---===S1-MFCE01C-0100_0001.djvu===--- FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles. Applicable for FC7J, FD7J, FE7J, FG8J, GH8J, FL8J, FM8J, FM1A, GT8J series, equipped with J07D-TI, J08E-TI, A09C engine When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner's Manual. All information and specifications in this manual are based upon the latest product information available at the time of print- ing. Hino Motors reserves the right to make changes at any time without prior notice. This manual is divided into 11 sections with a thumb index for each section at the edge of the pages. Please note that the publications below have also been prepared as relevant service manuals for the components and sys- tems in this vehicles. Manual Name Pub. No. Chassis Workshop Manual S1-MFCE01C 2/3 S1-MFCE01C 3/3 S1-MFCE01C EWD J07E-TI Engine Workshop Manual S5-MJ07E01B J08E-TI Engine Workshop Manual S5-MJ08E03C A09C Engine Workshop Manual S5-MA09E03A Trouble shooting Workshop Manual S7-MFCE01D 1/3 S7-MFCE01D 2/3 S7-MFCE01D 3/3 CHANGE CHANGE '12.01.27.update ---===S1-MFCE01C-0100_0002.djvu===--- CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. CHAPTER MANUAL No. S1-MFCE01C 1/3 MODELS FC7J, FD7J, FE7J, FG8J, GH8J, FL8J, FM8J, FM1A, GT8J GENERAL INTRODUCTION GN02-001 CLUTCH MAIN UNIT CL02-001 (CSP350) CL02-002 (DSP350) CL02-003 (CSP380) CL02-004 (SACHS MFZ430) CLUTCH CONTROL CL03-001 (CSP350, CSP380) CL03-002 (DSP350) CL03-003 (SACHS MFZ430) TRANSMISSION MAIN UNIT TR02-001 (LX06S) TR02-002 (LJ06S) TR02-003 (MF06S) TR02-004 (EATON FS6109) TR02-005 (EATON FS8209) TR02-006 (FULLER RTO11909ALL) TRANSFER MAIN UNIT TR03-001 (MA12C) AUTOMATIC TRANSMISSION TR04-001 (ALLISON 3000RDS, 3500RDS) P.T.O. (POWER TAKE-OFF) TR05-001 (TRANSMISSION SERIES: LX06S) TR05-002 (TRANSMISSION SERIES: LJ06S) TR05-003 (TRANSMISSION SERIES: MF06S) TR05-004 (EATON) TRANSMISSION/TRANSFER CONTROL TR06-001 (MT) TR06-002 (AMT) PROPELLER SHAFT PP02-001 (LD0932) PP02-002 (LF0940) PP02-003 (MC1040) PP02-004 (MG1140) PP02-005 (HD1050) PP02-006 (HY1345) PP02-007 (MC0000) DIFFARENTIAL EQUIPMENT DF01-001 (LOCKING TYPE DIFFERENTIAL GEAR) DIFFERENTIAL CARRIER DF02-001 (SH13) DF02-002 (SH14) DF02-003 (SH16) DF02-004 (SH17) DF02-005 (THD17) DF02-006 (SS15) CHANGE ---===S1-MFCE01C-0100_0003.djvu===--- CLUTCH EQUIPMENT CLUTCH MAIN UNIT CLUTCH CONTROL TRANSMISSION EQUIPMENT TRANSMISSION MAIN UNIT TRANSFER MAIN UNIT AUTOMATIC TRANSMISSION P.T.O. (POWER TAKE-OFF) TRANSMISSION / TRANSFER CONTROL PROPELLER SHAFT DIFFERENTIAL EQUIPMENT DIFFERENTIAL CARRIER INDEX: CHASSIS GROUP 1/4 PROPELLER SHAFT EQUIPMENT WORKSHOP MANUAL All rights reserved. This manual may not be reproduced or copied in whole in part, with- out the written consent of Hino Motors, Ltd. BRAKE EQUIPMENT SERVICE BRAKE ABS & ASR ES START (EASY & SMOOTH START SYSTEM) GENERAL INTRODUCTION This manual does not contain items on half-tone dot meshing. "BRAKE EQUIPMENT" to "WHEEL & TIRE": Refer to "S1-MFCE01C 2/3". "SUSPENSION" to "OTHERS": Refer to "S1-MFCE01C 3/3". CHANGE CHANGE ---===S1-MFCE01C-0100_0004.djvu===--- EXHAUST BRAKE RETARDER BRAKE PARKING BRAKE STEERING EQUIPMENT STEERING UNIT POWER STEERING INDEX: CHASSIS GROUP 2/4 AXLE EQUIPMENT FRONT AXLE REAR AXLE WHEEL & TIRE SUSPENSION EQUIPMENT SUSPENSION CHASSIS EQUIPMENT CHASSIS FRAME COUPLER (5TH WHEEL) PINTLE HOOK CAB EQUIPMENT CAB This manual does not contain items on half-tone dot meshing. "BRAKE EQUIPMENT" to "WHEEL & TIRE": Refer to "S1-MFCE01C 2/3". "SUSPENSION" to "OTHERS": Refer to "S1-MFCE01C 3/3". CHANGE CHANGE ---===S1-MFCE01C-0100_0005.djvu===--- ELECTRICAL EQUIPMENT ELECTRIC WIRE INDEX: CHASSIS GROUP 3/4 This manual does not contain items on half-tone dot meshing. "BRAKE EQUIPMENT" to "WHEEL & TIRE": Refer to "S1-MFCE01C 2/3". "SUSPENSION" to "OTHERS": Refer to "S1-MFCE01C 3/3". CHANGE CHANGE ---===S1-MFCE01C-0100_0006.djvu===--- ENGINE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS INDEX: CHASSIS GROUP 4/4 This manual does not contain items on half-tone dot meshing. "BRAKE EQUIPMENT" to "WHEEL & TIRE": Refer to "S1-MFCE01C 2/3". "SUSPENSION" to "OTHERS": Refer to "S1-MFCE01C 3/3". CHANGE CHANGE ---===S1-MFCE01C-0100_0007.djvu===--- FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles. Applicable for FC7J, FD7J, FE7J, FG8J, GH8J, FL8J, FM8J, FM1A, GT8J series, equipped with J07D-TI, J08E-TI, A09C engine When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner's Manual. All information and specifications in this manual are based upon the latest product information available at the time of print- ing. Hino Motors reserves the right to make changes at any time without prior notice. This manual is divided into 12 sections with a thumb index for each section at the edge of the pages. Please note that the publications below have also been prepared as relevant service manuals for the components and sys- tems in this vehicles. Manual Name Pub. No. Chassis Workshop Manual S1-MFCE01C 1/3 S1-MFCE01C 3/3 S1-MFCE01C EWD J07E-TI Engine Workshop Manual S5-MJ07E01B J08E-TI Engine Workshop Manual S5-MJ08E03C A09C Engine Workshop Manual S5-MA09E03A Trouble shooting Workshop Manual S7-MFCE01D 1/3 S7-MFCE01D 2/3 S7-MFCE01D 3/3 CHANGE CHANGE ---===S1-MFCE01C-0100_0008.djvu===--- CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. CHAPTER MANUAL No. S1-MFCE01C 2/3 MODELS FC7J, FD7J, FE7J, FG8J, GH8J, FL8J, FM8J, FM1A, GT8J BRAKE EQUIPMENT BR01-001 (MODELS: WITH AIR OVER HYDRAULIC BRAKE) BR01-002 (MODELS: WITH FULL AIR BRAKE) SERVICE BRAKE BR02-001 (MODELS: WITH AIR OVER HYDRAULIC BRAKE) BR02-002 (MODELS: WITH FULL AIR BRAKE) ABS & ASR BR03-001 (DENSO) BR03-002 (WABCO, FOR FULL AIR BRAKE) ES START (EASY & SMOOTH START SYSTEM) BR04-001 (MODELS: WITH DENSO ABS) BR04-002 (WABCO ABS FOR FULL AIR BRAKE) EXHAUST BRAKE BR05-001 RETARDER BRAKE BR06-001 (ELECTROMAGNETIC RETARDER) PARKING BRAKE BR07-001 (MODEL: FC) STEERING UNIT SR02-001 POWER STEERING SR03-001 FRONT AXLE AX02-001 (LF366) AX02-002 (LF458) AX02-003 (LF466) AX02-004 (MF67I) AX02-005 (DIFFERENTIAL GEAR SERIES: SS15) REAR AXLE AX03-001 (DIFFERENTIAL GEAR SERIES: SH13) AX03-002 (DIFFERENTIAL GEAR SERIES: SH14) AX03-003 (DIFFERENTIAL GEAR SERIES: SH16) AX03-004 (DIFFERENTIAL GEAR SERIES: SH17) AX03-005 (DIFFERENTIAL GEAR SERIES: THD17) WHEEL & TIRE AX04-001 CHANGE ADD ---===S1-MFCE01C-0100_0009.djvu===--- CLUTCH EQUIPMENT CLUTCH MAIN UNIT CLUTCH CONTROL TRANSMISSION EQUIPMENT TRANSMISSION MAIN UNIT TRANSFER MAIN UNIT AUTOMATIC TRANSMISSION P.T.O. (POWER TAKE-OFF) TRANSMISSION / TRANSFER CONTROL PROPELLER SHAFT DIFFERENTIAL EQUIPMENT DIFFERENTIAL CARRIER INDEX: CHASSIS GROUP 1/4 PROPELLER SHAFT EQUIPMENT WORKSHOP MANUAL All rights reserved. This manual may not be reproduced or copied in whole in part, with- out the written consent of Hino Motors, Ltd. BRAKE EQUIPMENT SERVICE BRAKE ABS & ASR ES START (EASY & SMOOTH START SYSTEM) GENERAL INTRODUCTION This manual does not contain items on half-tone dot meshing. "GENERAL INTRODUCTION" to "DIFFERENTIAL CARRIER": Refer to "S1-MFCE01C 1/3". "SUSPENSION" to "OTHERS": Refer to "S1-MFCE01C 3/3". CHANGE CHANGE ---===S1-MFCE01C-0100_0010.djvu===--- EXHAUST BRAKE RETARDER BRAKE PARKING BRAKE STEERING EQUIPMENT STEERING UNIT POWER STEERING INDEX: CHASSIS GROUP 2/4 AXLE EQUIPMENT FRONT AXLE REAR AXLE WHEEL & TIRE SUSPENSION EQUIPMENT SUSPENSION CHASSIS EQUIPMENT CHASSIS FRAME COUPLER (5TH WHEEL) PINTLE HOOK CAB EQUIPMENT CAB This manual does not contain items on half-tone dot meshing. "GENERAL INTRODUCTION" to "DIFFERENTIAL CARRIER": Refer to "S1-MFCE01C 1/3". "SUSPENSION" to "OTHERS": Refer to "S1-MFCE01C 3/3". CHANGE CHANGE ---===S1-MFCE01C-0100_0011.djvu===--- ELECTRICAL EQUIPMENT ELECTRIC WIRE INDEX: CHASSIS GROUP 3/4 This manual does not contain items on half-tone dot meshing. "GENERAL INTRODUCTION" to "DIFFERENTIAL CARRIER": Refer to "S1-MFCE01C 1/3". "SUSPENSION" to "OTHERS": Refer to "S1-MFCE01C 3/3". CHANGE CHANGE ---===S1-MFCE01C-0100_0012.djvu===--- ENGINE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS INDEX: CHASSIS GROUP 4/4 This manual does not contain items on half-tone dot meshing. "GENERAL INTRODUCTION" to "DIFFERENTIAL CARRIER": Refer to "S1-MFCE01C 1/3". "SUSPENSION" to "OTHERS": Refer to "S1-MFCE01C 3/3". CHANGE CHANGE ---===S1-MFCE01C-0100_0013.djvu===--- FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles. Applicable for FC7J, FD7J, FE7J, FG8J, GH8J, FL8J, FM8J, FM1A, GT8J series, equipped with J07D-TI, J08E-TI, A09C engine When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner's Manual. All information and specifications in this manual are based upon the latest product information available at the time of print- ing. Hino Motors reserves the right to make changes at any time without prior notice. This manual is divided into 6 sections with a thumb index for each section at the edge of the pages. Please note that the publications below have also been prepared as relevant service manuals for the components and sys- tems in this vehicles. Manual Name Pub. No. Chassis Workshop Manual S1-MFCE01C 1/3 S1-MFCE01C 2/3 S1-MFCE01C EWD J07E-TI Engine Workshop Manual S5-MJ07E01B J08E-TI Engine Workshop Manual S5-MJ08E03C A09C Engine Workshop Manual S5-MA09E03A Trouble shooting Workshop Manual S7-MFCE01D 1/3 S7-MFCE01D 2/3 S7-MFCE01D 3/3 CHANGE CHANGE ---===S1-MFCE01C-0100_0014.djvu===--- CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. CHAPTER MANUAL No. S1-MFCE01C 3/3 MODELS FC7J, FD7J, FE7J, FG8J, GH8J, FL8J, FM8J, FM1A, GT8J SUSPENSION SU02-001 (MODELS: FC, FD, FE, FG, GH) SU02-002 (MODELS: FL, FM) SU02-003 (MODEL:GT) SU02-004 (HENDRICKSON HAS 200, HAS 230, HAS 400) CHASSIS FRAME FC02-001 CAB EQUIPMENT CA01-001 CAB CA02-001 ELECTRICAL EQUIPMENT EL01-001 OTHERS DN06-001 (CAN COMMUNICATION) DN06-002 (HEADLIGHT AUTOLEVELING) CHANGE ---===S1-MFCE01C-0100_0015.djvu===--- CLUTCH EQUIPMENT CLUTCH MAIN UNIT CLUTCH CONTROL TRANSMISSION EQUIPMENT TRANSMISSION MAIN UNIT TRANSFER MAIN UNIT AUTOMATIC TRANSMISSION P.T.O. (POWER TAKE-OFF) TRANSMISSION / TRANSFER CONTROL PROPELLER SHAFT DIFFERENTIAL EQUIPMENT DIFFERENTIAL CARRIER INDEX: CHASSIS GROUP 1/4 PROPELLER SHAFT EQUIPMENT WORKSHOP MANUAL All rights reserved. This manual may not be reproduced or copied in whole in part, with- out the written consent of Hino Motors, Ltd. BRAKE EQUIPMENT SERVICE BRAKE ABS & ASR ES START (EASY & SMOOTH START SYSTEM) GENERAL INTRODUCTION This manual does not contain items on half-tone dot meshing. "GENERAL INTRODUCTION" to "DIFFERENTIAL CARRIER": Refer to "S1-MFCE01C 1/3". "BRAKE EQUIPMENT" to "WHEEL & TIRE": Refer to "S1-MFCE01C 2/3". CHANGE ---===S1-MFCE01C-0100_0016.djvu===--- EXHAUST BRAKE RETARDER BRAKE PARKING BRAKE STEERING EQUIPMENT STEERING UNIT POWER STEERING INDEX: CHASSIS GROUP 2/4 AXLE EQUIPMENT FRONT AXLE REAR AXLE WHEEL & TIRE SUSPENSION EQUIPMENT SUSPENSION CHASSIS EQUIPMENT CHASSIS FRAME COUPLER (5TH WHEEL) PINTLE HOOK CAB EQUIPMENT CAB This manual does not contain items on half-tone dot meshing. "GENERAL INTRODUCTION" to "DIFFERENTIAL CARRIER": Refer to "S1-MFCE01C 1/3". "BRAKE EQUIPMENT" to "WHEEL & TIRE": Refer to "S1-MFCE01C 2/3". CHANGE ---===S1-MFCE01C-0100_0017.djvu===--- ELECTRICAL EQUIPMENT ELECTRIC WIRE INDEX: CHASSIS GROUP 3/4 This manual does not contain items on half-tone dot meshing. "GENERAL INTRODUCTION" to "DIFFERENTIAL CARRIER": Refer to "S1-MFCE01C 1/3". "BRAKE EQUIPMENT" to "WHEEL & TIRE": Refer to "S1-MFCE01C 2/3". CHANGE ---===S1-MFCE01C-0100_0018.djvu===--- ENGINE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS INDEX: CHASSIS GROUP 4/4 This manual does not contain items on half-tone dot meshing. "GENERAL INTRODUCTION" to "DIFFERENTIAL CARRIER": Refer to "S1-MFCE01C 1/3". "BRAKE EQUIPMENT" to "WHEEL & TIRE": Refer to "S1-MFCE01C 2/3". CHANGE