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2014 HINO TRUCK Conventional 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL – PDF DOWNLOAD
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2014 HINO TRUCK Conventional 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL
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2014 HINO TRUCK Conventional 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL
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2014 HINO TRUCK CONVENTIONAL 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL – PDF DOWNLOAD:
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2014 HINO TRUCK Conventional 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL
FOREWORD.................................................................................................... 2 CHAPTER REFERENCES ......................................................................................... 3 INDEX ...................................................................................................... 4 GENERAL INTRODUCTION (CHASSIS).............................................................................. 8 GENERAL INTRODUCTION ................................................................................... 9 GENERAL PRECAUTIONS................................................................................. 9 IDENTIFICATION INFORMATION.......................................................................... 12 HOW TO USE THIS WORKSHOP MANUAL..................................................................... 21 PRECAUTIONS......................................................................................... 23 SEALANT ON THE TAPERED SCREW FOR PIPING............................................................. 26 NYLON TUBE REPLACEMENT METHOD....................................................................... 27 METRIC INFORMATION.................................................................................. 29 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS........................................................ 31 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS.......................................................... 31 RECOMMENDED LUBRICANTS.............................................................................. 33 VEHICLE LIFT AND SUPPORT LOCATIONS.................................................................. 35 INFORMATION DISPLAY................................................................................. 37 SYMPTOM SIMULATION.................................................................................. 42 GLOSSARY............................................................................................ 44 GLOSSARY OF SAE AND HINO TERMS...................................................................... 47 CLUTCH MAIN UNIT (EATON 1401)............................................................................... 50 CLUTCH ASSEMBLY (EATON SAS1401) ........................................................................ 51 DATA AND SPECIFICATIONS............................................................................. 51 DESCRIPTION......................................................................................... 51 TROUBLESHOOTING..................................................................................... 52 SPECIAL TOOL........................................................................................ 54 COMPONENT LOCATOR................................................................................... 55 OVERHAUL............................................................................................ 56 CLUTCH ASSEMBLY (EATON SOLO1401) ....................................................................... 63 DATA AND SPECIFICATIONS............................................................................. 63 COMPONENT LOCATOR................................................................................... 63 OVERHAUL............................................................................................ 64 INSPECTION AND REPAIR............................................................................... 71 CLUTCH MAIN UNIT (EATON 1402)............................................................................... 74 CLUTCH ASSEMBLY (EATON SAS1402) ........................................................................ 75 DATA AND SPECIFICATIONS............................................................................. 75 DESCRIPTION......................................................................................... 75 TROUBLESHOOTING..................................................................................... 76 SPECIAL TOOL........................................................................................ 78 COMPONENT LOCATOR................................................................................... 79 OVERHAUL............................................................................................ 80 CLUTCH ASSEMBLY (EATON SOLO1402) ....................................................................... 89 DATA AND SPECIFICATIONS............................................................................. 89 COMPONENT LOCATOR................................................................................... 89 OVERHAUL............................................................................................ 90 INSPECTION AND REPAIR............................................................................... 100 CLUTCH CONTROL.............................................................................................. 103 CLUTCH CONTROL UNIT .................................................................................... 104 DESCRIPTION......................................................................................... 104 INSPECTION AND ADJUSTMENT........................................................................... 105 CLUTCH PEDAL AND RELEASE UNIT .......................................................................... 108 COMPONENT LOCATOR................................................................................... 108 OVERHAUL............................................................................................ 109 INSPECTION AND REPAIR............................................................................... 111 CLUTCH MASTER CYLINDER ................................................................................. 112 COMPONENT LOCATOR................................................................................... 112 OVERHAUL............................................................................................ 113 INSPECTION AND REPAIR............................................................................... 113 TRANSMISSION MAIN UNIT (EATON FS 5406/6406)................................................................. 114 TRANSMISSION ASSEMBLY .................................................................................. 115 DATA AND SPECIFICATION.............................................................................. 115 DISMOUNTING AND MOUNTING............................................................................ 116 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS)................................................... 118 AUTOMATIC TRANSMISSION ASSEMBLY......................................................................... 119 TROUBLESHOOTING..................................................................................... 119 SPECIAL TOOL........................................................................................ 119 DISMOUNTING AND MOUNTING............................................................................ 119 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS)........................................................... 127 AUTOMATIC TRANSMISSION ASSEMBLY......................................................................... 128 TROUBLESHOOTING..................................................................................... 128 SPECIAL TOOL........................................................................................ 128 DISMOUNTING AND MOUNTING............................................................................ 128 TRANSMISSION/TRANSFER CONTROL(EATON MANUAL TRANSMISSION).................................................... 135 TRANSMISSION CONTROL UNIT............................................................................... 136 TROUBLESHOOTING..................................................................................... 136 COMPONENT LOCATOR................................................................................... 137 OVERHAUL............................................................................................ 138 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION).............................................. 139 TRANSMISSION CONTROL UNIT............................................................................... 140 TROUBLESHOOTING..................................................................................... 140 COMPONENT LOCATOR................................................................................... 140 OVERHAUL............................................................................................ 142 PROPELLER SHAFT (SPL 100, 140).............................................................................. 143 PROPELLER SHAFT ASSEMBLY................................................................................ 144 DATA AND SPECIFICATIONS............................................................................. 144 DESCRIPTION......................................................................................... 144 TROUBLESHOOTING..................................................................................... 145 COMPONENT LOCATOR................................................................................... 145 OVERHAUL............................................................................................ 147 DIFFERENTIAL CARRIER(MERITOR RS17.19.21&23)................................................................. 163 DIFFERENTIAL CARRIER ASSEMBLY........................................................................... 164 DATA AND SPECIFICATIONS............................................................................. 164 DESCRIPTION......................................................................................... 166 TROUBLESHOOTING..................................................................................... 169 SPECIAL TOOL........................................................................................ 170 COMPONENT LOCATOR................................................................................... 172 OVERHAUL............................................................................................ 176 INSPECTION AND REPAIR............................................................................... 216 DRIVER-CONTROLLED MAIN DIFFERENTIAL LOCK................................................................ 225 OVERHAUL............................................................................................ 225 INSPECTION AND REPAIR............................................................................... 228 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)............................................................... 229 SERVICE BRAKE ASSEMBLY.................................................................................. 230 DESCRIPTION......................................................................................... 230 DIAGRAM............................................................................................. 231 TROUBLESHOOTING..................................................................................... 233 BRAKE SYSTEM AIR BLEEDING........................................................................... 237 POWER STEERING SYSTEM AIR BLEEDING.................................................................. 239 BRAKE TEST.......................................................................................... 240 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)................................................................ 241 SERVICE BRAKE ASSEMBLY.................................................................................. 242 DESCRIPTION......................................................................................... 242 DATA AND SPECIFICATIONS............................................................................. 243 DIAGRAM............................................................................................. 244 TROUBLESHOOTING..................................................................................... 245 SERVICE BRAKE (HYDRAULIC BRAKE)............................................................................. 247 HYDRAULIC BRAKE......................................................................................... 248 INSPECTION AND ADJUSTMENT........................................................................... 248 HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTERCYLINDER.................................................... 251 DATA AND SPECIFICATIONS............................................................................. 251 DESCRIPTION......................................................................................... 251 PRINCIPLE OF OPERATION.............................................................................. 253 COMPONENT LOCATOR................................................................................... 255 HYDRO-MAX BOOSTER....................................................................................... 256 OVERHAUL............................................................................................ 256 MASTER CYLINDER......................................................................................... 262 OVERHAUL............................................................................................ 262 PRESSURE TESTS...................................................................................... 264 ABS MODULATOR........................................................................................... 265 DATA AND SPECIFICATIONS............................................................................. 265 DESCRIPTION......................................................................................... 265 WHEEL BRAKE (TYPE: 4 PISTON)............................................................................ 266 DATA AND SPECIFICATIONS............................................................................. 266 DESCRIPTION......................................................................................... 267 TROUBLESHOOTING..................................................................................... 268 SERVICE BRAKE (FULL AIR BRAKE).............................................................................. 281 AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS).................................................... 282 DESCRIPTION......................................................................................... 282 AD-IS AIR DRYER RESERVOIR SYSTEM TROUBLESHOOTING CHART.............................................. 293 CHECK VALVE............................................................................................. 297 DATA AND SPECIFICATIONS............................................................................. 297 DESCRIPTION......................................................................................... 297 INSPECTION AND REPAIR............................................................................... 298 BRAKE PEDAL............................................................................................. 300 OVERHAUL............................................................................................ 300 BRAKE VALVE............................................................................................. 303 DATA AND SPECIFICATIONS............................................................................. 303 DESCRIPTION......................................................................................... 303 COMPONENT LOCATOR................................................................................... 304 INSPECTION AND REPAIR............................................................................... 305 RELAY VALVE............................................................................................. 309 DATA AND SPECIFICATIONS............................................................................. 309 DESCRIPTION......................................................................................... 309 INSPECTION AND REPAIR............................................................................... 309 SPRING BRAKE MODULATING VALVE........................................................................... 313 DESCRIPTION......................................................................................... 313 COMPONENT LOCATOR................................................................................... 314 INSPECTION AND REPAIR............................................................................... 315 SPRING BRAKE CONTROL VALVE.............................................................................. 317 DESCRIPTION......................................................................................... 317 COMPONENT LOCATOR................................................................................... 318 INSPECTION AND REPAIR............................................................................... 319 BRAKE CHAMBER (FRONT)................................................................................... 322 DATA AND SPECIFICATIONS............................................................................. 322 DESCRIPTION......................................................................................... 322 COMPONENT LOCATOR................................................................................... 323 OVERHAUL............................................................................................ 324 INSPECTION AND REPAIR............................................................................... 325 BRAKE CHAMBER (REAR).................................................................................... 326 DATA AND SPECIFICATIONS............................................................................. 326 DESCRIPTION......................................................................................... 327 COMPONENT LOCATOR................................................................................... 328 INSPECTION AND REPAIR............................................................................... 329 PROTECTION VALVE........................................................................................ 340 DATA AND SPECIFICATIONS............................................................................. 340 DESCRIPTION......................................................................................... 340 INSPECTION.......................................................................................... 341 WHEEL BRAKE............................................................................................. 343 DATA AND SPECIFICATIONS............................................................................. 343 DESCRIPTION......................................................................................... 344 COMPONENT LOCATOR................................................................................... 345 OVERHAUL............................................................................................ 347 INSPECTION AND REPAIR............................................................................... 364 AUTOMATIC SLACK ADJUSTER................................................................................ 366 DESCRIPTION......................................................................................... 366 DIAGNOSTICS......................................................................................... 367 COMPONENT LOCATOR................................................................................... 368 OVERHAUL............................................................................................ 370 INSTALLING THE SLACK ADJUSTER ONTO THE CAMSHAFT..................................................... 378 CHECK & ADJUSTMENT.................................................................................. 380 ABS (ABS : HYDRAULIC (E VERSION))........................................................................... 387 OVERVIEW................................................................................................ 388 COMPOSITION AND OPERATION............................................................................... 389 FUNCTION................................................................................................ 392 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS..................................................... 393 OVERVIEW AND FUNCTION................................................................................... 394 ABS (ABS : FULL AIR)........................................................................................ 406 OVERVIEW................................................................................................ 407 COMPOSITION AND OPERATION............................................................................... 408 FUNCTION................................................................................................ 411 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS..................................................... 412 OVERVIEW AND FUNCTION................................................................................... 413 INSPECTION (FRONT WHEEL BRAKE).......................................................................... 418 INSPECTION (REAR WHEEL BRAKE)........................................................................... 420 EXHAUST BRAKE............................................................................................... 426 EXHAUST BRAKE SYSTEM ................................................................................... 427 SYSTEM DIAGRAM...................................................................................... 427 TROUBLESHOOTING..................................................................................... 428 ADJUSTMENT.......................................................................................... 428 BRAKE CYLINDER ......................................................................................... 430 DATA AND SPECIFICATIONS............................................................................. 430 DESCRIPTION......................................................................................... 430 COMPONENT LOCATOR................................................................................... 431 PARKING BRAKE (BOSCH 12")................................................................................... 432 PARKING BRAKE ASSEMBLY ................................................................................. 433 DATA AND SPECIFICATIONS............................................................................. 433 DESCRIPTION......................................................................................... 433 TROUBLESHOOTING..................................................................................... 434 COMPONENT LOCATOR................................................................................... 435 OVERHAUL............................................................................................ 437 INSPECTION AND REPAIR............................................................................... 451 ADJUSTMENT.......................................................................................... 452 FOREWORD.................................................................................................... 455 CHAPTER REFERENCES ......................................................................................... 456 INDEX....................................................................................................... 457 STEERING EQUIPMENT.......................................................................................... 461 STEERING SYSTEM ........................................................................................ 462 TROUBLESHOOTING..................................................................................... 462 STEERING UNIT............................................................................................... 467 STEERING LINKAGE ....................................................................................... 468 DESCRIPTION......................................................................................... 468 COMPONENT LOCATOR................................................................................... 469 SPECIAL TOOL........................................................................................ 470 OVERHAUL............................................................................................ 470 INSPECTION AND REPAIR............................................................................... 475 POWER STEERING.............................................................................................. 477 POWER STEERING GEAR UNIT ............................................................................... 478 DATA AND SPECIFICATIONS............................................................................. 478 DESCRIPTION......................................................................................... 479 OPERATION........................................................................................... 480 COMPONENT LOCATOR................................................................................... 482 TORQUE CHART........................................................................................ 484 HAZARD WARNING DEFINITIONS.......................................................................... 484 DISCLAIMER.......................................................................................... 485 PATENTS............................................................................................. 485 MAINTENANCE TIPS.................................................................................... 485 ON-VEHICLE SERVICE.................................................................................. 487 RESEAL & REPAIR..................................................................................... 497 POWER STEERING PUMP .................................................................................... 531 DATA AND SPECIFICATIONS............................................................................. 531 DESCRIPTION......................................................................................... 531 OPERATION........................................................................................... 532 COMPONENT LOCATOR................................................................................... 533 OVERHAUL............................................................................................ 535 INSPECTION AND REPAIR............................................................................... 541 FRONT AXLE (MFS)............................................................................................ 542 FRONT AXLE (MFS) ....................................................................................... 543 DATA AND SPECIFICATIONS............................................................................. 543 TROUBLESHOOTING..................................................................................... 545 COMPONENT LOCATOR................................................................................... 547 SERVICE NOTES....................................................................................... 551 SPECIAL TOOLS....................................................................................... 552 INTRODUCTION........................................................................................ 557 INSPECTION.......................................................................................... 558 DISASSEMBLY......................................................................................... 564 PREPARE PARTS FOR ASSEMBLY.......................................................................... 571 ASSEMBLY............................................................................................ 579 ADJUSTMENT.......................................................................................... 591 LUBRICATION AND MAINTENANCE......................................................................... 600 MAINTENANCE......................................................................................... 604 REAR AXLE................................................................................................... 605 REAR AXLE .............................................................................................. 606 DATA AND SPECIFICATIONS............................................................................. 606 COMPONENT LOCATOR................................................................................... 613 SPECIAL TOOL........................................................................................ 616 DISASSEMBLY......................................................................................... 618 PREPARE PARTS FOR ASSEMBLY.......................................................................... 620 ASSEMBLY............................................................................................ 624 ADJUSTMENT.......................................................................................... 634 LUBRICATION AND MAINTENANCE......................................................................... 636 WHEEL & TIRE................................................................................................ 638 WHEEL AND TIRE ......................................................................................... 639 DATA AND SPECIFICATIONS............................................................................. 639 DESCRIPTION......................................................................................... 643 SPECIAL TOOL........................................................................................ 644 PRECAUTIONS......................................................................................... 645 INSPECTION.......................................................................................... 646 INSPECTION AND REPAIR............................................................................... 647 WHEEL .................................................................................................. 648 OVERHAUL............................................................................................ 648 SUSPENSION.................................................................................................. 653 LEAF SUSPENSION ASSEMBLY ............................................................................... 654 DATA AND SPECIFICATIONS............................................................................. 654 DESCRIPTION......................................................................................... 656 TROUBLESHOOTING..................................................................................... 658 COMPONENT LOCATOR................................................................................... 659 OVERHAUL............................................................................................ 663 INSPECTION AND REPAIR............................................................................... 668 AIR SUSPENSION ASSEMBLY ................................................................................ 671 DATA AND SPECIFICATIONS............................................................................. 671 SYSTEM DIAGRAM FOR HEIGHT CONTROL................................................................... 671 DESCRIPTION......................................................................................... 672 TROUBLESHOOTING..................................................................................... 673 COMPONENT LOCATOR................................................................................... 674 OVERHAUL............................................................................................ 675 INSPECTION AND REPAIR............................................................................... 679 CHASSIS FRAME............................................................................................... 681 CHASSIS FRAME .......................................................................................... 682 TROUBLESHOOTING..................................................................................... 682 INSPECTION.......................................................................................... 682 REPAIRS............................................................................................. 683 CAB......................................................................................................... 688 CAB ASSEMBLY ........................................................................................... 689 DATA AND SPECIFICATIONS............................................................................. 689 TROUBLESHOOTING..................................................................................... 690 DISMOUNTING AND MOUNTING............................................................................ 691 INSPECTION AND REPAIR............................................................................... 694 HOOD ................................................................................................... 695 COMPONENT LOCATOR................................................................................... 695 OVERHAUL............................................................................................ 696 FRP REPAIR PROCEDURE................................................................................ 699 RADIATOR GRILLE ........................................................................................ 704 COMPONENT LOCATOR................................................................................... 704 OVERHAUL............................................................................................ 705 DOOR ................................................................................................... 706 COMPONENT LOCATOR................................................................................... 706 OVERHAUL............................................................................................ 707 SEAT ................................................................................................... 710 COMPONENT LOCATOR................................................................................... 710 INSTRUMENT PANEL ....................................................................................... 713 COMPONENT LOCATOR................................................................................... 713 DISMOUNTING AND MOUNTING............................................................................ 714 HEATER AND AIR CONDITIONER ............................................................................. 715 COMPONENT LOCATOR................................................................................... 715 SPECIAL TOOL........................................................................................ 715 AIR CONDITIONING SYSTEM ................................................................................ 716 SPECIFICATION DATA.................................................................................. 716 PRECAUTIONS REGARDING REFRIGERANT (HFC134a)......................................................... 716 PRECAUTIONS FOR REPLENISHING THE REFRIGERANT GAS.................................................... 717 TROUBLESHOOTING (FAULT DIAGNOSIS BY SYMPTOMS)....................................................... 718 GAS LEAKAGE INSPECTION.............................................................................. 727 PRECAUTIONS FOR REMOVING/INSTALLING THE AIR CONDITIONER............................................. 730 RECOVERY AND REPLENISHMENT OF REFRIGERANT........................................................... 732 MAINTENANCE......................................................................................... 736 REPLACEMENT......................................................................................... 738 DISMOUNTING AND MOUNTING............................................................................ 740 WINDSHIELD ............................................................................................. 741 COMPONENT LOCATOR................................................................................... 741 REPLACEMENT......................................................................................... 742 AFFIXING WEATHERSTRIP PROCEDURE..................................................................... 743 FRONT BUMPER............................................................................................ 747 COMPONENT LOCATOR................................................................................... 747 ELECTRICAL EQUIPMENT........................................................................................ 749 ELECTRICAL PARTS........................................................................................ 750 DATA AND SPECIFICATIONS............................................................................. 750 COMPONENT LOCATOR................................................................................... 751 TROUBLESHOOTING..................................................................................... 760 GENERAL INSTRUCTION................................................................................. 761 HANDLING PRECAUTION................................................................................. 766 INSPECTION.......................................................................................... 768 INSPECTION AND ADJUSTMENT........................................................................... 789 SPEEDOMETER CONVERSION RATE LIST.................................................................... 790 ELECTRIC WIRE............................................................................................... 791 DIAGRAM................................................................................................. 792 HOW TO USE THIS CHAPTER............................................................................. 792 SPECIFICATION SYMBOL LIST........................................................................... 797 TERMS CONTRADISTINCTION LIST........................................................................ 805 DIAGRAM............................................................................................. 808 POSITION OF CONNECTOR............................................................................... 944 CONNECTOR........................................................................................... 969 PIN LIST OF WIRE TO WIRE CONNECTOR (IN THE BULK HEAD CONNECTOR BOX)................................. 994 PIN LIST OF WIRE TO WIRE CONNECTOR (OUT OF THE BULK HEAD CONNECTOR BOX)............................. 996 CONNECTOR LIST...................................................................................... 998 FOREWORD....................................................................................................1011 CHAPTER REFERENCES .........................................................................................1012 INDEX.......................................................................................................1013 GENERAL INTRODUCTION (ENGINE)...............................................................................1015 GENERAL INTRODUCTION (ENGINE) ..........................................................................1016 GENERAL PRECAUTIONS.................................................................................1016 HOW TO USE THIS WORKSHOP MANUAL.....................................................................1019 IDENTIFICATION INFORMATION..........................................................................1021 PRECAUTIONS.........................................................................................1022 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS........................................................1025 DISMOUNTING AND MOUNTING............................................................................1026 SYMPTOM SIMULATION..................................................................................1029 GLOSSARY OF SAE AND HINO TERMS......................................................................1031 ENGINE INTRODUCTION (J08E)..................................................................................1034 ENGINE ASSEMBLY ........................................................................................1035 DATA AND SPECIFICATIONS.............................................................................1035 TROUBLESHOOTING.....................................................................................1037 TROUBLESHOOTING (COMMON RAIL SYSTEM)................................................................1044 ENGINE TUNEUP.......................................................................................1045 SPECIAL TOOL........................................................................................1051 OVERHAUL CRITERIA...................................................................................1052 DISMOUNTING AND MOUNTING............................................................................1053 LIQUID GASKET AND APPLICATION POINTS................................................................1055 ENGINE MECHANICAL (J08E)....................................................................................1060 CYLINDER HEAD ..........................................................................................1061 COMPONENT LOCATOR...................................................................................1061 SPECIAL TOOL........................................................................................1064 OVERHAUL............................................................................................1065 INSPECTION AND REPAIR...............................................................................1076 CRANKSHAFT FRONT END ...................................................................................1080 COMPONENT LOCATOR...................................................................................1080 SPECIAL TOOL........................................................................................1081 OVERHAUL............................................................................................1082 FLYWHEEL AND FLYWHEEL HOUSING ..........................................................................1084 COMPONENT LOCATOR...................................................................................1084 SPECIAL TOOL........................................................................................1085 OVERHAUL............................................................................................1085 INSPECTION AND REPAIR...............................................................................1091 TIMING GEAR ............................................................................................1092 COMPONENT LOCATOR...................................................................................1092 SPECIAL TOOL........................................................................................1093 OVERHAUL............................................................................................1094 INSPECTION AND REPAIR...............................................................................1096 MAIN MOVING PARTS AND CYLINDER BLOCK ...................................................................1098 COMPONENT LOCATOR...................................................................................1098 SPECIAL TOOL........................................................................................1101 OVERHAUL............................................................................................1103 INSPECTION AND REPAIR...............................................................................1116 AIR INTAKE SYSTEM (J08E)....................................................................................1120 AIR INTAKE MANIFOLD AND PIPE ...........................................................................1121 COMPONENT LOCATOR...................................................................................1121 DISMOUNTING AND MOUNTING............................................................................1122 AIR INTAKE .............................................................................................1123 COMPONENT LOCATOR...................................................................................1123 AIR CLEANER ............................................................................................1124 DESCRIPTION.........................................................................................1124 OVERHAUL............................................................................................1125 AIR HOSE ...............................................................................................1126 COMPONENT LOCATOR...................................................................................1126 OVERHAUL............................................................................................1127 AIR FLOW SENSOR ........................................................................................1128 COMPONENT LOCATOR...................................................................................1128 REPLACEMENT.........................................................................................1129 BOOST PRESSURE SENSOR ..................................................................................1130 COMPONENT LOCATOR...................................................................................1130 REPLACEMENT.........................................................................................1131 EXHAUST SYSTEM (J08E).......................................................................................1132 EXHAUST MANIFOLD AND PIPE ..............................................................................1133 COMPONENT LOCATOR...................................................................................1133 DISMOUNTING AND MOUNTING............................................................................1134 EXHAUST PIPE AND MUFFLER UNIT ..........................................................................1135 DESCRIPTION.........................................................................................1135 COMPONENT LOCATOR...................................................................................1136 OVERHAUL............................................................................................1142 DPR (DIESEL PARTICULATE REDUCTION SYSTEM) ..............................................................1153 SYSTEM CONFIGURATION................................................................................1153 STRUCTURE OF DPR-CLEANER............................................................................1154 DPR MAINTENANCE.....................................................................................1155 DPR INSPECTION......................................................................................1155 INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY........1156 INSPECTION BY WAY OF HINO-DX........................................................................1157 INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL)........................1161 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO-DX..................................1164 CHECKING THE DPR STATE..............................................................................1164 REPLACEMENT OF DPR FILTER...........................................................................1165 OVERALL OPERATION FLOW..............................................................................1169 DIFFERENTIAL PRESSURE SENSOR ...........................................................................1177 COMPONENT LOCATOR...................................................................................1177 DISMOUNTING AND MOUNTING............................................................................1178 EXHAUST CONTROL CYLINDER ...............................................................................1181 SYSTEM CONFIGURATION................................................................................1181 DPR INSPECTION CHECK SHEET..........................................................................1182 LUBRICATING SYSTEM (J08E)...................................................................................1185 LUBRICATING SYSTEM .....................................................................................1186 DIAGRAM.............................................................................................1186 OIL PUMP AND OIL STRAINER ..............................................................................1188 COMPONENT LOCATOR...................................................................................1188 OVERHAUL............................................................................................1189 INSPECTION AND REPAIR...............................................................................1190 OIL FILTER AND OIL COOLER ..............................................................................1192 COMPONENT LOCATOR...................................................................................1192 SPECIAL TOOL........................................................................................1193 DISMOUNTING AND MOUNTING............................................................................1194 INSPECTION AND REPAIR...............................................................................1195 COOLING SYSTEM (J08E).......................................................................................1196 COOLING SYSTEM .........................................................................................1197 DIAGRAM.............................................................................................1197 COOLANT PUMP ...........................................................................................1198 COMPONENT LOCATOR...................................................................................1198 THERMOSTAT .............................................................................................1199 COMPONENT LOCATOR...................................................................................1199 OVERHAUL............................................................................................1200 RADIATOR AND INTERCOOLER ...............................................................................1202 COMPONENT LOCATOR...................................................................................1202 OVERHAUL............................................................................................1202 RADIATOR ...............................................................................................1204 COMPONENT LOCATOR...................................................................................1204 SPECIAL TOOL........................................................................................1205 OVERHAUL............................................................................................1205 INSPECTION AND REPAIR...............................................................................1209 COOLING FAN ............................................................................................1210 COMPONENT LOCATOR...................................................................................1210 INSPECTION AND REPAIR...............................................................................1211 FUEL SYSTEM (J08E)..........................................................................................1212 FUEL SYSTEM ............................................................................................1213 DIAGRAM.............................................................................................1213 COMPONENT LOCATOR...................................................................................1214 SUPPLY PUMP ............................................................................................1215 DESCRIPTION.........................................................................................1215 COMPONENT LOCATOR...................................................................................1216 SPECIAL TOOL........................................................................................1216 OVERHAUL............................................................................................1217 COMMON RAIL ............................................................................................1226 DESCRIPTION.........................................................................................1226 INSPECTION..........................................................................................1226 REPLACEMENT.........................................................................................1228 INJECTOR ...............................................................................................1232 DESCRIPTION.........................................................................................1232 REPLACEMENT.........................................................................................1233 FUEL FILTER ............................................................................................1241 DESCRIPTION.........................................................................................1241 AIR BLEEDING........................................................................................1242 BUBBLE SEPARATOR .......................................................................................1244 DESCRIPTION.........................................................................................1244 BUBBLE SEPARATOR .......................................................................................1245 COMPONENT LOCATOR...................................................................................1245 TURBOCHARGER (J08E).........................................................................................1247 TURBOCHARGER ...........................................................................................1248 DESCRIPTION.........................................................................................1248 TROUBLESHOOTING.....................................................................................1249 OVERHAUL CRITERIA...................................................................................1265 EMISSION CONTROL (J08E).....................................................................................1267 EGR VALVE AND EGR PIPE .................................................................................1268 COMPONENT LOCATOR...................................................................................1268 EGR VALVE ..............................................................................................1269 DESCRIPTION.........................................................................................1269 DISMOUNTING AND MOUNTING............................................................................1270 CLOSED VENTILATOR ......................................................................................1273 DESCRIPTION.........................................................................................1273 REPLACEMENT OF CLOSED VENTILATOR....................................................................1273 SELECTIVE CATALYTIC REDUCTION (SCR) ....................................................................1274 GENERAL DESCRIPTION.................................................................................1274 COMPONENT LOCATOR...................................................................................1276 INSPECTION..........................................................................................1277 DISMOUNTING AND MOUNTING............................................................................1278 INSPECTION AND REPAIR...............................................................................1293 BURNER SYSTEM ..........................................................................................1294 COMPONENT LOCATOR...................................................................................1294 BURNER SYSTEM WARNING AND CAUTION...................................................................1295 DISMOUNTING AND MOUNTING............................................................................1296 INSPECTION AND REPAIR...............................................................................1305 ALTERNATOREN1(J08E: REMY 12V-130A,135A,180A)................................................................1306 ALTERNATOR..............................................................................................1307 DATA AND SPECIFICATIONS.............................................................................1307 TROUBLESHOOTING.....................................................................................1307 COMPONENT LOCATOR...................................................................................1308 OVERHAUL............................................................................................1309 INSPECTION AND REPAIR...............................................................................1312 STARTER (J08E)..............................................................................................1313 STARTER.................................................................................................1314 DATA AND SPECIFICATIONS.............................................................................1314 DESCRIPTION.........................................................................................1314 TROUBLESHOOTING.....................................................................................1315 COMPONENT LOCATOR...................................................................................1316 OVERHAUL............................................................................................1317 INSPECTION AND REPAIR...............................................................................1321 AIR COMPRESSOR (J08E: 340 cm3)..............................................................................1324 AIR COMPRESSOR..........................................................................................1325 DATA AND SPECIFICATIONS.............................................................................1325 DESCRIPTION.........................................................................................1326 TROUBLESHOOTING.....................................................................................1327 COMPONENT LOCATOR...................................................................................1328 SPECIAL TOOL........................................................................................1329 OVERHAUL............................................................................................1329 INSPECTION AND REPAIR...............................................................................1337 ENGINE CONTROL (J08E).......................................................................................1340 ACCELERATOR PEDAL.......................................................................................1341 DESCRIPTION.........................................................................................1341 ENGINE ECU..............................................................................................1342 COMPONENT LOCATOR...................................................................................1342 REPLACEMENT.........................................................................................1343 FOREWORD....................................................................................................1350 CHAPTER REFERENCES..........................................................................................1351 INDEX.......................................................................................................1352 GENERAL INTRODUCTION........................................................................................1353 GENERAL INTRODUCTION....................................................................................1354 GENERAL PRECAUTIONS.................................................................................1354 IDENTIFICATION INFORMATION..........................................................................1357 HOW TO USE THIS WORKSHOP MANUAL.....................................................................1364 INTRODUCTION TO DESCRIPTIONS........................................................................1364 PRECAUTIONS.........................................................................................1367 SEALANT ON THE TAPERED SCREW FOR PIPING.............................................................1370 METRIC INFORMATION..................................................................................1371 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS........................................................1373 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS..........................................................1374 RECOMMENDED LUBRICANTS..............................................................................1375 INFORMATION DISPLAY.................................................................................1377 GLOSSARY............................................................................................1382 GLOSSARY OF SAE AND HINO TERMS......................................................................1385 TERMS CONTRADISTINCTION LIST........................................................................1388 TROUBLE SHOOTING - COMPONENTS...............................................................................1390 ENGINE BASIC............................................................................................1391 ENGINE ASSEMBLY.....................................................................................1391 ENGINE ASSEMBLY (COMMON RAIL SYSTEM)................................................................1398 TURBOCHARGER (J08E).....................................................................................1399 TURBOCHARGER........................................................................................1399 ALTERNATOR (J08E: REMY 12V-130A, 135A, 180A)............................................................1408 ALTERNATOR..........................................................................................1408 STARTER (J08E)..........................................................................................1409 STARTER.............................................................................................1409 AIR COMPRESSOR (J08E: 340 cm3)..........................................................................1410 AIR COMPRESSOR......................................................................................1410 CLUTCH MAIN UNIT........................................................................................1411 CLUTCH ASSEMBLY (EATON SAS1401).....................................................................1411 CLUTCH ASSEMBLY (EATON SAS1402).....................................................................1413 AUTOMATIC TRANSMISSION..................................................................................1415 AUTOMATIC TRANSMISSION ASSEMBLY.....................................................................1415 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) .............................................1416 TRANSMISSION CONTROL UNIT...........................................................................1416 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION).........................................1417 TRANSMISSION CONTROL UNIT...........................................................................1417 PROPELLER SHAFT (SPL 100, 140)..........................................................................1418 PROPELLER SHAFT ASSEMBLY............................................................................1418 DIFFERENTIAL CARRIER (MERITOR RS-17, 19, 21 AND 23).....................................................1419 DIFFERENTIAL CARRIER ASSEMBLY.......................................................................1419 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)...........................................................1420 SERVICE BRAKE ASSEMBLY..............................................................................1420 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)............................................................1425 SERVICE BRAKE ASSEMBLY..............................................................................1425 SERVICE BRAKE (HYDRAULIC BRAKE).........................................................................1427 WHEEL BRAKE (TYPE: 4 PISTON)........................................................................1427 SERVICE BRAKE (FULL AIR BRAKE)..........................................................................1429 AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS)................................................1429 EXHAUST BRAKE...........................................................................................1433 EXHAUST BRAKE SYSTEM................................................................................1433 PARKING BRAKE (BOSCH 12)................................................................................1434 PARKING BRAKE ASSEMBLY..............................................................................1434 STEERING EQUIPMENT......................................................................................1435 STEERING SYSTEM.....................................................................................1435 FRONT AXLE (MFS)........................................................................................1439 FRONT AXLE (MFS)....................................................................................1439 REAR AXLE...............................................................................................1441 REAR AXLE...........................................................................................1441 WHEEL AND TIRE..........................................................................................1442 WHEEL AND TIRE......................................................................................1442 SUSPENSION..............................................................................................1444 LEAF SUSPENSION ASSEMBLY............................................................................1444 AIR SUSPENSION ASSEMBLY.............................................................................1444 CHASSIS FRAME...........................................................................................1445 CHASSIS FRAME.......................................................................................1445 CAB.....................................................................................................1446 CAB ASSEMBLY........................................................................................1446 AIR CONDITIONING SYSTEM.............................................................................1447 ELECTRICAL EQUIPMENT....................................................................................1457 ELECTRICAL PARTS....................................................................................1457 TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM...............................................................1459 ABOUT HINO-DX...........................................................................................1460 About Hino-DX.......................................................................................1460 BASIC PROCEDURE FOR TROUBLESHOOTING.....................................................................1461 BASIC PROCEDURE FOR TROUBLESHOOTING.................................................................1461 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE........................................................1463 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....................................................1463 SYMPTOM SIMULATION......................................................................................1466 SYMPTOM SIMULATION..................................................................................1466 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART...........................................................1468 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART.......................................................1468 ELECTRONIC CIRCUIT INSPECTION PROCEDURE.................................................................1469 ELECTRONIC CIRCUIT INSPECTION PROCEDURE.............................................................1469 INSPECTION PROCEDURE FOR MULTIPLE DTCS..................................................................1474 INSPECTION PROCEDURE FOR MULTIPLE DTCS..............................................................1474 ENGINE CONTROL SYSTEM (J08E) ...............................................................................1475 ENGINE CONTROL SYSTEM...................................................................................1477 PRECAUTIONS FOR DIAGNOSIS...........................................................................1477 SYSTEM BLOCK DIAGRAM................................................................................1479 SYSTEM DIAGRAM......................................................................................1480 PRECAUTIONS.........................................................................................1482 SENSOR LOCATION.....................................................................................1485 COMPUTER (ECU) PIN ASSIGNMENT.......................................................................1494 ENGINE ECU CONNECTOR................................................................................1498 INSPECTION..........................................................................................1502 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...............................................................1503 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.................................................................1504 GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL......................................................1519 GROUP SHARING THE SENSOR GND TERMINAL...............................................................1520 ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET).......................................1521 NO DTC..............................................................................................1524 DTC: P0016..........................................................................................1527 DTC: P003A..........................................................................................1531 DTC: P0045..........................................................................................1538 DTC: P0047..........................................................................................1545 DTC: P0048..........................................................................................1552 DTC: P006E..........................................................................................1559 DTC: P006F..........................................................................................1564 DTC: P007B..........................................................................................1569 DTC: P007C and P007D................................................................................1587 DTC: P0088..........................................................................................1596 DTC: P0096..........................................................................................1620 DTC: P0097 and P0098 ...............................................................................1635 DTC: P00AF..........................................................................................1644 DTC: P0101..........................................................................................1649 DTC: P0104..........................................................................................1661 DTC: P0106..........................................................................................1669 DTC: P0108..........................................................................................1676 DTC: P0112 and P0113................................................................................1684 DTC: P0115..........................................................................................1693 DTC: P0117 and P0118................................................................................1705 DTC: P011A..........................................................................................1715 DTC: P011C..........................................................................................1726 DTC: P0122 and P0123................................................................................1734 DTC: P0128..........................................................................................1747 DTC: P016E and P016F ...............................................................................1754 DTC: P0182 and P0183 ...............................................................................1778 DTC: P0191..........................................................................................1787 DTC: P0192 and P0193 ...............................................................................1809 DTC: P01A5..........................................................................................1820 DTC: P01A6..........................................................................................1829 DTC: P0200..........................................................................................1838 DTC: P0201, P0202, P0203, P0204, P0205 and P0206....................................................1841 DTC: P0217..........................................................................................1850 DTC: P0219..........................................................................................1857 DTC: P0222 and P0223................................................................................1864 DTC: P0234..........................................................................................1876 DTC: P0237..........................................................................................1883 DTC: P0263, P0266, P0269, P0272, P0275 and P0278....................................................1892 DTC: P026C and P026D................................................................................1908 DTC: P0299..........................................................................................1926 DTC: P0300..........................................................................................1933 DTC: P0301, P0302, P0303, P0304, P0305 and P0306....................................................1943 DTC: P0335..........................................................................................1955 DTC: P0336..........................................................................................1963 DTC: P0340..........................................................................................1971 DTC: P0341..........................................................................................1978 DTC: P0381..........................................................................................1986 DTC: P0401..........................................................................................1993 DTC: P0402..........................................................................................2011 DTC: P0404..........................................................................................2024 DTC: P0405 and P0406................................................................................2031 DTC: P041B..........................................................................................2038 DTC: P041C and P041D................................................................................2053 DTC: P0420..........................................................................................2063 DTC: P0489 and P0490................................................................................2070 DTC: P049D..........................................................................................2077 DTC: P04D5 and P04D6................................................................................2084 DTC: P0500 and P0501................................................................................2093 DTC: P0504..........................................................................................2101 DTC: P0519..........................................................................................2109 DTC: P0524..........................................................................................2113 DTC: P0562 and P0563................................................................................2120 DTC: P05F1..........................................................................................2128 DTC: P0605..........................................................................................2138 DTC: P0606..........................................................................................2141 DTC: P0607..........................................................................................2144 DTC: P0610..........................................................................................2147 DTC: P0611..........................................................................................2151 DTC: P0617..........................................................................................2154 DTC: P0628 and P0629................................................................................2159 DTC: P062F..........................................................................................2168 DTC: P0630..........................................................................................2173 DTC: P0642..........................................................................................2177 DTC: P0643..........................................................................................2184 DTC: P064C..........................................................................................2192 DTC: P0652..........................................................................................2199 DTC: P0653..........................................................................................2205 DTC: P0671, P0672, P0675 and P0676 .................................................................2212 DTC: P0683..........................................................................................2224 DTC: P0686..........................................................................................2231 DTC: P06D3 and P06D4................................................................................2236 DTC: P0704..........................................................................................2244 DTC: P073D..........................................................................................2250 FOREWORD....................................................................................................2258 CHAPTER REFERENCES..........................................................................................2259 INDEX.......................................................................................................2260 ENGINE CONTROL SYSTEM (J08E) ...............................................................................2261 ENGINE CONTROL SYSTEM...................................................................................2263 DTC: P081A..........................................................................................2263 DTC: P081B..........................................................................................2268 DTC: P0850..........................................................................................2273 DTC: P1133..........................................................................................2280 DTC: P119F..........................................................................................2288 DTC: P141F..........................................................................................2295 DTC: P1426..........................................................................................2298 DTC: P1427..........................................................................................2306 DTC: P1428..........................................................................................2314 DTC: P1458..........................................................................................2323 DTC: P1459..........................................................................................2330 DTC: P14B0..........................................................................................2337 DTC: P14B2..........................................................................................2342 DTC: P14B3 and P14B4................................................................................2347 DTC: P14B7 and P14B8................................................................................2354 DTC: P14BC and P14BD................................................................................2361 DTC: P14BF..........................................................................................2368 DTC: P1515..........................................................................................2375 DTC: P1530..........................................................................................2381 DTC: P1601..........................................................................................2386 DTC: P200C..........................................................................................2391 DTC: P203F..........................................................................................2402 DTC: P204F..........................................................................................2407 DTC: P207F..........................................................................................2411 DTC: P20EE..........................................................................................2423 DTC: P2100..........................................................................................2435 DTC: P2101..........................................................................................2442 DTC: P2103..........................................................................................2450 DTC: P2120..........................................................................................2457 DTC: P2122 and P2123................................................................................2462 DTC: P2127 and P2128................................................................................2471 DTC: P2135..........................................................................................2482 DTC: P2138..........................................................................................2489 DTC: P2146..........................................................................................2495 DTC: P2147 and P2148................................................................................2503 DTC: P2149..........................................................................................2512 DTC: P2150 and P2151................................................................................2520 DTC: P2184 and P2185................................................................................2529 DTC: P2214..........................................................................................2538 DTC: P2227..........................................................................................2552 DTC: P2228 and P2229................................................................................2557 DTC: P2269..........................................................................................2562 DTC: P226C..........................................................................................2568 DTC: P22D3..........................................................................................2577 DTC: P240F..........................................................................................2582 DTC: P242B..........................................................................................2595 DTC: P242C and P242D................................................................................2605 DTC: P244A..........................................................................................2615 DTC: P244B..........................................................................................2641 DTC: P2457..........................................................................................2670 DTC: P2459..........................................................................................2687 DTC: P2463..........................................................................................2690 DTC: P246F..........................................................................................2704 DTC: P2470 and P2471................................................................................2714 DTC: P2563..........................................................................................2724 DTC: P2564 and P2565................................................................................2731 DTC: P259E..........................................................................................2740 DTC: P259F..........................................................................................2747 DTC: P2635..........................................................................................2754 DTC: P268A and P2696................................................................................2776 DTC: P2BA9..........................................................................................2783 DTC: U0073..........................................................................................2789 DTC: U010A..........................................................................................2793 DTC: U010C..........................................................................................2796 DTC: U010E..........................................................................................2799 DTC: U029D..........................................................................................2802 DTC: U029E..........................................................................................2805 DTC: U02A2..........................................................................................2808 DTC: U0301..........................................................................................2811 DTC: U1001..........................................................................................2815 DTC: U110A..........................................................................................2818 DTC: U111E..........................................................................................2821 DEF SCR SYSTEM (DCU) .......................................................................................2824 DEF SCR SYSTEM..........................................................................................2825 PRECAUTIONS FOR DIAGNOSIS...........................................................................2825 SYSTEM BLOCK DIAGRAM................................................................................2827 SYSTEM DIAGRAM......................................................................................2828 SENSOR LOCATION.....................................................................................2829 COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT................................................2831 SIGNAL CHECK HARNESS................................................................................2832 INSPECTION..........................................................................................2832 MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN....................................................2833 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...............................................................2833 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.................................................................2835 DTC: P0071..........................................................................................2840 DTC: P0072..........................................................................................2855 DTC: P0073..........................................................................................2865 DTC: P0562..........................................................................................2875 DTC: P0563..........................................................................................2879 DTC: P060C..........................................................................................2883 DTC: P062F..........................................................................................2886 DTC: P0667..........................................................................................2889 DTC: P0668..........................................................................................2892 DTC: P0669..........................................................................................2895 DTC: P068A..........................................................................................2898 DTC: P142A..........................................................................................2906 DTC: P142B..........................................................................................2911 DTC: P202E..........................................................................................2926 DTC: P203C..........................................................................................2933 DTC: P203D..........................................................................................2937 DTC: P2044..........................................................................................2941 DTC: P2045..........................................................................................2945 DTC: P2047..........................................................................................2949 DTC: P2048..........................................................................................2952 DTC: P2049..........................................................................................2958 DTC: P204B..........................................................................................2965 DTC: P204C..........................................................................................2969 DTC: P204D..........................................................................................2976 DTC: P205B..........................................................................................2983 DTC: P205C..........................................................................................2996 DTC: P205D..........................................................................................3000 DTC: P206A..........................................................................................3004 DTC: P208A..........................................................................................3008 DTC: P208B..........................................................................................3013 DTC: P208C..........................................................................................3016 DTC: P208D..........................................................................................3020 DTC: P20A0..........................................................................................3024 DTC: P20A1..........................................................................................3031 DTC: P20A2..........................................................................................3035 DTC: P20A3..........................................................................................3042 DTC: P20B1..........................................................................................3048 DTC: P20B2..........................................................................................3054 DTC: P20B3..........................................................................................3066 DTC: P20B4..........................................................................................3072 DTC: P20E8..........................................................................................3078 DTC: P20E9..........................................................................................3089 DTC: P20F4..........................................................................................3097 DTC: P2201..........................................................................................3104 DTC: P2202..........................................................................................3117 DTC: P2203..........................................................................................3121 DTC: P2204..........................................................................................3125 DTC: P2209..........................................................................................3135 DTC: P2212..........................................................................................3146 DTC: P2215..........................................................................................3157 DTC: P2216..........................................................................................3161 DTC: P2222..........................................................................................3165 FOREWORD....................................................................................................3177 CHAPTER REFERENCES..........................................................................................3178 INDEX.......................................................................................................3179 DEF SCR SYSTEM (DCU) .......................................................................................3180 DEF SCR SYSTEM.......................................................................................... 0 DTC: P2481..........................................................................................3181 DTC: P2482..........................................................................................3188 DTC: P2483..........................................................................................3196 DTC: P2510..........................................................................................3214 DTC: P2BAE..........................................................................................3221 DTC: U0029..........................................................................................3232 DTC: U0038..........................................................................................3235 DTC: U0100..........................................................................................3238 DTC: U029D..........................................................................................3243 DTC: U029E..........................................................................................3246 DTC: U02A2..........................................................................................3249 DTC: U0597..........................................................................................3252 BURNER CONTROL SYSTEM (BCU) ................................................................................3255 BURNER CONTROL SYSTEM...................................................................................3256 PRECAUTIONS FOR DIAGNOSIS...........................................................................3256 SYSTEM BLOCK DIAGRAM................................................................................3258 SYSTEM DIAGRAM......................................................................................3259 SENSOR LOCATION.....................................................................................3260 SIGNAL CHECK HARNESS................................................................................3262 INSPECTION..........................................................................................3262 MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN....................................................3263 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...............................................................3263 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.................................................................3265 DTC: P018C..........................................................................................3272 DTC: P018D..........................................................................................3277 DTC: P0351..........................................................................................3283 DTC: P0413..........................................................................................3293 DTC: P0414..........................................................................................3300 DTC: P0416..........................................................................................3306 DTC: P0417..........................................................................................3311 DTC: P0545..........................................................................................3315 DTC: P0546..........................................................................................3321 DTC: P0562..........................................................................................3327 DTC: P0563..........................................................................................3330 DTC: P060C..........................................................................................3333 DTC: P062F..........................................................................................3336 DTC: P0642..........................................................................................3339 DTC: P0643..........................................................................................3345 DTC: P1400..........................................................................................3351 DTC: P1401..........................................................................................3395 DTC: P1402..........................................................................................3400 DTC: P1403..........................................................................................3405 DTC: P1404..........................................................................................3413 DTC: P1405..........................................................................................3420 DTC: P1406..........................................................................................3430 DTC: P1407..........................................................................................3444 DTC: P1408..........................................................................................3456 DTC: P1409..........................................................................................3461 DTC: P140A..........................................................................................3466 DTC: P140B..........................................................................................3472 DTC: P140C..........................................................................................3485 DTC: P140D..........................................................................................3497 DTC: P140E..........................................................................................3545 DTC: P140F..........................................................................................3591 DTC: P141B..........................................................................................3624 DTC: P141C..........................................................................................3631 DTC: P141D..........................................................................................3637 DTC: P2029..........................................................................................3645 DTC: P2032..........................................................................................3660 DTC: P2033..........................................................................................3667 DTC: P2080..........................................................................................3673 DTC: P2084..........................................................................................3680 DTC: P20D3..........................................................................................3687 DTC: P20D4..........................................................................................3691 DTC: P2300..........................................................................................3695 DTC: P2301..........................................................................................3706 DTC: P2302..........................................................................................3712 DTC: P2430..........................................................................................3715 DTC: P2431..........................................................................................3721 DTC: P2432..........................................................................................3726 DTC: P2433..........................................................................................3731 DTC: P2437..........................................................................................3737 DTC: P2438..........................................................................................3742 DTC: P2440..........................................................................................3748 DTC: P2441..........................................................................................3751 DTC: P2506 .........................................................................................3762 DTC: P2507..........................................................................................3768 DTC: P2508..........................................................................................3773 DTC: P2531..........................................................................................3778 DTC: P2532..........................................................................................3781 DTC: P2633..........................................................................................3784 DTC: P2634..........................................................................................3788 DTC: P3040..........................................................................................3793 DTC: P3041..........................................................................................3797 DTC: U0100..........................................................................................3802 BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION)) ...........................................................3805 ABS.....................................................................................................3806 OVERVIEW............................................................................................3806 COMPOSITION AND OPERATION...........................................................................3807 FUNCTION............................................................................................3811 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS.................................................3812 OVERVIEW AND FUNCTION...............................................................................3813 BRAKE CONTROL SYSTEM (ABS:FULL AIR) ........................................................................3825 ABS.....................................................................................................3826 OVERVIEW............................................................................................3826 COMPOSITION AND OPERATION...........................................................................3827 FUNCTION............................................................................................3830 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS.................................................3831 OVERVIEW AND FUNCTION...............................................................................3832 INSPECTION (FRONT WHEEL BRAKE)......................................................................3837 INSPECTION (REAR WHEEL BRAKE).......................................................................3839 VEHICLE CONTROL SYSTEM......................................................................................3845 VEHICLE CONTROL SYSTEM..................................................................................3846 PRECAUTIONS FOR DIAGNOSIS...........................................................................3846 SYSTEM BLOCK DIAGRAM................................................................................3848 SIGNAL CHECK HARNESS................................................................................3849 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...............................................................3857 VEHICLE CONTROL ECU INSPECTION......................................................................3858 DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE.............................................3866 DTC: P0500..........................................................................................3867 DTC: P0501..........................................................................................3872 DTC: P0562..........................................................................................3876 DTC: P0563..........................................................................................3880 DTC: P0617..........................................................................................3883 DTC: P0704..........................................................................................3887 DTC: P0850..........................................................................................3895 DTC: P1142..........................................................................................3903 DTC: P1143..........................................................................................3909 DTC: P1565..........................................................................................3915 DTC: U0101..........................................................................................3923 DTC: U0105 .........................................................................................3926 DTC: U0155..........................................................................................3929 NO ACTIVATION OF AUXILIARY BRAKE....................................................................3932 NO ACTIVATION/RELEASE OF ENGINE REVOLUTION CONTROL..................................................3942 NO ACTIVATION/RELEASE OF CRUISE FUNCTION............................................................3950 NO ACTIVATION/RELEASE OF ECO MODE...................................................................3962 CAN COMMUNICATION...........................................................................................3968 CAN COMMUNICATION SYSTEM................................................................................3969 CAN COMMUNICATION TROUBLESHOOTING...................................................................3969 Outline.........................................................................................3969 Definition of Terms.............................................................................3969 Work Flow.......................................................................................3970 ECU individual code list........................................................................3970 CAN communication circuit diagram...............................................................3972 CAN communication relation connector location...................................................3975 ENGINE CAN COMMUNICATION LINE.......................................................................3979 CONNECTION DIAGRAM..............................................................................3979 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE.....................................3979 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE................................................3981 DISCONNECTION INSPECTION FOR ENGINE CAN_H/L_COMMUNICATION LINE..................................3984 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE......................................................3988 INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE......................................................3996 INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE............................................4004 INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE............................................4008 INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE).......................4012 INSPECTION FOR BCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE).......................4017 INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE..............................................4023 INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE..............................................4028 INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE................................................4034 DIAGNOSIS CAN COMMUNICATION LINE....................................................................4040 CONNECTION DIAGRAM..............................................................................4040 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE.....................................4040 PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE.............................................4042 DISCONNECTION INSPECTION FOR DIAGNOSIS CAN_H/L_COMMUNICATION LINE...............................4045 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H-LINE............................................4049 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN L-LINE............................................4054 INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)....................4059 INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE................................................4063 INSPECTION FOR BCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)....................4067 CONTROL CAN COMMUNICATION LINE......................................................................4069 CONNECTION DIAGRAM (ALLISON AUTOMATIC TRANSMISSION).............................................4069 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)....4069 CONNECTION DIAGRAM (MANUAL TRANSMISSION)........................................................4070 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION)...............4070 PRE-INSPECTION FOR CAN COMMUNICATION LINE.......................................................4071 DISCONNECTION INSPECTION FOR CAN_H/L_COMMUNICATION LINE.........................................4075 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE......................................................4077 INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE......................................................4079 INSPECTION FOR AUTOMATIC TRANSMISSION ECU CAN COMMUNICATION LINE................................4081 FOREWORD....................................................................................................4084 CHAPTER REFERENCES .........................................................................................4085 INDEX.......................................................................................................4086 System Configuration, Connection and Setup..................................................................4087 Special Tool and Outline of Function....................................................................4088 Special Tool and Outline of Function................................................................4088 Recommended system..................................................................................4090 Installing Interface Driver.............................................................................4094 Installing Interface Driver.........................................................................4094 Upgrading Hino-Bowie....................................................................................4095 Upgrading Hino-Bowie................................................................................4095 Instruction for Updating the Hino Bowie Interface...................................................4095 Object Devices......................................................................................4095 Materials Required for Updates......................................................................4095 Hino-Bowie Interface Update Instruction.............................................................4095 Hino-Bowie Hardware Driver Update Instructions......................................................4099 Activation of Software..................................................................................4102 Activation of Software..............................................................................4102 Connection to the vehicle...............................................................................4103 Connection to the vehicle...........................................................................4103 System Design ..........................................................................................4104 Registration of user (Administrator)................................................................4104 Setting-up Option...................................................................................4106 HINO Diagnostic eXplorer....................................................................................4122 Outline of HINO-DX Function.............................................................................4124 Outline of HINO-DX Function.........................................................................4124 Method of Diagnosis.................................................................................4125 HINO-DX Name of the Screen..............................................................................4126 HINO-DX Name of the Screen..........................................................................4126 Starting up HINO DX.....................................................................................4128 Starting up HINO DX.................................................................................4128 Reading DTC code........................................................................................4130 Reading DTC code....................................................................................4130 How to read DTC.....................................................................................4130 After System Fix....................................................................................4132 Diagnostic Information..................................................................................4138 Diagnostic Information..............................................................................4138 Symptom Based Diagnostic Information................................................................4139 DTC Based Diagnostic Information....................................................................4140 System individual function..............................................................................4141 System individual function..........................................................................4141 Injector correction.................................................................................4142 Accelerator sensor adjustment.......................................................................4148 Intake air volume check.............................................................................4149 Fuel leak check.....................................................................................4150 VNT check...........................................................................................4151 EGR check...........................................................................................4152 Turbocharger check..................................................................................4154 Inspecting common rail pressure.....................................................................4156 DPR check...........................................................................................4157 Deviation learning after pump replacement...........................................................4161 Intake throttle valve check.........................................................................4164 Change settings of upper limit of vehicle speed.....................................................4165 DEF addition test...................................................................................4166 Test pattern........................................................................................4167 DEF leak test.......................................................................................4168 BCU Event log check.................................................................................4169 System Protection Data..................................................................................4170 System Protection Data..............................................................................4170 What can be done in System Protection Data..........................................................4170 Sample of system protection data items..............................................................4172 Learned Values..........................................................................................4175 Learned Values......................................................................................4175 What can be done in Learned Values..................................................................4175 Sample of learned values items......................................................................4176 Past Work Information ..................................................................................4177 Past Work Information / Hino-DX report..............................................................4177 What can be done in Past Work Information...........................................................4178 Save/Load ECU Feature...................................................................................4182 Save/Load ECU Feature...............................................................................4182 What can be done in Save / Load ECU Feature.........................................................4182 Save ECU configuration data.........................................................................4183 Write ECU configuration data........................................................................4184 Delete the ECU configuration data...................................................................4185 Procedure - Import / Export ECU configuration data..................................................4186 Activation Test.........................................................................................4189 Activation Test.....................................................................................4189 What can be done in Activation Test.................................................................4189 Procedure - Activation Test.........................................................................4190 Diagnostic simulation...................................................................................4195 Diagnostic simulation...............................................................................4195 Procedure - Simulation..............................................................................4195 Vehicle Feature Confirmation............................................................................4196 Vehicle Feature Confirmation........................................................................4196 HINO DX version information.............................................................................4197 HINO DX version information.........................................................................4197 Customization...........................................................................................4198 Customization.......................................................................................4198 What can be done in Customization...................................................................4198 Procedure - Customization...........................................................................4199 Detail of customization items (Engine ECU)..........................................................4202 Detail of customization items (Vehicle control ECU).................................................4213 Detail of customization items (meter)...............................................................4217 Data Monitor............................................................................................4218 Data Monitor........................................................................................4218 What can be done in Data Monitor....................................................................4218 Procedure - Data Monitor............................................................................4219 Monitor set up......................................................................................4219 Data Monitor Setup..................................................................................4223 Data Monitor Operation..............................................................................4226 Other function......................................................................................4228 Trigger function....................................................................................4230 Graph Line Drawing..................................................................................4232 Graph Print.........................................................................................4232 Reproducing method of data monitor (making a graph of data).........................................4233 Data monitor items (Engine ECU).....................................................................4241 Data monitor items (VCS)............................................................................4249 Data monitor items (DCU)............................................................................4251 Data monitor items (BCU)............................................................................4253 BCU Event Log collection by the Data monitor........................................................4255 Manufacturer Parameter..................................................................................4257 Manufacturer Parameter..............................................................................4257 What can be done in Manufacturer Parameter..........................................................4257 Procedure - Manufacturer Parameter..................................................................4258 Manufacturer Parameter Items........................................................................4261 HINO Reprog Manager.........................................................................................4265 General outline of HINO RM function.....................................................................4266 General outline of HINO RM function.................................................................4266 Screen name of HINO-RM..................................................................................4267 Screen name of HINO-RM..............................................................................4267 Reprogramming function..................................................................................4269 Reprogramming function..............................................................................4269 ECU Replacement.....................................................................................4270 ECU program update..................................................................................4271 Engine exchange.....................................................................................4272 Startup of HINO-RM......................................................................................4273 Startup of HINO-RM..................................................................................4273 Re-programming work.....................................................................................4275 Re-programming work.................................................................................4275 Reprogramming to the state of vehicle ..................................................................4285 ECU Replacement.....................................................................................4285 ECU program update..................................................................................4286 Engine replacement..................................................................................4286 SS DATA Creator.............................................................................................4288 SS DATA Creator - Outline of function...................................................................4289 SS DATA Creator - Outline of function...............................................................4289 Procedure - SS DATA Creator.............................................................................4290 Procedure - SS DATA Creator.........................................................................4290 Analysis Example................................................................................4294 Analysis Example............................................................................................4294 Power RELEVANT ENGINE MODEL N04C: J05E: J08E............................................................4295 Phenomenon: Experience a lack of engine power.......................................................4295 Power RELEVANT ENGINE MODEL All engine series...........................................................4297 Phenomenon: Experience a lack of engine power.......................................................4297 Power RELEVANT ENGINE MODEL Models adopting VN Turbo....................................................4299 Phenomenon: Lack of engine power (Engine does not blow up when running at high speed)...............4299 Power RELEVANT ENGINE MODEL All engine series...........................................................4301 Phenomenon: Lack of engine power....................................................................4301 Power RELEVANT ENGINE MODEL E13C........................................................................4303 Phenomenon: Lack of engine power (Poor response to accelerator).....................................4303 Power RELEVANT ENGINE MODEL E13C........................................................................4305 Phenomenon: Lack of power (Slow vehicle speed)......................................................4305 Overheat RELEVANT ENGINE MODEL Engines adopting Cool EGR................................................4307 Phenomenon: Overheat (Large quantity of white smoke after replacing LLC)............................4307 Starting malfunction RELEVANT ENGINE MODEL All engine series............................................4309 Phenomenon: Poor engine start ability...............................................................4309 Starting malfunction RELEVANT ENGINE MODEL N04C, J05E, J08E.............................................4311 Phenomenon: Hunting.................................................................................4311 Reference information.......................................................................................4313 Trouble case example....................................................................................4314 Trouble case example................................................................................4314 List of DTC (Diagnostic Trouble Code) ..................................................................4317 Related to Common Rail..............................................................................4317 Pitfalls of Trouble Diagnosis...........................................................................4322 Pitfalls of Trouble Diagnosis.......................................................................4322
Description:
2014 HINO TRUCK Conventional 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL
- This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
- Applicable for HINO 238, 258LP, 268, 338 series, equipped with J08E-VB and J08E-VC engine When making any repairs on your vehicle, be careful not to be injured through improper procedures.
- As for maintenance items, refer to the Driver’s / Owner’s Manual. All information and specifications in this manual are based upon the latest product information available at the time of printing
- . Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice
- . Please note that the publications below have also been prepared as relevant workshop manuals for the components and systems in these vehicles.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
