FOREWORD

This workshop manual has been prepared to provide information covering repairs on 2003 FD, FE, and SG series Hino trucks.

To use Hino trucks for years, smoothly, safely, and economically without trouble, it is important to perform inspections.

Maintenance required to be performed is the responsibility of the owner. Some recommended repairs of your truck are mentioned.

When making any repair of your truck, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner's and Driver's Manual.

All information and specifications in this manual are based upon the latest product information available at the time of printing.

HINO DIESEL TRUCKS (U.S.A.),INC. reserves the right to make changes at any time without prior notice.

S1134E-181

GENERAL lNTRODUCTtON

CLUTCH

CLUTCH CONTROL

TRANSMISSION CONTROL

PROPFI.I FR SHAF•T

hRONT AXLE

STEERING

SERVICE BRAKE

EXHAUST BRAKE

WHEELS & TIRES

16

17

ELECTRICAL EQUIPMENT

ALTERNATOR STARTER COMPRESSOR

TURBOCHARGER

POWER STEERING

WORKSHOP MANUAL

e2003 Hl¥0 BIESEL RU¢kS(U.S.A.),I¥C.

AUTOMATIC TRANSMISSION ANTILOCK BRAKE SYSTGM TOTAL ELECTRONiCS SYSTEM SERVICE SPECIFICATIONS

WIRING DIAGRAMS

75

All rights reserved. This manual may not be reproduced or copied in whole or in part, without the written consent of HINO DIESEL TRUCKS (U.S.A.),INC.

Models FD, FE and SG GENERALINTRODUCTION J-1

1-218E•06

CHAPTER I

GENERAL INTRODUCTION

Models FD, FE and SG

IDENTIFICATION INFORMAT

1•2 GENERAL INTRODUCTION Models FD, FE and SG

IDENTIFICATION INFORMATION

1. VEHICLE IDENTIFICATION NUMBER

   VEHICLE IDENTIFICATION NUMBER (VIN) is comprised of 17 digits and letters. The VIN plate, as shown in Fig. 1, is affixed to the left-side door step of the cab.

   The following is an explanation of the items that are listed on the VIN plate.

   
   

   
   

   P.S. CODE SQ

Fig. 1

1. VIN

   See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page.

   MODEL SERIES	P.S. CODE	CLUTC I SIZE	TRANS- MISSION SERIES	IST	TRANSMISSION RATIO 2ND 3RD 4TH STH	6TH	REAR AXLE SERIES	REAR AyLg RATIO	SERVICE BRAKE	PARK- ING BRAKE
   FA4J	SA-HC6 OA-Jc6	350 MM -	LFOSS AT545	7.46 3.45	4.18 2.42 1.42 1.00 2.25 1.41 1.00 -	- -	GH13-2 SH13•2	3.36 3.36		c
   FB4J	sA-I-iC6 SA-IGA	3s0MM -	LFOSS AT545	7.46 3W	4.IB 2.42 1.42 1.0tl 2.25 1.41 1.00 -	- -	SH13-2 SH13•2	3.36 3.36	A
   FD2J	SA-GF6 SA-TF6	350 MM -	LF08S LCT2400	6.00 3.51	3.86 Z 4 1.42 1.00 1.90 1W 1.00 0.74	0.76 -	SH14-1 SH14-1	5.12 4.33	A A	c c
   FE2J	SA QF6 SA•RF6	350 MM -	LJOBS LCT2400	6.00 3.51	4.27 Z80 1.56 1.00 1.00 1.44 1.N 0.74	0.77 -	SH14-1 SH14-1 ‘	5.12 5.85	A
   	SA•TS6	380MM	MF06S	7.39	4.75 3.07 1.93 1.34	1.00	SH16-1	J.10”	F	W
   SG1J	SAWs6 SA-VS6	- 380MM	MDSOOOP RT8709	3.4B 9.16	1.86 1.41 1.00 0.75 6.53 4.80 3.57 2.56	- 1.83	SH16•1 SH16-1	5.42 4.10	F F	W W

2. P.S.CODE AND VEHICLE COMPONENTS

A

A

CODE

SERVICE BRAKE CONTROL CODE V : VACUUM SERVO

A : AIR OVER HYDRAULIC F : FULL AIR

PARKING BRAKE CONTROL CODE

C : ACTING ON TRANSMISSION OUTPUT SHAFT W: ACTING ON REAR WHEEL

VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE

  WMI                  VDS    

’12) l*j''(•)(s)(6) r)()

C / D                       VIS                

" (9) ' -(10) (IN)’ ”' ('12) " (13)" (14) (15j \1e› t17) '

SEQUENTIAL NUMBER

ASSEMBLY

PLANT

MOD F CAT ON

----' CODE

S

T

u

DESCRIPTION

,

,

A NEW LETTER WILL BE ALLOTED AT EVERY MAJOR MODIFICATION

E 6 CAB/BODY TYPE, IES, BRAKE SYSTEM

ISNO

EL ESLH B S

CHEC DI IT

'

'.w..-...........................w. w....-

Models

, ,

’-“- -”-”-““-”-” "-”-“““‘“""“”,

¡

COOE	LINE & CAB/BODY TYPE	SERIES GVWR OR OVERALL LENGTH	BRAAE SYSTEMS
FA	FORWARD CONTROL TYPE	6,350 kg-7,030@	HYDRAULIC
FB	PORWARO CONTROL TYPE TRUCK	7,258 kg-8,165kg [16,001-IN.000 (lbs.) ) (CLASS 5)	AIR OVER HYDRAULIC
FD	FORWARD COhTROL TVPE TRUCK	8,865 kg-J0,433@ [19,501-23,000 (I08.) ] (CLASS 6)	AIR OVER HYDRAULIC
FE	FORWARD CONTROL TYPE MUCK	10,434 kg-11,795kg [23.%1-26.fXQ (lbs.j j ‹cess gj	AIR OVER HYDRAULIC
	FORWARD CONTROL TYPE TRUCK	13,809 kg-14,988kg [30,o‹i1-33,000 (lb6.) ] (CLAss 7)	FULL AIR

!

FD,

FE

and

¡

1•4 GENERAL INTRODUCTION

T›«g vt«i taE0»4ALa0C1O2aur0C«rMr izsocsoTMAPutngAT«¥Oo

Models FD, FE and SG

- EXAMPLE -

Fig. 2

SM1-060E

1. VEHICLE CERTIFICATION LABEL

   The Vehicle Certification Label, as shown in Fig. 2, is affixed to the left hand side door of the cab. The name of manufacturer, production year and month, and verifica- tion of items which are in conformity with Federal Motor Vehicle Safety Standards are displayed.

   
   

   ENGINE MODEL: J-SERIES ENGINE

   NUMBER

   SM1-J014

   cunssis NUMBEn

2. ENGINE NUMBER

   The Engine Number, as shown in Fig. 3 is on the right side of the engine block.

   
   

3. CHASSIS NUMBER

The Chassis Number is displayed on the left siderail of

the frame near the front axle, as shown in Fig. 4.

Models J08C-TP and J08C-TR

CHAPTER É

Models: J08C-TP and J08C-TR

TROUBLESHOO SPECIAL TOO

ENGINE OVERHAUL CRITE DISNIOUNTING THE ENGINE ASSEMB

ENGIXE 3-1•1

3-228E-06

2-1

REMOVAL OF THE ENGINE COMPONENT PARTS ............... 3- 5-1 CAMSHAFT HOUSING AND CYLINDER HE

CRANKSHAFT FRONT END, OIL PAN, FLWHEEL AND FLYWHEEL H 3- 7-1

TIMING GEA 3- 8-1

PISTON, CRANKSHAFT AND CYLINDER BLOCK .................3- 9-1 LUBRICATING SYSTE 10-1

COOLING SYSTE 11-1

AIR INTAKE AND EXHA

ENGINE CONTROL SY 3-14-1

ELECTRICA 3-15-1

AIR COMPRESSOR AND POWER STEERING PUMP 3-16-1

INSTALLATION OF THE ENGINE COMPONENT PARTS 3-17-1

ENGINE 18-1

MOUNTING OF THE ENGINE ASSEM

LIQUID GASKET AND APPLICATION POIN POWER TAKE-OFF (I

20-1

21-1

3-1-2 ENGINE Models J08C-TP and J08C-TR

SymQIOIZl

Engine overheating

Models J08C-TP and J08C•TR

TROUBLESHOOTING

(ENGINE)

Possible cause

C o ant

ENGINE 3-1-3

Remedy/Prevention

• Insufficient coolant ....................,....,. Add coolant

• Defective thermostat Replace the thermostat

• Overflow of coolant due to leakage of Repair

  exhaust into cooling system

• Damaged rubber hose Replace rubber hose

• Coolant leakage due to deteriorated. Replace rubber hose

  rubber hose

  s Coolant leakage from coolant pump Replace the coolant pump

• Coolant leakage from rubber hose Retighten or replace clamp

  connection

  e Coolant leakage from cylinder head Replace gasket

  gasket

  
  

  Coo nt pu p

  e Bearing seizure Replace

• Damaged (corroded) vane Replace vane

  
  

  Roaatodr

  e Clogged with rust and scale. Clean radiator

  • Clogged with iron oxide due to leakage „...,.. Clean coolant passage and of exhaust into cooling system correct exhaust leakage

• Coolant leakage Repair or replace radiator

  c Damaged cooling fan Replace cooling fan

• Clogged radiator core due to mud or Clean radiator

  other debris

  e Defective radiator cap pressure valve Replace radiator cap

  
  

  Abnormal combustion

e Incorrect injection timing Adjust injection timing

• Reduced injection pressure Adjust injection pressure

e Poor fuel. Use good quality fuel

e Poor nozzle spray Adjust or replace nozzle

• Unsatisfactory automatic timer. Repair or replace timer

advance angle

3-1-4 ENGINE

Symptom

Engine overheating

Models J08C-TP and J08C-TR

Possible cause Remedy/Prevention

Other problems

Defective or deteriorated engine oil Change engine oil

Unsatisfactory operation of oil pump Replace or repair

Insufficient oil ...............,. Add oil

Brake drag .......,. Adjust

Excessive oil consumptior›

Wear of piston rings and cylinder liner. Replace piston rings and

cylinder liner

Worn, sticking or broken piston rings. Replace piston rings and

cylinder liner

Insufficient tension on piston rings Replace piston rings and

cylinder liner Unsatisfactory break-in of piston rings. Replace piston rings and

cylinder liner

Unsuitable oil (viscosity too low) ......,. Change oil as required and

replace piston rings and cylinder liner

Incorrectly fitted piston rings (upside down) .. Replace piston rings Gaps of piston rings in line with each other .. Reassemble piston rings

Worn valve stem Replace valve and valve guide

Worn valve guide Replace valve guide

Incorrectly fitted valve stem seal ......,....,. Replace the stem seal

Excessive lubricant on rocker arm Check clearance of rocker arm

and shafl

cEeso fesed

• Defective oil level gauge Replace oil level gauge

• Oil level too high Drain excess oil

Models J08C-TP and J08C•TR

Possible cause

ENGINE 3-1-5

Remedy/Prevention

Excessive oil consumption

Oil leakage from miscellaneous parts

s Oil leakage from oil seal. Replace oil seal

s Cracks or biowhole in cylinder block. Replace cylinder block

e Oil leakage from connections of oil lines Tighten connections of oil lines

• Oil leakage from oil cooler Replace oil cooler

• Oil leakage from oil pan gasket Replace oil pan gasket

• Oil leakage from O-ring Replace O-ring

  
  

  Oth prob e s

  e Overcooled engine ,...................................,. Warm up engine before moving

  (low temperature wear) vehicle

  Check cooling system

  
  

  NOTE: If oil consumption is excessive, the problems above will occur. Complaints from the

  customer ere often related to such problems.

  1. White smoke is emitted continuously when the engine is run at high speed.

  2. White smoke is emitted only immediately after the engine speed is abruptly raised when idling.

  3. The tail pipe is blackened with oil.

  4. OII leaks from the flanges of the exhaust manifold.

  5. Lack of power.

  6. Excessive blow-by gas.

  
  

  Piston seizure

  Pistons, cylinder liners and piston rings

  e Incorrect clearance between piston Replace piston, piston rings

  and cylinder liner and cylinder liner

• Unsatisfactory installation of piston pin Replace piston, piston rings,

  cylinder liner and piston pin as required

• Broken piston ring Replace piston, piston rings

and cylinder liner

o Difference in expansion due to use of. Replace piston, piston rings

wrong piston and cylinder liner

3•1-6 ENGINE

Piston seizure

Models J08C-TP and J08C-TR

Possible cause Remedy/Prevention

•

•

•

•

•

•

•

•

•

e

e e

•

• e e e

•

• e

•

Coo  n  

Reduction in capacity of coolant pump Replace the coolant pump

(due to vane corrosion)

Leakage of coolant. Repair

Insufficient coolant Add coolant

Dirty coolant Clean and replace coolant

Defective radiator. Repair or replace the radiator

(coolant leakage, clogging)

Defective rubber hose (leakage) ...,. Replace rubber hose

Defective thermostat Replace the thermostat

Leakage of exhaust into cooling system Repair

Operat on

Abrupt stoppage of engine after running Operate engine properly

at high speed

Hill climbing using unsuitable gear ....,..„. Select suitable gear

Oi

Insufficient oil Add oil

Dirty oil Change oil

Poor quality oil Replace with proper engine oil

High oil temperature. Repair

Low oil pressure Repair

Defective oil pump ......................,. Repair oil pump

Reduced performance due to worn Replace oil pump

oil pump

Suction strainer sucking air. Add oil and/or repair strainer

Abnor a combu on

Use of defective fuel Change fuel

Incorrect injection timing Adjust injection timing

Engine overheating ...................,. See Symptom: “Engine

overheating”

Models J08C-TP and J08C•TR ENGINE 3•1•7

NOTE: If piston seizure occurs, the problemB above will occur. Complaints from the customer

are oNen related to these problems.

1. White smoke is emitted.

2. Lack of power

3. Excessive blow-by gas

Lack of power

Possible cause Remedy/Prevention

   j  tion pu  p  Refer to “FUEL INJECTION

PUMP”

intake

• Clogged air cleaner..,. Clean element or replace

  element

  
  

  O erheat g See Symptom: “Engine

  overheating”

  
  

  Fue and no e

  e Poor nozzle spray ...........................,. Adjust or replace injection

  nozzle

• Nozzle clogged with carbon ,.,........„. Clean nozzle

  e Wear or seizure of nozzle Replace nozzle

• Air in fuel system. Repair and bleed air from fuel

  system

• Clogged fuel filter. Replace element

• Use of poor fuel. Use good quality fuel

  
  

  Pistons, cylinder liners and piston rings

• Seized or wear of piston Replace the piston, piston rings

and liner

e Wom or broken piston rings, Replace piston rings, piston

piston and cylinder liner and liner