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