0 <(0

200 150 I- a.. u

::::> 0 ::i 140

Fig. 3-1-1 Engine perfomance curves

Output, intermittent rating PS (KW) at rpm 188 (138.3) at 2,200 rpm

NOTE: Outputs are converted to DIN 6270 standard ambient conditions;

1,000 1,200 1,400 1,600 1,800 2,000 2,200

LEFT SIDE VIEW

(Remarkable tightening torque positions)

¢12P1.75 1,100-1,200 kg·cm

I ¢10P1.5 I 300-500 kg•cm I

¢14P2 1,000-1,300 kg-cm

¢16P1 .5 2,600-2,900 kg•cm

c/J22P1.5 5,500-7,000 kg•cm

,,....._--------1 ¢30P1 .5 I 1,000-1,200 kg•cm I SM3-588

¢8 P1.25 190-270 kg•cm

q,14 P2.,0 1, 100-1,500 kg•cm

¢16 P2.0 2,700-2,900 kg•cm

Illustration Tool No. Tool name Usage

/ 09442-1200 ./PISTON RING For removing and install the

For installing or removing

For removing the nozzle holder

0�402-1140. PRESS For camshaft end plug