WORKSHOP MANOAL
GENERAL INTRODUCTION
GENERAL INTRODUCTION
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1
GI-S176E-01
CHAPTER GI
GENERAL INTRODUCTION
GENERAL PRECAUTIONS.........................GI-2
HOW TO USE THIS WORKSHOP MANUAL.............GI-3
IDENTIFICATION INFORMATION .................GI-4
TIGHTENING TORQUE OF STANDARD BOLT..........GI-5
RECOMMENDED LUBRICANTS......................GI-6
GI-2
GENERAL INTRODUCTION
GENERAL PRECAUTIONS
Some recommended and standard maintenance services for your vehicle are mentioned in this section.
When performing maintenance on your vehicle be careful not to get injured by improper work.
Improper or incomplete work can cause a malfunction of the vehicle which may result in personal injury and/or property
damage.
WARNING
When working on your vehicle, observe the following general precautions to prevent personal injury and/or property
damage in addition to the particular NOTES or WARNINGS.
Most threaded fasteners are metric.
Be careful not to mix with threaded fasteners using the inch system.
О Always wear safety glasses or goggles to protect your eyes.
О Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.
О Bind long hair securely behind the head.
О To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator,
muffler, exhaust pipe and tail pipe.
О Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when
the engine is running.
О Always stop the engine by pulling out the engine stop knob. Leave the knob pulled out as long as the engine
is stopped. And turn off the starter switch, unless the operation requires the engine running. Removing the
key from the switch is recommended.
О Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide.
О Do not smoke while working on the truck since fuel and gages from the battery are flammable.
О Take utmost care when working on the battery. It contains corrosive sulfuric acid.
О Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which
can result in personal injury and/or property damage.
О Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts and can
cause personal injury.
GENERAL INTRODUCTION
GI-3
HOW TO USE THIS WORKSHOP MANUAL.
This workshop manual is designed as a guide for servicing
vehicle.
An INDEX is provided on the first page of each chapter.
TROUBLESHOOTING is dealt with each chapter.
When beginning operations, refer to the sections on for a
guide to appropriate diagnoses.
SPECIAL TOOLS are dealt with in each chapter.
When ordering a special tool, make sure that the parts number
is correct.
REPAIR PROCEDURES
Repair procedures which are self-explanatory such as simple
installation and removal of parts have been omitted. Illustra-
tions such as the one below have been provided to make such
simple procedures clear. Only essential procedures requiring
directions have been dealt with explicitly.
EXAMPLE:
TIMING GEAR AND CAMSHAFT
1.	Thrust bearing	5.	Bushing	9.
2.	Camshaft gear	6.	Idler gear thrust plate 10.
3.	Oil pump drive gear 7.	straight pin	11.
4.	Idler gear	8.	Idler gear shaft	12.
Crankshaft gear	13. Front end plate gasket
Injection pump drive gear 14. Front end plate
Idler gear thrust plate
Camshaft
GI-4
GENERAL INTRODUCTION
In some cases, illustrations may be of parts which differ in
some nonessential way from the parts found on your par-
ticular vehicle. In such cases, however, the principale or
procedure being illustrated applies regardless of such non-
essential differences.
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBERS.
Please quote these numbers when ordering spare parts or
reporting technical matter as they will give you prompt service
attention.
The engine serial number is engraved on the engine cylinder
block.
TIGHTENING TORQUE OF STANDARD BOLT	Unit ,kgtcm,
ilbf-ft '
Bolt identifi- cation	Bolt diameter (mm) Tightening conditions	4	6	8	10	12	14	16	18	20	22	24
	Even tightening area. Bolt nut, coating, naked bolt, lubricant, etc. Optimum conditions.	0.99-1.47 f 10-15 t t 0.8-1.0 J	3.54-5.19 r 36-53 । I 2.7-3.8 J	8.63-12.55 j 88-128 t t 7-9 J	17.07 - 25.00 r 174-2551 I 13-18 7	29.82 - 43.63 Г 304 - 445, 1 1 22 - 32	1	47.67 - 69.82 ( 486 - 712 1 7 36-51	74.34- 108.85 ( 758-1,110 1 7 55-80 7	101.99-150.04 (1,040-1,5301 7 76-110 7	145.14 - 212.81 (1,480-2,170) 7 108-156 J	199.08-292.23 (2,030 - 2,9801 7 147-215 7	251.06-367.74 (2,560-3,7501 7 86-271 7
o1	Cast iron or aluminum tightening surface. Washers. Medium conditions.	1.38-1.96 {	4.71-6.96 j 48-71 . 1 3.5-5.1 J	11.48-16.86 у 117-172 . 1 9-12 J	22.76 - 33.34 , 232-340 i i 17-24 7	39.72 - 58.05 r 405 - 592, 1 1 30 - 42	1	63.45-93.16 ( 647 - 950 1 1 47 - 68 f	99.05-145.13 (1,010-1,4801 7 74- 107 7	136.32-200.05 (1,390-2,0401 7 101-147 7	193.20-284.39 (1,970 - 2,9001 7 143-209 7	264.78 - 389.32 ( 2,700 - 3,9701 7 196-287 1	334.41 - 490.33 (3,410-5,0001 7 247 - 361 7
	Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions.	1.67-2.45 ( 17-25. 7 1.3- 1.8 J	5.89 - 8.62 I- 60-88 . 1 4.4-6.3 7	14.32-20.98 r 146-2141 i 11-15 J	28.44-41.67 < 290 - 425 i I 21-30 7	49.63 - 72.76 r 506 - 742, I ' 37 - 53 1	79.34-115.71 f 809-1,180 1 7 59-85 7	123.57-181.42 (1,260-1,850) 7 92-133 '	170.64-249.08 (1,740 -2,540 \ 7 126-183 7	241.25-355.00 (2,460 - 3,6201 7 178-261 ’	331.47-485.42 (3,380-4,9501 7 245 - 358 7	417.77-612.91 ( 4,260 - 6,2501 7 309 - 452 7
rll	Even tightening area. Bolt nut, coating, naked bolt, lubricant, etc. Optimum conditions.	1.57-2.35 { 16-24. 1 1.2-1.7 f	5.69-8.13 r 58-83 . t 4.2-6.0 J	13.54-19.71 r 138-201 i i 10-14 J	26.78 - 39.22 । 273 - 400 i l 20-28 7	46.78 - 68.64 ( 477-700, | 1 35-50	1	74.93-109.83 ( 764-1,120 1 7 56-81	7	116.70-171.61 (1,190-1,7501 7 87-126 7	160.83-235.35 (1,640 - 2,4001 7 119+ 173 7	227.52 - 334.40 (2,320-3,4101 7 168-246 7	311.86-458.95 (3,180-4,6801 7 231 -338 7	394.23 - 525.63 ( 4,020 - 5,3601 7 291 -387 7
	Cast iron or aluminum tightening surface. Washers. Medium conditions.	2.16-3.13 ( 22-32 ) i 1.6-2.3*	736-10.78 < 75-110 . l 5.5-7.9 J	17.95 - 26.47 r 183-2701 l 14-19 J	35.70 - 52.26 < 364 - 533 i i 27-38 7	62.38-91.39 ( 636 - 932, j 1 47 - 67 Г	100.03-147.09 (1,020 — 1,5001 7 74-108 7	155.93-228.49 f 1,590-2,3301 7 116-168 ;	213.79-313.81 (2,180-3,2001 7 158-231 7	304.01 - 446.20 (3,100-4,5501 7 225-329 7	416.79-608.99 (4,250-6,2101 7 308-449 7	525.64-769.82 f 5,360 - 7,850 i 7 388 - 567 7
	Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions.	2.65-3.92 r 27 - 40 . i 2.0-2.8 7	9.22 -13.53 г 94-138 । t 6.8-9.9 J	22.46 - 32.95 . 229 - 336 , I 17-24 J	44.63-65.41 r 455-667 1 : i 33-48 7	77.97-114.24 f 795 -1,165, I 7 58-84 *	124.55-183.38 (1,270-1,8701 7 92-135 7	195.16-286.35 (1,990-2,9201 7 144-211 7	267.73-392.26 (2,730-4,0001 7 198-289 7	379.52 - 557.01 (3,870-5,6801 7 280-410 7	521174-764.91 (5.310-7,8001 7 385 - 564 7	657.05 - 965.95 ( 6,700 - 9,850 1 7 485-712 7
	Even tightening area. Bolt nut, coating, naked bolt, lubricant, etc. Optimum conditions.	2.36-3.13 { 24-32 . 1 1.8-2.3 J	8.05 -10.78 r 82-110 > I 6.0-7.9 J	19.62 - 26.18 ,200 - 267 1 I 15-19 7	38.94 - 56.29 f 397-5741 I 29-41 7	2 1 1	99.05-145.13 (1,010-1,9801 7 74-107	169.66-226.53 (1,730-2,3101 7 126-167 7	233.40-310.87 (2,380-3,170) 7 173-229 7	331.47-442.27 (3,380-4,5101 7 244-326 7	454.05 - 605.07 (4,630-6,1701 7 335 - 446 7	573.69 - 763.93 (5,850-7,7901 7 424-563 ’
	Cast iron or aluminum tightening surface. Washers. Medium conditions.	3.14-4.11 J 32"421 1 2.4 -3.0 J	10.79-14.31 r 110- 146j i 8.0- 10.5 J	26.19-34.91 , 267 - 356 i ' I 19-25 7	51.88-69.23 , 529-7061 I 39-51 7	90.72 - 120.62 г 925-1,230, 1 7 67-88 *	145.14- 193.19 (1,480-1,9701 7 108-142 7	226.54-302.04 (2,310-3,0801 7 168-222 7	310.88-414.82 (3,170-4,230) 7 230-305 7	442.28-589.37 (4,510-6,0101 7 327 - 434 7	605 .08 - 807.08 (6,170-8,2301 7 447 - 595 7	763.94-1,018.91 (7,790-10,390 i 7 564-751 7
	Tightening area having black coarse surface. Rusty. Naked bolt or lubricant unavailable. Poor tightening conditions.	3.93-5.19 . 40-53 . 1 2.9-3.8 7	13.44-17.94 г 137-183-. 110.0- 13.2J	32.76-43.63 r 334 - 445 i I 25 - 32 7	64.93 - 86.49 r 662 - 882 i I 48-63 7	113.76-151.02 (1,160- 1,540,1 7 84-111 7	181.43-242.22 (1,850 - 2,4701 7 134-178 7	283.42 - 377.55 ( 2,890 - 3,8501 7 210-278 7	389.33-518.77 ( 3,970 - 5,2901 7 288 - 382 7	553.10-736.47 | 5,640-7,5101 7 408 - 543 7	757.08-1,009.10 (7,720-10,2901 7 559-744 7	955.17-1,273.88 (9,740-12,9901 7 705 - 939 7
NOTE: The torque values given in this table should be applied where bolt torque is not specified.
GENERAL INTRODUCTION	G1-5
Hinti
RECOMMENDED LUBRICANTS FOR ALL HINO VEHICLES
LUBRICANTS	POSITIONS	ATMOS- PHERIC TEMP.	S.A.E. NO.	BP	CALTEX	CASTROL	ESSO	GULF	MOBIL	SHELL	TOTAL
ENGINE OIL (A.P.l. CO) Previous Classification (A.P.l. OS) (MIL-L-2104C) (MIL-L-45199B)	Cylinder Block injection Pump Air Cleaner	Above 32'C (90'F)	40	Vanellus C-3 40	RPM DELO 400 Oil SAE 40 or 15W/40 RPM DELO 300 Oil SAE 40	Castrol or Deusol CRD 40.Turbomax Castrol or Deusol Rx Super 40.1 5W/40	Essolube D-3 40. XD-3 40	Guff Super Duty Motor Oil 40, 15W-40	Mobil Delvac 1340 Mobil Delvac Super 1 5W-40	Mynna Oil 40. 20W-40.15W-40 Rimula X Chi 40 Rimula CT 40	TOTAL Rubia S 40 TOTAL Rub»a TM 15W40
		32'~0'C (90' 32'F)	30	Vanellus C-3 30	RPM DELO 400 Oil SAE 30 or 15W/40 RPM DELO 300 Oil SAE 30	Castrol or Deusol CRD 30 Castrol or Deusol RX Super 30.15W/40	Essolube D-3 30. XD-3 30	Gulf Super Duty Motor OH 30.1 5W-40	Mobil Delvac 1330 Mobil Delvac Super 15W-40	Myrina Oil 30. 20W-40.15W-40 Rimula X 0*1 30. 10W-30 Rimula CT30	TOTAL Rubia S 30 TOTAL Rubia TM 15W40
		O' - 12'C (32‘ 10'F)	20	Vanellus C-3 20W	RPM DELO 400 Oil SAE 20/20W. 15W/40 RPM DELO 300 Oil SAE 20/20W	Castrol or Deusol CRD 20W/20 Castrol or Deusol RX Super 20W/20. 15WZ40	Essolube D-3 20W. XD-3 15W-40	Gulf Super Duty Motor 0H20.15W-40	Mobil Delvac 1310 Mobil Delvac Super 15W-40	Myrina Oil 20. 20W-40.15W-40 Rimula X OH 20 Rimula CT20	TOTAL Rubia S 20 TOTAL Rubia TM 15W40
ENGINE OIL (A.P.l CC) Previous Classification (A PI. DM) (MIL-L-46152) (MIL-L-2104B)		Above 32'C (90'F)	40	Vanellus M 40	RPM DELO 200 Oil SAE 40 RPM DELO 100 Oil SAE 40	Castrol or Deusol CRX 40 Castrol or Deusol RX Super 40.15W/40	Essolube HDX 40. HDX Plus 40	Gulflube Motor 0>l XHD40.15W-40	Mobil Delvac 1240 Mobil Delvac 1140	Rotella TX40.20W-50 Rotella SX Oil 40. 20W-40	TOTAL Rubia H 40
		32- 0-C (90' 32'F)	30	Vanellus M 30	RPM DELO 200 Oil SAE 30 RPM DELO 100 Oil SAE 30	Castrol or Deusol CRX 30 Castrol or Deusol RX Super 30.1 5W/40	Essolube HDX 30. HDX Plus 30	Gutflube Motor Oil XHD 30. 15W-40	Mobil Delvac 1230 Mobil Delvac 1130	Rotella TX30.20W-50 Rotella SX Oil 30, 20W-40	TOTAL Rubia H 30
		O' 12'C (32' 10’F)	20	Vanellus M 20W	RPM DELO 200 Oil SAE 2O/2OW RPM DELO 100 Oil SAE 20/20W	Castrol or Deusol CRX 20W/20 Castrol or Deusol RX Super 20W/20. 15W/40	Essolube HDX 20, HDX Plus 2OW-2O	Gulflube Motor Oil XHD 20.15W-40	Mobil Delvac 1220 Mobil Delvac 1120	Rotella TX20.20W-50 Rotella SX Oil 20/20W.20W-40	TOTAL Rubta H 20
COOLANT PUMP BEARING GREASE (MIL-G-109248)	Coolant Pump Bearing			Energrease L-2	Marfak Multipurpose 2 or Mariak Ait Purpose 2	Castrol LM Grease	Esso Multipurpose Grease	Gulflex Poly	Mobilgrease MP.77.MS	Rettnax A Alvania Grease R2	TOTAL MULTIS 2
STARTER GREASE	Bushing. Clutch. Dnve Shaft. Pinion Shift Lever & Reduction Gear			—	Molytex Grease EP2	—	—	—	Mobtlgrease 29	Aero Shell Grease 17	—
GENERATOR & STARTER BEARING GREASE	Generator Bearing Starter Bearing			Energrease LT 2	RPM Grease SRI 2				—	—	Mobilgrease 28	Aero Shell Grease 7	—
INJECTION PUMP TIMER GREASE (MIL-G- 10924B)	Injection Pump Timer			Energrease L-2	Marfak Multipurpose 2 or Marfak AH Purpose 2	Castrol LM Grease	Esso Multipurpose Grease	Gulflex Poly	Mobiigrease MP.77.MS	Retinax A Alvania Grease R2	TOTAL Multis EP 1
ANTI FREEZE (MIL-H-5559A)	Engine. Radiator			Ann Frost	AF Engine Coolant	Castrol Anti-Freeze Castrol Long Ute Coolant	Esso Anti Freeze Coolant	Cruise Master Antifreeze And Summer Coolant	Mobil Permazone	ShellzonelU.S A.) Glycoshell Plus (Europtan Countries) Shellsafe Anti-Freeze P281 Coolguard	TOTAL ANTIGEL
Note: Lubricants were amended according to new classification by A.P.l. (American Petroleum Institute)
'82-12-200 CT.S.DX*)
GI-6	GENERAL INTRODUCTION