HINO J05C J08C TD TP TR Diesel Engine Workshop Manual

QUALITY PARTS, THE PERFECT FIT QUICK REFERENCE PARTS CATALOG 1998 - 2003 MODEL YEAR EDITION HINO DIESEL TRUCKS (U.S.A.) INC QUICK REFERENCE PARTS CATALOG 1998 - 2004 MODEL YEAR EDITION Note: all parts listed for 2003 models also ﬁt 2004 models.

TABLE OF CONTENTS SECTION CONTENTS PAGE i MODEL INFORMATION & CATALOGS Hino Model Determination ....................................................................................................................... A-1 Model Designator Chart ........................................................................................................................... A-2 Gross Weight Ratings .............................................................................................................................. A-2 Engine Type ............................................................................................................................................. A-2 Hino Model Availability By Model Year .................................................................................................... A-3 Model Number Interpretation ................................................................................................................... A-3 Hino Parts Catalogs ................................................................................................................................. A-4 Hino Workshop Manuals.......................................................................................................................... A-5 AIR CONDITIONING AND HEATING Air Conditioning Kits, Replacement Parts and Compressor Drive Belt ................................................... 1 Heater Fan Motor, Fan Switch and Heater Core ..................................................................................... 1 ACCESSORIES Block Heater ............................................................................................................................................ 2 Air Ride Suspension Seat - Base Kit ....................................................................................................... 2 Radio Kits................................................................................................................................................. 2 Heated Mirrors ......................................................................................................................................... 2 Stainless Steel Wheel Liners ................................................................................................................... 3 Locking Fuel Caps ................................................................................................................................... 3 Floor Mat Sets ......................................................................................................................................... 3 Storage Bin Drawer ................................................................................................................................. 3 Grille Guards ............................................................................................................................................ 3 CAB Air Deflectors ................................................................................................................................... 3 BEARINGS Front Wheel Bearings .............................................................................................................................. 4 Rear Axle Bearings .................................................................................................................................. 4 BRAKE SYSTEM Relined Exchange Brake Shoes .............................................................................................................. 6 Brake Shoe Lining ................................................................................................................................... 6 Brake Drums ............................................................................................................................................ 6 Brake Shoe Retracting Spring ................................................................................................................. 7 Wheel Cylinders - Front Brakes ............................................................................................................... 7 Wheel Cylinders - Rear Brakes ............................................................................................................... 8 Brake Chambers - Front Brakes .............................................................................................................. 8 Brake Chambers - Rear Brakes............................................................................................................... 8 Air Brake Valve Assemblies..................................................................................................................... 9 Air Brake Foot Valve Assemblies ............................................................................................................ 10 Air Compressor Assemblies .................................................................................................................... 10 Brake Master Cylinders - FA/FB .............................................................................................................. 10 Brake Servo Assemblies - FA/FB ............................................................................................................ 10 ABS Wheel Sensors ................................................................................................................................ 10 Vacuum Brake ABS Modulator ................................................................................................................ 10 Air Brake Valve Assemblies - Air Over Hydraulic Systems 2000-1-FB ................................................... 11 Air Brake Valve Assemblies - Air Over Hydraulic Systems 1998-FD/FE/FF ........................................... 12 Air Brake Valve Assemblies - Air Over Hydraulic Systems 1999-2001-FD/FE/FF.................................. 13 Air Brake Valve Assemblies - Full Air Systems 1998-SG........................................................................ 14

TABLE OF CONTENTS SECTION CONTENTS PAGE ii BRAKE SYSTEM Air Brake Valve Assemblies - Full Air Systems 1999-2001-SG ................................................................... 15 Rockwell Automatic Slack Adjusters - Full Air Systems ................................................................................ 16 Parking Brake Cable ...................................................................................................................................... 16 Parking Brake Drums, Shoes, Lining & Return Springs ................................................................................ 16 CAB AND LAMPS Hino Paints .................................................................................................................................................... 17 FA/FB - Cab Panels & Trim, Bumpers, Glass, and Mirrors ........................................................................... 18 FD/FE - Cab Panels & Trim, Bumpers, Glass, and Mirrors ........................................................................... 20 FF/SG - Cab Panels & Trim, Bumpers, Glass, and Mirrors .......................................................................... 24 Mirror Replacement Parts.............................................................................................................................. 28 Seat Assemblies ............................................................................................................................................ 30 FA/FB - Lamp Assemblies & Lens................................................................................................................. 32 FD/FE/FF/SG - Lamp Assemblies & Lens ..................................................................................................... 34 CABLES Transmission Control Shift Cables - Manual Transmission........................................................................... 36 Engine Control and Speedometer Cables ..................................................................................................... 36 CHASSIS Front and Rear Suspension - Shocks, Springs and King Pin Sets ............................................................... 37 Steering - P/S Pump, Gear Box, Tie Rod Ends, Drag Links ......................................................................... 38 Axles .............................................................................................................................................................. 39 Lug Nuts, Studs & Hub Bolt Kits .................................................................................................................... 39 Rear Wheel Inner Cap Nuts .......................................................................................................................... 39 Lug Nut Wrench ............................................................................................................................................. 40 Wheels ........................................................................................................................................................... 40 Valve Stem For Tubeless Wheels ................................................................................................................. 40 Universal Joints ............................................................................................................................................. 40 Front And Rear Spring Repair: Bushings, Pins & Hardware ......................................................................... 41 CLUTCH & FLYWHEEL Clutches ......................................................................................................................................................... 42 Clutch Release Bearing, Hubs & Forks ......................................................................................................... 42 Clutch Cylinders and Repair kits ................................................................................................................... 43 Flywheels ....................................................................................................................................................... 43 Flywheel Dowel Pins (Pressure Plate Alignment Dowels) ............................................................................ 43 COOLING SYSTEM - Water Pump, Hoses, Drive Belts, Thermostats, Radiators, Kits FA/FB Cooling System .................................................................................................................................. 44 FD/FE/FF/SG Cooling System ...................................................................................................................... 45 ELECTRICAL Starters, Alternators & Alternator Drive Belts ................................................................................................ 46 Fusible Links and Cover ................................................................................................................................ 46 Battery Box Covers ........................................................................................................................................ 47 Electrical Horns.............................................................................................................................................. 47 Relay & Flasher Assemblies.......................................................................................................................... 47 Engine Electrical - Water Temperature Sender, Oil Pressure Switch, Glow Plugs ...................................... 47 Instruments and Gauges ............................................................................................................................... 48 Electrical Switches ......................................................................................................................................... 49 Steering Column Combination Switch ........................................................................................................... 49 Ignition Switch & Key blanks ......................................................................................................................... 49 Complete Lock Sets & Door Key With Tumblers........................................................................................... 49

TABLE OF CONTENTS SECTION CONTENTS PAGE iii ENGINE Engine Series Identification ........................................................................................................................... 50 Piston Liners .................................................................................................................................................. 51 Piston and Liner Kits...................................................................................................................................... 51 Piston, Piston Ring Sets, Wrist Pins, Snap Rings, Wrist Pin Kits & Connecting Rod Bearing Sets ............. 51 Main Bearings & Thrust Washers .................................................................................................................. 52 Valves, Valve Springs, Valve Guides & Seals............................................................................................... 52 Oil Pump Assemblies .................................................................................................................................... 52 Oil Filler Cap .................................................................................................................................................. 52 Drain Plug - Oil Pan ....................................................................................................................................... 52 EXHAUST SYSTEM FA/FB Exhaust System ................................................................................................................................. 53 FD/FE/FF/SG Exhaust System...................................................................................................................... 54 FILTERS Oil, Fuel & Air Filters...................................................................................................................................... 55 Power Steering & Automatic Transmission Filters ........................................................................................ 55 FUEL SYSTEM Fuel Tank, Caps, Fuel Gauge Sending Unit .................................................................................................. 56 Fuel Injection System - Nozzles, Pumps ....................................................................................................... 56 GASKETS Engine Gaskets & Gasket Overhaul Sets ..................................................................................................... 57 Transmission Gasket Sets............................................................................................................................. 57 OIL SEALS Engine Oil Seals ............................................................................................................................................ 58 Axle Seals ...................................................................................................................................................... 58 Transmission & Differential Oil Seals ............................................................................................................ 58 TURBOCHARGER FA/FB Turbocharger ...................................................................................................................................... 59 FD/FE/FF/SG Turbocharger .......................................................................................................................... 60 WINDSHIELD WIPERS Windshield Wipers ......................................................................................................................................... 61

A-1 MODEL INFORMATION & CATALOGS HINO MODEL DETERMINATION In order to use this catalog and determine the correct part number for the vehicle, it is necessary to determine the Model and model year. In some cases, it may be necessary to determine the wheelbase length, engine model and the type of transmission. The Model, model year, wheelbase and engine model information is contained on the Vehicle Identification Number (VIN) plate. This plate is located on the drivers door sill as shown. Use the following chart to determine the Model, model year and engine for the vehicle. W 1998 1 2001 X 1999 2 2002 Y 2000 3 2003

A-2 MODEL DESIGNATOR CHART ENGINE TYPE MODEL INFORMATION & CATALOGS CODE MANUFACTURER MODEL DESCRIPTION 4J HINO MOTORS, LTD J05C-TB/TD 5.3 LITERS, DIESEL, 165HP / 168HP 2J HINO MOTORS, LTD. J08C-TD/TP 8.0 LITERS, DIESEL, 200HP / 200HP 1J HINO MOTORS, LTD. J08C-TE/TR 8.0 LITERS, DIESEL, 250HP / 252HP VIN CODE CAB/BODY TYPE SERIES, GVWR (lbs) BRAKE SYSTEMS FA FORWARD CONTROL TYPE TRUCK 14,001 - 15,500 (Class 4) HYDRAULIC BRAKE SYSTEM FB FORWARD CONTROL TYPE TRUCK 16,001 - 18,000 (Class 5) HYDRAULIC BRAKE SYSTEM FD FORWARD CONTROL TYPE TRUCK 19,501 - 22,500 (Class 6) AIR OVER HYDRAULIC BRAKE SYSTEM FE FORWARD CONTROL TYPE TRUCK 22,501 - 26,000 (Class 6) AIR OVER HYDRAULIC BRAKE SYSTEM FF FORWARD CONTROL TYPE TRUCK 26,001 - 30,000 (Class 7) AIR OVER HYDRAULIC BRAKE SYSTEM SG FORWARD CONTROL TYPE TRUCK 30,001 - 33,000 (Class 7) AIR BRAKE SYSTEM GAWR (kg) GAWR (lbs.) MODELS TIRE SIZE GVWR (kg) FRONT REAR GVWR (lbs.) FRONT REAR FA 215/85R16-10 6,800 2,430 4,480 15,000 5,360 9,880 FB 215/75R17.5-12 8,000 2,700 5,500 17,600 5,950 12,100 235/85R16-10 7,740 2,700 5,040 17,060 5,950 11,100 FD 9R22.5-12(F) 10,100 3,500 7,170 22,300 7,700 15,800 245/70R19.5-133/131J 10,100 3,500 7,200 22,300 7,700 15,900 225/70R22.5-140/137M 11,790 4,670 9,200 25,995 10,300 20,280 FE 11R22.5-14(G) 11,790 4,670 9,200 25,995 10,300 20,300 295/75R22.5-14(G) 11,790 4,670 9,200 25,995 10,300 20,300 FF 11R22.5-14(G) 13,600 5,300 9,610 30,000 11,700 21,200 295/75R22.5-14(G) 13,600 5,300 9,610 30,000 11,700 21,200 SG 11R22.5-14(G) 14,900 5,300 9,610 32,900 11,700 21,200 295/75R22.5-14(G) 14,900 5,300 9,610 32,900 11,700 21,200 GROSS WEIGHT RATINGS

A-3 MODEL INFORMATION & CATALOGS HINO MODEL DETERMINATION HINO MODEL AVAILABILITY BY MODEL YEAR MODEL YEARS MODELS 98 99 00 01 02 03 04 05 06 07 08 09 10 11 FA1517 (FA4J) X X X X X X FB1817 (FB4J) X X X X X X FD2220 (FD2J) X X X X X X FE2620 (FE2J) X X X X X X FF3020 (FF2J) X X X X X SG3320 (SG2J) X X X X X SG3325 (SG1J) X X X X X X MODEL NUMBER INTERPRETATION (EXAMPLE) FD MODEL GVWR 22 = 22300 Ibs. H.P. 20 = 200 HP FD 22 20 (FD2J)

A-4 MODEL INFORMATION & CATALOGS HINO PARTS CATALOGS NOTE: 1998 through 2001 Hino Parts Catalogs are available in sets of microfiche or in printed parts catalogs. When ordering a printed parts catalog, please utilize the listed catalog number followed by the letter “B” (ie. FB2231EB). Please specify which you require when ordering. YEAR MODEL CATALOG NO. LATEST REVISION DATE 1998 FA/FB4J FB2231E JUNE 1997 FD/FE2J FD2171E JUNE 1997 FF2J FF2571E JUNE 1997 SG2J SG2201E JUNE 1997 SG1J SG2191E JUNE 1997 1999 FA/FB4J FB2240E JAN. 1998 FD/FE2J FD2180E JAN. 1998 FF2J FF2580E JAN. 1998 SG2J SG2220E JAN. 1998 SG1J SG2210E JAN. 1998 2000 FA/FB4J FB2250E AUG. 1998 FD/FE/FF2J FD2190E AUG. 1998 SG2J/SG1J SG2230E AUG. 1998 2001 FA/FB4J FB2260E MAR. 2000 FD/FE/FF2J FD2200E MAR. 2000 SG2J/SG1J SG2240E MAR. 2000 2002 FA/FB4J FA2231E MAR. 2001 FD/FE/FF2J FD2210E MAR. 2001 SG2J/SG1J SG22451E MAR. 2001 2003 FA/FB4J FD/FE/FF2J CD-ROM JUNE 2002 SG2J/SG1J

A-5 MODEL INFORMATION & CATALOGS HINO WORKSHOP MANUALS MODEL YEAR MODEL DESCRIPTION MANUAL PART NUMBER 1998 FA, FB ENGINE, CHASSIS, BODY, ELECTRICAL S1239E09 FD, FE, FF, SG ENGINE S1134E131 CHASSIS, BODY, ELECTRICAL S1134E132 1999 FA, FB ENGINE, CHASSIS, BODY, ELECTRICAL S1239E10 FD, FE, FF, SG ENGINE S1134E141 CHASSIS, BODY, ELECTRICAL S1134E142 2000 FA, FB ENGINE, CHASSIS, BODY, ELECTRICAL S1239E11 FD, FE, FF, SG ENGINE S1134E151 CHASSIS, BODY, ELECTRICAL S1134E152 2001 FA, FB ENGINE, CHASSIS, BODY, ELECTRICAL S1239E12 FD, FE, FF, SG ENGINE S1134E161 CHASSIS, BODY, ELECTRICAL S1134E162 2002 FA, FB ENGINE, CHASSIS, BODY, ELECTRICAL S1239E13 FD, FE, FF, SG ENGINE S1134E171 CHASSIS, BODY, ELECTRICAL S1134E172 2003 FA, FB ENGINE, CHASSIS, BODY, ELECTRICAL S1239E14 FD, FE, FF, SG ENGINE S1134E181 CHASSIS, BODY, ELECTRICAL S1134E182

NOTES A-6 MODEL INFORMATION & CATALOGS

HINO J05C J08C TD TP TR Diesel Engine Workshop Manual

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