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2015 HINO TRUCK Conventional 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL – PDF DOWNLOAD
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2015 HINO TRUCK Conventional 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL
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2015 HINO TRUCK Conventional 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL
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2015 HINO TRUCK CONVENTIONAL 238 258LP 268 338 J08E VB,VC WORKSHOP MANUAL – PDF DOWNLOAD:
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2015 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................................................................. 19 PRECAUTIONS..................................................................................... 22 SEALANT ON THE TAPERED SCREW FOR PIPING......................................................... 25 NYLON TUBE REPLACEMENT METHOD................................................................... 26 METRIC INFORMATION.............................................................................. 28 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.................................................... 30 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS...................................................... 30 RECOMMENDED LUBRICANTS.......................................................................... 32 VEHICLE LIFT AND SUPPORT LOCATIONS.............................................................. 34 INFORMATION DISPLAY............................................................................. 36 SYMPTOM SIMULATION.............................................................................. 41 GLOSSARY........................................................................................ 43 GLOSSARY OF SAE AND HINO TERMS.................................................................. 46 CLUTCH MAIN UNIT (EATON 1401)........................................................................... 49 CLUTCH ASSEMBLY (EATON SAS1401) .................................................................... 50 DATA AND SPECIFICATIONS......................................................................... 50 DESCRIPTION..................................................................................... 50 TROUBLESHOOTING................................................................................. 51 SPECIAL TOOL.................................................................................... 53 COMPONENT LOCATOR............................................................................... 54 OVERHAUL........................................................................................ 55 CLUTCH ASSEMBLY (EATON SOLO1401) ................................................................... 62 DATA AND SPECIFICATIONS......................................................................... 62 COMPONENT LOCATOR............................................................................... 62 OVERHAUL........................................................................................ 63 INSPECTION AND REPAIR........................................................................... 70 CLUTCH MAIN UNIT (EATON 1402)........................................................................... 73 CLUTCH ASSEMBLY (EATON SAS1402) .................................................................... 74 DATA AND SPECIFICATIONS......................................................................... 74 DESCRIPTION..................................................................................... 74 TROUBLESHOOTING................................................................................. 75 SPECIAL TOOL.................................................................................... 77 COMPONENT LOCATOR............................................................................... 78 OVERHAUL........................................................................................ 79 CLUTCH ASSEMBLY (EATON SOLO1402) ................................................................... 88 DATA AND SPECIFICATIONS......................................................................... 88 COMPONENT LOCATOR............................................................................... 88 OVERHAUL........................................................................................ 89 INSPECTION AND REPAIR........................................................................... 99 CLUTCH CONTROL.......................................................................................... 102 CLUTCH CONTROL UNIT ................................................................................ 103 DESCRIPTION..................................................................................... 103 INSPECTION AND ADJUSTMENT....................................................................... 104 CLUTCH PEDAL AND RELEASE UNIT ...................................................................... 107 COMPONENT LOCATOR............................................................................... 107 OVERHAUL........................................................................................ 108 INSPECTION AND REPAIR........................................................................... 110 CLUTCH MASTER CYLINDER ............................................................................. 111 COMPONENT LOCATOR............................................................................... 111 OVERHAUL........................................................................................ 112 INSPECTION AND REPAIR........................................................................... 112 TRANSMISSION MAIN UNIT (EATON FS 5406/6406)............................................................. 113 TRANSMISSION ASSEMBLY............................................................................... 114 DATA AND SPECIFICATION.......................................................................... 114 DISMOUNTING AND MOUNTING........................................................................ 115 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS)............................................... 117 AUTOMATIC TRANSMISSION ASSEMBLY..................................................................... 118 TROUBLESHOOTING................................................................................. 118 SPECIAL TOOL.................................................................................... 118 DISMOUNTING AND MOUNTING........................................................................ 118 AUTOMATIC TRANSMISSION (ALLISON 3000RDS,3500RDS)........................................................ 126 AUTOMATIC TRANSMISSION ASSEMBLY..................................................................... 127 TROUBLESHOOTING................................................................................. 127 SPECIAL TOOL.................................................................................... 127 DISMOUNTING AND MOUNTING........................................................................ 127 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION)............................................... 134 TRANSMISSION CONTROL UNIT........................................................................... 135 TROUBLESHOOTING................................................................................. 135 COMPONENT LOCATOR............................................................................... 136 OVERHAUL........................................................................................ 137 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)......................................... 138 TRANSMISSION CONTROL UNIT........................................................................... 139 TROUBLESHOOTING................................................................................. 139 COMPONENT LOCATOR............................................................................... 139 OVERHAUL........................................................................................ 141 PROPELLER SHAFT (SPL 100, 140).......................................................................... 142 PROPELLER SHAFT ASSEMBLY ........................................................................... 143 DATA AND SPECIFICATIONS......................................................................... 143 DESCRIPTION..................................................................................... 143 TROUBLESHOOTING................................................................................. 144 COMPONENT LOCATOR............................................................................... 144 OVERHAUL........................................................................................ 146 DIFFERENTIAL CARRIER (MERITORRS17.19.21&23)............................................................. 162 DIFFERENTIAL CARRIER ASSEMBLY ...................................................................... 163 DATA AND SPECIFICATIONS......................................................................... 163 DESCRIPTION..................................................................................... 165 TROUBLESHOOTING................................................................................. 168 SPECIAL TOOL.................................................................................... 169 COMPONENT LOCATOR............................................................................... 171 OVERHAUL........................................................................................ 175 INSPECTION AND REPAIR........................................................................... 215 DRIVER-CONTROLLED MAIN DIFFERENTIAL LOCK........................................................... 224 OVERHAUL........................................................................................ 224 INSPECTION AND REPAIR........................................................................... 227 BRAKE EQUIPMENT (MODELS WITH HYDRAULICBRAKE)............................................................ 228 SERVICE BRAKE ASSEMBLY ............................................................................. 229 DESCRIPTION..................................................................................... 229 DIAGRAM......................................................................................... 230 TROUBLESHOOTING................................................................................. 232 BRAKE SYSTEM AIR BLEEDING....................................................................... 236 POWER STEERING SYSTEM AIR BLEEDING.............................................................. 238 BRAKE TEST...................................................................................... 239 BRAKE EQUIPMENT (MODELS WITH FULL AIRBRAKE)............................................................. 240 SERVICE BRAKE ASSEMBLY ............................................................................. 241 DESCRIPTION..................................................................................... 241 DATA AND SPECIFICATIONS......................................................................... 242 DIAGRAM......................................................................................... 243 TROUBLESHOOTING................................................................................. 244 SERVICE BRAKE (HYDRAULIC BRAKE)......................................................................... 246 HYDRAULIC BRAKE .................................................................................... 247 INSPECTION AND ADJUSTMENT....................................................................... 247 HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER CYLINDER............................................... 250 DATA AND SPECIFICATIONS......................................................................... 250 DESCRIPTION..................................................................................... 250 PRINCIPLE OF OPERATION.......................................................................... 252 COMPONENT LOCATOR............................................................................... 254 HYDRO-MAX BOOSTER .................................................................................. 255 OVERHAUL........................................................................................ 255 MASTER CYLINDER .................................................................................... 261 OVERHAUL........................................................................................ 261 PRESSURE TESTS.................................................................................. 263 ABS MODULATOR ...................................................................................... 264 DATA AND SPECIFICATIONS......................................................................... 264 DESCRIPTION..................................................................................... 264 WHEEL BRAKE (TYPE: 4 PISTON) ....................................................................... 265 DATA AND SPECIFICATIONS......................................................................... 265 DESCRIPTION..................................................................................... 266 TROUBLESHOOTING................................................................................. 267 SERVICE BRAKE (FULL AIR BRAKE).......................................................................... 280 AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX ADIS)................................................ 281 DESCRIPTION..................................................................................... 281 AD-IS AIR DRYER RESERVOIR SYSTEM TROUBLESHOOTING CHART.......................................... 292 CHECK VALVE ........................................................................................ 296 DATA AND SPECIFICATIONS......................................................................... 296 DESCRIPTION..................................................................................... 296 INSPECTION AND REPAIR .......................................................................... 297 BRAKE PEDAL ........................................................................................ 299 OVERHAUL........................................................................................ 299 BRAKE VALVE ........................................................................................ 302 DATA AND SPECIFICATIONS......................................................................... 302 DESCRIPTION..................................................................................... 302 COMPONENT LOCATOR............................................................................... 303 INSPECTION AND REPAIR........................................................................... 304 RELAY VALVE ........................................................................................ 308 DATA AND SPECIFICATIONS......................................................................... 308 DESCRIPTION..................................................................................... 308 INSPECTION AND REPAIR........................................................................... 308 SPRING BRAKE MODULATING VALVE ...................................................................... 312 DESCRIPTION..................................................................................... 312 COMPONENT LOCATOR............................................................................... 313 INSPECTION AND REPAIR........................................................................... 314 SPRING BRAKE CONTROL VALVE ......................................................................... 316 DESCRIPTION..................................................................................... 316 COMPONENT LOCATOR............................................................................... 317 INSPECTION AND REPAIR........................................................................... 318 BRAKE CHAMBER (FRONT) .............................................................................. 321 DATA AND SPECIFICATIONS......................................................................... 321 DESCRIPTION..................................................................................... 321 COMPONENT LOCATOR............................................................................... 322 OVERHAUL........................................................................................ 323 INSPECTION AND REPAIR .......................................................................... 324 BRAKE CHAMBER (REAR) ............................................................................... 325 DATA AND SPECIFICATIONS......................................................................... 325 DESCRIPTION..................................................................................... 326 COMPONENT LOCATOR............................................................................... 327 INSPECTION AND REPAIR .......................................................................... 328 PROTECTION VALVE ................................................................................... 339 DATA AND SPECIFICATIONS......................................................................... 339 DESCRIPTION..................................................................................... 339 INSPECTION...................................................................................... 340 WHEEL BRAKE ........................................................................................ 342 DATA AND SPECIFICATIONS......................................................................... 342 DESCRIPTION..................................................................................... 343 COMPONENT LOCATOR............................................................................... 344 OVERHAUL........................................................................................ 346 INSPECTION AND REPAIR .......................................................................... 363 AUTOMATIC SLACK ADJUSTER ........................................................................... 365 DESCRIPTION..................................................................................... 365 DIAGNOSTICS..................................................................................... 366 COMPONENT LOCATOR............................................................................... 367 OVERHAUL........................................................................................ 369 INSTALLING THE SLACK ADJUSTER ONTO THE CAMSHAFT................................................. 377 CHECK & ADJUSTMENT.............................................................................. 379 ABS (ABS : HYDRAULIC (E VERSION))....................................................................... 386 ABS ................................................................................................ 387 OVERVIEW........................................................................................ 387 COMPOSITION AND OPERATION....................................................................... 388 FUNCTION........................................................................................ 391 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS............................................. 392 OVERVIEW AND FUNCTION........................................................................... 393 ABS (ABS : FULL AIR).................................................................................... 405 ABS ................................................................................................ 406 OVERVIEW........................................................................................ 406 COMPOSITION AND OPERATION....................................................................... 407 FUNCTION........................................................................................ 410 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS............................................. 411 OVERVIEW AND FUNCTION........................................................................... 412 INSPECTION (FRONT WHEEL BRAKE).................................................................. 417 INSPECTION (REAR WHEEL BRAKE)................................................................... 419 EXHAUST BRAKE........................................................................................... 425 EXHAUST BRAKE SYSTEM ............................................................................... 426 SYSTEM DIAGRAM.................................................................................. 426 TROUBLESHOOTING................................................................................. 427 ADJUSTMENT...................................................................................... 427 BRAKE CYLINDER ..................................................................................... 429 DATA AND SPECIFICATIONS......................................................................... 429 DESCRIPTION..................................................................................... 429 PARKING BRAKE (BOSCH 12")............................................................................... 430 DATA AND SPECIFICATIONS............................................................................. 431 DATA AND SPECIFICATIONS......................................................................... 431 DESCRIPTION..................................................................................... 431 TROUBLESHOOTING................................................................................. 432 COMPONENT LOCATOR............................................................................... 433 OVERHAUL........................................................................................ 435 INSPECTION AND REPAIR........................................................................... 449 ADJUSTMENT...................................................................................... 450 FOREWORD................................................................................................ 453 CHAPTER REFERENCES...................................................................................... 454 INDEX................................................................................................... 455 STEERING EQUIPMENT...................................................................................... 459 STEERING SYSTEM .................................................................................... 460 TROUBLESHOOTING................................................................................. 460 STEERING UNIT........................................................................................... 465 STEERING LINKAGE ................................................................................... 466 DESCRIPTION..................................................................................... 466 COMPONENT LOCATOR............................................................................... 467 SPECIAL TOOL.................................................................................... 468 OVERHAUL........................................................................................ 468 INSPECTION AND REPAIR........................................................................... 473 POWER STEERING.......................................................................................... 475 POWER STEERING GEAR UNIT ........................................................................... 476 DATA AND SPECIFICATIONS......................................................................... 476 DESCRIPTION..................................................................................... 477 OPERATION....................................................................................... 478 COMPONENT LOCATOR............................................................................... 480 TORQUE CHART.................................................................................... 482 HAZARD WARNING DEFINITIONS...................................................................... 482 DISCLAIMER...................................................................................... 483 PATENTS......................................................................................... 483 MAINTENANCE TIPS................................................................................ 483 ON-VEHICLE SERVICE.............................................................................. 485 RESEAL & REPAIR................................................................................. 495 POWER STEERING PUMP ................................................................................ 529 DATA AND SPECIFICATIONS......................................................................... 529 DESCRIPTION..................................................................................... 529 OPERATION....................................................................................... 530 COMPONENT LOCATOR............................................................................... 531 OVERHAUL........................................................................................ 533 INSPECTION AND REPAIR........................................................................... 539 FRONT AXLE (MFS)........................................................................................ 540 FRONT AXLE (MFS) ................................................................................... 541 DATA AND SPECIFICATIONS......................................................................... 541 TROUBLESHOOTING................................................................................. 543 COMPONENT LOCATOR............................................................................... 545 SERVICE NOTES................................................................................... 549 SPECIAL TOOLS................................................................................... 550 INTRODUCTION.................................................................................... 555 INSPECTION...................................................................................... 556 DISASSEMBLY..................................................................................... 562 PREPARE PARTS FOR ASSEMBLY...................................................................... 569 ASSEMBLY........................................................................................ 577 ADJUSTMENT...................................................................................... 589 LUBRICATION AND MAINTENANCE..................................................................... 598 MAINTENANCE..................................................................................... 602 REAR AXLE............................................................................................... 603 REAR AXLE .......................................................................................... 604 DATA AND SPECIFICATIONS......................................................................... 604 COMPONENT LOCATOR............................................................................... 611 SPECIAL TOOL.................................................................................... 614 DISASSEMBLY..................................................................................... 616 PREPARE PARTS FOR ASSEMBLY...................................................................... 618 ASSEMBLY........................................................................................ 622 ADJUSTMENT...................................................................................... 632 LUBRICATION AND MAINTENANCE..................................................................... 634 WHEEL & TIRE............................................................................................ 636 WHEEL AND TIRE...................................................................................... 637 DATA AND SPECIFICATIONS......................................................................... 637 DESCRIPTION..................................................................................... 641 SPECIAL TOOL.................................................................................... 642 PRECAUTIONS..................................................................................... 643 INSPECTION...................................................................................... 644 INSPECTION AND REPAIR........................................................................... 645 WHEEL............................................................................................... 646 OVERHAUL........................................................................................ 646 SUSPENSION.............................................................................................. 651 LEAF SUSPENSION ASSEMBLY............................................................................ 652 DATA AND SPECIFICATIONS......................................................................... 652 DESCRIPTION..................................................................................... 654 TROUBLESHOOTING................................................................................. 656 COMPONENT LOCATOR............................................................................... 657 OVERHAUL........................................................................................ 661 INSPECTION AND REPAIR........................................................................... 666 AIR SUSPENSION ASSEMBLY ............................................................................ 669 DATA AND SPECIFICATIONS......................................................................... 669 SYSTEM DIAGRAM FOR HEIGHT CONTROL............................................................... 669 DESCRIPTION..................................................................................... 670 TROUBLESHOOTING................................................................................. 671 COMPONENT LOCATOR............................................................................... 672 OVERHAUL........................................................................................ 673 INSPECTION AND REPAIR........................................................................... 677 CHASSIS FRAME........................................................................................... 679 CHASSIS FRAME ...................................................................................... 680 TROUBLESHOOTING................................................................................. 680 INSPECTION...................................................................................... 680 REPAIRS......................................................................................... 681 CAB..................................................................................................... 686 CAB ASSEMBLY ....................................................................................... 687 DATA AND SPECIFICATIONS......................................................................... 687 TROUBLESHOOTING................................................................................. 688 DISMOUNTING AND MOUNTING........................................................................ 689 INSPECTION AND REPAIR........................................................................... 692 HOOD ............................................................................................... 693 COMPONENT LOCATOR............................................................................... 693 OVERHAUL........................................................................................ 694 FRP REPAIR PROCEDURE............................................................................ 697 RADIATOR GRILLE .................................................................................... 702 COMPONENT LOCATOR............................................................................... 702 OVERHAUL........................................................................................ 703 DOOR ............................................................................................... 704 COMPONENT LOCATOR............................................................................... 704 OVERHAUL........................................................................................ 705 SEAT ............................................................................................... 708 COMPONENT LOCATOR............................................................................... 708 INSTRUMENT PANEL ................................................................................... 711 COMPONENT LOCATOR............................................................................... 711 DISMOUNTING AND MOUNTING........................................................................ 712 HEATER AND AIR CONDITIONER ......................................................................... 713 COMPONENT LOCATOR............................................................................... 713 SPECIAL TOOL.................................................................................... 713 AIR CONDITIONING SYSTEM ............................................................................ 714 SPECIFICATION DATA.............................................................................. 714 PRECAUTIONS REGARDING REFRIGERANT (HFC134a)..................................................... 714 PRECAUTIONS FOR REPLENISHING THE REFRIGERANT GAS................................................ 715 TROUBLESHOOTING (FAULT DIAGNOSIS BY SYMPTOMS)................................................... 716 GAS LEAKAGE INSPECTION.......................................................................... 725 PRECAUTIONS FOR REMOVING/INSTALLING THE AIR CONDITIONER......................................... 728 RECOVERY AND REPLENISHMENT OF REFRIGERANT....................................................... 730 MAINTENANCE..................................................................................... 734 REPLACEMENT..................................................................................... 736 DISMOUNTING AND MOUNTING........................................................................ 738 WINDSHIELD ......................................................................................... 739 COMPONENT LOCATOR............................................................................... 739 REPLACEMENT..................................................................................... 740 AFFIXING WEATHERSTRIP PROCEDURE................................................................. 741 FRONT BUMPER ....................................................................................... 745 COMPONENT LOCATOR............................................................................... 745 ELECTRICAL EQUIPMENT.................................................................................... 747 ELECTRICAL PARTS ................................................................................... 748 DATA AND SPECIFICATIONS......................................................................... 748 COMPONENT LOCATOR............................................................................... 749 TROUBLESHOOTING................................................................................. 758 GENERAL INSTRUCTION............................................................................. 759 HANDLING PRECAUTION............................................................................. 764 INSPECTION...................................................................................... 766 INSPECTION AND ADJUSTMENT....................................................................... 787 SPEEDOMETER CONVERSION RATE LIST................................................................ 788 ELECTRIC WIRE........................................................................................... 789 DIAGRAM ............................................................................................ 790 HOW TO USE THIS CHAPTER......................................................................... 790 SPECIFICATION SYMBOL LIST....................................................................... 796 TERMS CONTRADISTINCTION LIST.................................................................... 804 DIAGRAM......................................................................................... 806 POSITION OF CONNECTOR........................................................................... 943 CONNECTOR....................................................................................... 968 PIN LIST OF WIRE TO WIRE CONNECTOR (IN THE BULK HEAD CONNECTOR BOX)............................. 992 PIN LIST OF WIRE TO WIRE CONNECTOR (OUT OF THE BULK HEAD CONNECTOR BOX)......................... 994 CONNECTOR LIST.................................................................................. 996 FOREWORD................................................................................................1008 CHAPTER REFERENCES......................................................................................1009 INDEX...................................................................................................1010 GENERAL INTRODUCTION (ENGINE)...........................................................................1012 GENERAL INTRODUCTION (ENGINE) .....................................................................1013 GENERAL PRECAUTIONS.............................................................................1013 HOW TO USE THIS WORKSHOP MANUAL.................................................................1016 IDENTIFICATION INFORMATION......................................................................1018 PRECAUTIONS.....................................................................................1019 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....................................................1022 DISMOUNTING AND MOUNTING........................................................................1023 SYMPTOM SIMULATION..............................................................................1026 GLOSSARY OF SAE AND HINO TERMS..................................................................1028 ENGINE INTRODUCTION ....................................................................................1031 ENGINE ASSEMBLY ....................................................................................1032 DATA AND SPECIFICATIONS.........................................................................1032 TROUBLESHOOTING.................................................................................1034 TROUBLESHOOTING (COMMON RAIL SYSTEM)............................................................1041 ENGINE TUNEUP...................................................................................1042 SPECIAL TOOL....................................................................................1048 OVERHAUL CRITERIA...............................................................................1049 DISMOUNTING AND MOUNTING........................................................................1050 LIQUID GASKET AND APPLICATION POINTS............................................................1052 ENGINE MECHANICAL ......................................................................................1057 CYLINDER HEAD ......................................................................................1058 COMPONENT LOCATOR...............................................................................1058 SPECIAL TOOL....................................................................................1061 OVERHAUL........................................................................................1062 INSPECTION AND REPAIR...........................................................................1073 CRANKSHAFT FRONT END ...............................................................................1077 COMPONENT LOCATOR...............................................................................1077 SPECIAL TOOL....................................................................................1078 OVERHAUL........................................................................................1079 FLYWHEEL AND FLYWHEEL HOUSING ......................................................................1081 COMPONENT LOCATOR...............................................................................1081 SPECIAL TOOL....................................................................................1082 OVERHAUL........................................................................................1082 INSPECTION AND REPAIR...........................................................................1088 TIMING GEAR ........................................................................................1089 COMPONENT LOCATOR...............................................................................1089 SPECIAL TOOL....................................................................................1090 OVERHAUL........................................................................................1091 INSPECTION AND REPAIR...........................................................................1093 MAIN MOVING PARTS AND CYLINDER BLOCK ...............................................................1095 COMPONENT LOCATOR...............................................................................1095 SPECIAL TOOL....................................................................................1098 OVERHAUL........................................................................................1100 INSPECTION AND REPAIR...........................................................................1113 AIR INTAKE SYSTEM ......................................................................................1117 AIR INTAKE MANIFOLD AND PIPE .......................................................................1118 COMPONENT LOCATOR...............................................................................1118 DISMOUNTING AND MOUNTING........................................................................1119 AIR INTAKE .........................................................................................1120 COMPONENT LOCATOR...............................................................................1120 AIR CLEANER ........................................................................................1121 DESCRIPTION.....................................................................................1121 OVERHAUL........................................................................................1122 AIR HOSE ...........................................................................................1123 COMPONENT LOCATOR...............................................................................1123 OVERHAUL........................................................................................1125 AIR FLOW SENSOR ....................................................................................1126 COMPONENT LOCATOR...............................................................................1126 REPLACEMENT.....................................................................................1127 BOOST PRESSURE SENSOR ..............................................................................1128 COMPONENT LOCATOR...............................................................................1128 REPLACEMENT.....................................................................................1129 EXHAUST SYSTEM .........................................................................................1130 EXHAUST MANIFOLD AND PIPE ..........................................................................1131 COMPONENT LOCATOR...............................................................................1131 DISMOUNTING AND MOUNTING........................................................................1132 EXHAUST PIPE AND MUFFLER UNIT ......................................................................1133 DESCRIPTION.....................................................................................1133 COMPONENT LOCATOR...............................................................................1134 REPLACEMENT OF ATC..............................................................................1140 OVERHAUL........................................................................................1142 DPR (DIESEL PARTICULATE REDUCTION SYSTEM) ..........................................................1151 SYSTEM CONFIGURATION............................................................................1151 STRUCTURE OF DPR-CLEANER........................................................................1152 DPR MAINTENANCE.................................................................................1153 DPR INSPECTION..................................................................................1153 INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY....1154 INSPECTION BY WAY OF HINO DX II.................................................................1155 INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL)....................1159 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DXⅡ.............................1162 CHECKING THE DPR STATE..........................................................................1162 REPLACEMENT OF DPR FILTER.......................................................................1163 OVERALL OPERATION FLOW..........................................................................1165 DIFFERENTIAL PRESSURE SENSOR .......................................................................1173 COMPONENT LOCATOR...............................................................................1173 DISMOUNTING AND MOUNTING........................................................................1174 INSPECTION AND REPAIR...........................................................................1174 FUEL ADDITION VALVE ................................................................................1177 COMPONENT LOCATOR...............................................................................1177 OVERHAUL........................................................................................1178 EXHAUST CONTROL CYLINDER ...........................................................................1188 SYSTEM CONFIGURATION............................................................................1188 DPR INSPECTION CHECK SHEET......................................................................1189 ATC UPSTREAM TEMPERATURE SENSOR ....................................................................1192 COMPONENT LOCATOR...............................................................................1192 OVERHAUL........................................................................................1193 LUBRICATING SYSTEM .....................................................................................1194 LUBRICATING SYSTEM .................................................................................1195 DIAGRAM.........................................................................................1195 OIL PUMP AND OIL STRAINER ..........................................................................1197 COMPONENT LOCATOR...............................................................................1197 OVERHAUL........................................................................................1198 INSPECTION AND REPAIR...........................................................................1199 OIL FILTER AND OIL COOLER ..........................................................................1201 COMPONENT LOCATOR...............................................................................1201 SPECIAL TOOL....................................................................................1202 DISMOUNTING AND MOUNTING........................................................................1203 INSPECTION AND REPAIR...........................................................................1204 COOLING SYSTEM .........................................................................................1205 COOLING SYSTEM .....................................................................................1206 DIAGRAM.........................................................................................1206 COOLANT PUMP .......................................................................................1207 COMPONENT LOCATOR...............................................................................1207 THERMOSTAT .........................................................................................1208 COMPONENT LOCATOR...............................................................................1208 OVERHAUL........................................................................................1209 RADIATOR AND INTERCOOLER ...........................................................................1211 COMPONENT LOCATOR...............................................................................1211 OVERHAUL........................................................................................1211 RADIATOR ...........................................................................................1213 COMPONENT LOCATOR...............................................................................1213 SPECIAL TOOL....................................................................................1214 OVERHAUL........................................................................................1214 INSPECTION AND REPAIR...........................................................................1218 COOLING FAN ........................................................................................1219 COMPONENT LOCATOR...............................................................................1219 INSPECTION AND REPAIR...........................................................................1220 FUEL SYSTEM ............................................................................................1221 FUEL SYSTEM ........................................................................................1222 DIAGRAM.........................................................................................1222 COMPONENT LOCATOR...............................................................................1223 SUPPLY PUMP ........................................................................................1224 DESCRIPTION.....................................................................................1224 COMPONENT LOCATOR...............................................................................1225 SPECIAL TOOL....................................................................................1225 OVERHAUL........................................................................................1226 COMMON RAIL ........................................................................................1235 DESCRIPTION.....................................................................................1235 INSPECTION......................................................................................1235 REPLACEMENT.....................................................................................1237 INJECTOR ...........................................................................................1241 DESCRIPTION.....................................................................................1241 REPLACEMENT.....................................................................................1242 FUEL FILTER ........................................................................................1250 DESCRIPTION.....................................................................................1250 AIR BLEEDING....................................................................................1251 FUEL FILTER (BUBBLE SEPARATOR) .....................................................................1253 DESCRIPTION.....................................................................................1253 OVERHAUL........................................................................................1254 FUEL TANK ..........................................................................................1257 COMPONENT LOCATOR...............................................................................1257 FUEL CUTOFF VALVE ..................................................................................1259 COMPONENT LOCATOR...............................................................................1259 OVERHAUL........................................................................................1260 TURBOCHARGER ...........................................................................................1261 TURBOCHARGER .......................................................................................1262 DESCRIPTION.....................................................................................1262 TROUBLESHOOTING.................................................................................1263 REPLACEMENT.....................................................................................1272 INSPECTION AFTER MOUNTING.......................................................................1278 EMISSION CONTROL .......................................................................................1279 EGR VALVE AND EGR PIPE .............................................................................1280 COMPONENT LOCATOR...............................................................................1280 EGR VALVE ..........................................................................................1281 DESCRIPTION.....................................................................................1281 DISMOUNTING AND MOUNTING........................................................................1282 CLOSED VENTILATOR ..................................................................................1285 DESCRIPTION.....................................................................................1285 REPLACEMENT OF CLOSED VENTILATOR................................................................1285 REPLACING THE ELEMENT...........................................................................1286 SELECTIVE CATALYTIC REDUCTION (SCR) ................................................................1287 GENERAL DESCRIPTION.............................................................................1287 COMPONENT LOCATOR...............................................................................1289 INSPECTION......................................................................................1290 SPECIAL TOOL....................................................................................1291 DISMOUNTING AND MOUNTING........................................................................1292 INSPECTION AND REPAIR...........................................................................1307 ALTERNATOR (J08E: REMY 12V-130A,135A,180A)..............................................................1308 ALTERNATOR .........................................................................................1309 DATA AND SPECIFICATIONS.........................................................................1309 TROUBLESHOOTING.................................................................................1309 COMPONENT LOCATOR...............................................................................1310 OVERHAUL........................................................................................1311 INSPECTION AND REPAIR...........................................................................1314 STARTER ................................................................................................1315 STARTER ............................................................................................1316 DATA AND SPECIFICATIONS.........................................................................1316 DESCRIPTION.....................................................................................1316 TROUBLESHOOTING.................................................................................1317 COMPONENT LOCATOR...............................................................................1318 OVERHAUL........................................................................................1319 INSPECTION AND REPAIR...........................................................................1323 AIR COMPRESSOR (J08E: 340 cm3)..........................................................................1326 AIR COMPRESSOR .....................................................................................1327 DATA AND SPECIFICATIONS.........................................................................1327 DESCRIPTION.....................................................................................1328 TROUBLESHOOTING.................................................................................1329 COMPONENT LOCATOR...............................................................................1330 SPECIAL TOOL....................................................................................1331 OVERHAUL........................................................................................1331 INSPECTION AND REPAIR...........................................................................1339 ENGINE CONTROL .........................................................................................1342 ACCELERATOR PEDAL ..................................................................................1343 DESCRIPTION.....................................................................................1343 ENGINE ECU .........................................................................................1344 COMPONENT LOCATOR...............................................................................1344 REPLACEMENT.....................................................................................1345 FOREWORD................................................................................................1352 CHAPTER REFERENCES......................................................................................1353 INDEX...................................................................................................1354 GENERAL INTRODUCTION....................................................................................1355 GENERAL INTRODUCTION................................................................................1356 GENERAL PRECAUTIONS.............................................................................1356 IDENTIFICATION INFORMATION......................................................................1359 HOW TO USE THIS WORKSHOP MANUAL.................................................................1366 INTRODUCTION TO DESCRIPTIONS....................................................................1366 PRECAUTIONS.....................................................................................1369 SEALANT ON THE TAPERED SCREW FOR PIPING.........................................................1372 METRIC INFORMATION..............................................................................1373 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....................................................1375 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS......................................................1376 RECOMMENDED LUBRICANTS..........................................................................1377 INFORMATION DISPLAY.............................................................................1379 GLOSSARY........................................................................................1384 GLOSSARY OF SAE AND HINO TERMS..................................................................1387 TERMS CONTRADISTINCTION LIST....................................................................1390 TROUBLE SHOOTING - COMPONENTS...........................................................................1392 ENGINE BASIC........................................................................................1393 ENGINE ASSEMBLY.................................................................................1393 ENGINE ASSEMBLY (COMMON RAIL SYSTEM)............................................................1400 TURBOCHARGER (J08E).................................................................................1401 TURBOCHARGER....................................................................................1401 ALTERNATOR (J08E: REMY 12V-130A, 135A, 180A)........................................................1410 ALTERNATOR......................................................................................1410 STARTER (J08E)......................................................................................1411 STARTER.........................................................................................1411 AIR COMPRESSOR (J08E: 340 cm3)......................................................................1412 AIR COMPRESSOR..................................................................................1412 CLUTCH MAIN UNIT....................................................................................1413 CLUTCH ASSEMBLY (EATON SAS1401).................................................................1413 CLUTCH ASSEMBLY (EATON SAS1402).................................................................1415 AUTOMATIC TRANSMISSION..............................................................................1417 AUTOMATIC TRANSMISSION ASSEMBLY.................................................................1417 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) ..........................................1418 TRANSMISSION CONTROL UNIT.......................................................................1418 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)......................................1419 TRANSMISSION CONTROL UNIT.......................................................................1419 PROPELLER SHAFT (SPL 100, 140)......................................................................1419 PROPELLER SHAFT ASSEMBLY........................................................................1419 DIFFERENTIAL CARRIER (MERITOR RS-17, 19, 21 AND 23).................................................1420 DIFFERENTIAL CARRIER ASSEMBLY...................................................................1420 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE).......................................................1421 SERVICE BRAKE ASSEMBLY..........................................................................1421 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)........................................................1426 SERVICE BRAKE ASSEMBLY..........................................................................1426 SERVICE BRAKE (HYDRAULIC BRAKE).....................................................................1428 WHEEL BRAKE (TYPE: 4 PISTON)....................................................................1428 SERVICE BRAKE (FULL AIR BRAKE)......................................................................1430 AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS)............................................1430 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 AIR SUSPENSION DUMP SYSTEM......................................................................1446 CAB ASSEMBLY....................................................................................1446 AIR CONDITIONING SYSTEM.........................................................................1448 ELECTRICAL EQUIPMENT................................................................................1458 ELECTRICAL PARTS................................................................................1458 TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM............................................................1460 ABOUT HINO DXⅡ......................................................................................1461 About HINO DXⅡ..................................................................................1461 BASIC PROCEDURE FOR TROUBLESHOOTING.................................................................1463 BASIC PROCEDURE FOR TROUBLESHOOTING.............................................................1463 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....................................................1465 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE................................................1465 SYMPTOM SIMULATION..................................................................................1468 SYMPTOM SIMULATION..............................................................................1468 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART.......................................................1470 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART...................................................1470 ELECTRONIC CIRCUIT INSPECTION PROCEDURE.............................................................1471 ELECTRONIC CIRCUIT INSPECTION PROCEDURE.........................................................1471 INSPECTION PROCEDURE FOR MULTIPLE DTCS..............................................................1476 INSPECTION PROCEDURE FOR MULTIPLE DTCS..........................................................1476 ENGINE CONTROL SYSTEM (J08E) ...........................................................................1477 ENGINE CONTROL SYSTEM...............................................................................1480 PRECAUTIONS FOR DIAGNOSIS.......................................................................1480 SYSTEM BLOCK DIAGRAM............................................................................1482 SYSTEM DIAGRAM..................................................................................1483 PRECAUTIONS.....................................................................................1485 SENSOR LOCATION.................................................................................1488 COMPUTER (ECU) PIN ASSIGNMENT...................................................................1497 ENGINE ECU CONNECTOR............................................................................1501 INSPECTION......................................................................................1505 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...........................................................1506 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.............................................................1507 GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL..................................................1525 GROUP SHARING THE SENSOR GND TERMINAL...........................................................1526 ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)...................................1527 NO DTC..........................................................................................1531 INSPECTION PROCEDURE FOR WHEN THE DEF MIXED INTO THE ENGINE COOLANT.............................1534 DTC: P0005......................................................................................1536 DTC: P0006 and P0007............................................................................1540 DTC: P0016......................................................................................1545 DTC: P0027......................................................................................1547 DTC: P003A......................................................................................1552 DTC: P0045......................................................................................1557 DTC: P0047......................................................................................1562 DTC: P0048......................................................................................1567 DTC: P006E......................................................................................1572 DTC: P006F......................................................................................1576 DTC: P007B......................................................................................1580 DTC: P007C and P007D............................................................................1593 DTC: P0088......................................................................................1600 DTC: P0096......................................................................................1608 DTC: P0097 and P0098 ...........................................................................1619 DTC: P00AF......................................................................................1626 DTC: P0101......................................................................................1630 DTC: P0104......................................................................................1637 DTC: P0106......................................................................................1643 DTC: P0108......................................................................................1649 DTC: P0112 and P0113............................................................................1655 DTC: P0115......................................................................................1662 DTC: P0117 and P0118............................................................................1670 DTC: P011A......................................................................................1677 DTC: P011C......................................................................................1685 DTC: P0122 and P0123............................................................................1691 DTC: P0128......................................................................................1701 DTC: P0148 .....................................................................................1706 DTC: P016E and P016F ...........................................................................1717 DTC: P0182 and P0183 ...........................................................................1727 DTC: P0191......................................................................................1734 DTC: P0192 and P0193 ...........................................................................1742 DTC: P01A5......................................................................................1750 DTC: P01A6......................................................................................1757 DTC: P0200......................................................................................1764 DTC: P0201, P0202, P0203, P0204, P0205 and P0206................................................1766 DTC: P0217......................................................................................1772 DTC: P0219......................................................................................1777 DTC: P0222 and P0223............................................................................1783 DTC: P0234......................................................................................1792 DTC: P0237......................................................................................1797 DTC: P0263, P0266, P0269, P0272, P0275 and P0278................................................1804 DTC: P026C and P026D............................................................................1815 DTC: P0299......................................................................................1827 DTC: P0300......................................................................................1832 DTC: P0301, P0302, P0303, P0304, P0305 and P0306................................................1840 DTC: P0335......................................................................................1849 DTC: P0336......................................................................................1855 DTC: P0340......................................................................................1861 DTC: P0341......................................................................................1866 DTC: P0381......................................................................................1872 DTC: P0401......................................................................................1877 DTC: P0402......................................................................................1891 DTC: P0404......................................................................................1900 DTC: P0405 and P0406............................................................................1905 DTC: P041B......................................................................................1911 DTC: P041C and P041D............................................................................1919 DTC: P0420......................................................................................1927 DTC: P0421......................................................................................1929 DTC: P0422......................................................................................1932 DTC: P0489 and P0490............................................................................1935 DTC: P049D......................................................................................1941 DTC: P04D5 and P04D6............................................................................1946 DTC: P04DA......................................................................................1954 FOREWORD................................................................................................1964 CHAPTER REFERENCES......................................................................................1965 INDEX...................................................................................................1966 ENGINE CONTROL SYSTEM (J08E) ...........................................................................1967 ENGINE CONTROL SYSTEM...............................................................................1970 DTC: P0500 and P0501............................................................................1970 DTC: P0504......................................................................................1976 DTC: P0506 and P0507............................................................................1982 DTC: P0524......................................................................................1985 DTC: P0545 and P0546............................................................................1990 DTC: P054E and P054F............................................................................1998 DTC: P0562 and P0563............................................................................2001 DTC: P05F1......................................................................................2007 DTC: P0605......................................................................................2015 DTC: P0606......................................................................................2017 DTC: P0607......................................................................................2019 DTC: P0610......................................................................................2021 DTC: P0611......................................................................................2024 DTC: P0617......................................................................................2026 DTC: P0628 and P0629............................................................................2030 DTC: P062F......................................................................................2037 DTC: P0630......................................................................................2041 DTC: P0642......................................................................................2044 DTC: P0643......................................................................................2049 DTC: P064C......................................................................................2055 DTC: P0652......................................................................................2060 DTC: P0653......................................................................................2065 DTC: P0671, P0672, P0675 and P0676 .............................................................2070 DTC: P0683......................................................................................2080 DTC: P0686......................................................................................2085 DTC: P06D3 and P06D4............................................................................2089 DTC: P0704......................................................................................2096 DTC: P073D......................................................................................2101 DTC: P081A......................................................................................2107 DTC: P081B......................................................................................2111 DTC: P0850......................................................................................2115 DTC: P1133......................................................................................2120 DTC: P119F......................................................................................2126 DTC: P1426......................................................................................2131 DTC: P1427......................................................................................2137 DTC: P1428......................................................................................2143 DTC: P1458......................................................................................2149 DTC: P1459......................................................................................2154 DTC: P14B0......................................................................................2159 DTC: P14B2......................................................................................2163 DTC: P14B3 and P14B4............................................................................2167 DTC: P14B7 and P14B8............................................................................2173 DTC: P14BC and P14BD............................................................................2179 DTC: P14BF......................................................................................2185 DTC: P1515......................................................................................2190 DTC: P1530......................................................................................2195 DTC: P1601......................................................................................2198 DTC: P200C......................................................................................2202 DTC: P2032 and P2033............................................................................2208 DTC: P203F......................................................................................2216 DTC: P204F......................................................................................2220 DTC: P207F......................................................................................2222 DTC: P2080......................................................................................2233 DTC: P2084......................................................................................2241 DTC: P20CD......................................................................................2249 DTC: P20CE......................................................................................2253 DTC: P20CF......................................................................................2257 DTC: P20D8......................................................................................2260 DTC: P20DE......................................................................................2265 DTC: P20DF......................................................................................2269 DTC: P20E0......................................................................................2274 DTC: P20EE......................................................................................2279 DTC: P2100......................................................................................2290 DTC: P2101......................................................................................2295 DTC: P2103......................................................................................2301 DTC: P2120......................................................................................2306 DTC: P2122 and P2123............................................................................2310 DTC: P2127 and P2128............................................................................2318 DTC: P2135......................................................................................2326 DTC: P2138......................................................................................2331 DTC: P2146......................................................................................2336 DTC: P2147 and P2148............................................................................2342 DTC: P2149......................................................................................2349 DTC: P2150 and P2151............................................................................2355 DTC: P2184 and P2185............................................................................2362 DTC: P2214......................................................................................2369 DTC: P2227......................................................................................2379 DTC: P2228 and P2229............................................................................2383 DTC: P2269......................................................................................2387 DTC: P226C......................................................................................2391 DTC: P22D3......................................................................................2398 DTC: P240F......................................................................................2402 DTC: P2428......................................................................................2411 DTC: P242B......................................................................................2415 DTC: P242C and P242D............................................................................2423 DTC: P244A......................................................................................2431 DTC: P244B......................................................................................2447 DTC: P2457......................................................................................2460 DTC: P2458......................................................................................2473 DTC: P2459......................................................................................2482 DTC: P2463......................................................................................2484 DTC: P246F......................................................................................2489 DTC: P2470 and P2471............................................................................2497 DTC: P24A0......................................................................................2505 DTC: P24A1......................................................................................2508 DTC: P24A2......................................................................................2510 DTC: P2563......................................................................................2519 DTC: P2564 and P2565............................................................................2524 DTC: P259E......................................................................................2531 DTC: P259F......................................................................................2536 DTC: P2635......................................................................................2541 DTC: P268A and P2696............................................................................2549 DTC: P2BA9......................................................................................2555 DTC: U0073......................................................................................2559 DTC: U010A......................................................................................2562 DTC: U010C......................................................................................2565 DTC: U010E......................................................................................2568 DTC: U029D......................................................................................2571 DTC: U029E......................................................................................2574 DTC: U02A2......................................................................................2577 DTC: U0301......................................................................................2580 DTC: U1001......................................................................................2583 DTC: U110A......................................................................................2586 FOREWORD................................................................................................2590 CHAPTER REFERENCES......................................................................................2591 INDEX...................................................................................................2592 DEF SCR SYSTEM (DCU) ...................................................................................2593 DEF SCR SYSTEM......................................................................................2594 PRECAUTIONS FOR DIAGNOSIS.......................................................................2594 SYSTEM BLOCK DIAGRAM............................................................................2596 SYSTEM DIAGRAM..................................................................................2597 SENSOR LOCATION.................................................................................2598 COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT............................................2601 SIGNAL CHECK HARNESS............................................................................2602 INSPECTION......................................................................................2602 MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN................................................2603 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...........................................................2604 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.............................................................2605 DTC: P0071......................................................................................2611 DTC: P0072......................................................................................2621 DTC: P0073......................................................................................2628 DTC: P0562......................................................................................2635 DTC: P0563......................................................................................2638 DTC: P060C......................................................................................2641 DTC: P062F......................................................................................2643 DTC: P0667......................................................................................2645 DTC: P0668......................................................................................2647 DTC: P0669......................................................................................2649 DTC: P068A......................................................................................2651 DTC: P142A......................................................................................2656 DTC: P142B......................................................................................2665 DTC: P202E......................................................................................2675 DTC: P203C......................................................................................2679 DTC: P203D......................................................................................2682 DTC: P2044......................................................................................2685 DTC: P2045......................................................................................2688 DTC: P2047......................................................................................2691 DTC: P2048......................................................................................2694 DTC: P2049......................................................................................2698 DTC: P204B......................................................................................2703 DTC: P204C......................................................................................2706 DTC: P204D......................................................................................2711 DTC: P205B......................................................................................2716 DTC: P205C......................................................................................2725 DTC: P205D......................................................................................2728 DTC: P206A......................................................................................2731 DTC: P208A......................................................................................2734 DTC: P208B......................................................................................2738 DTC: P208C......................................................................................2741 DTC: P208D......................................................................................2745 DTC: P20A0......................................................................................2749 DTC: P20A1......................................................................................2754 DTC: P20A2......................................................................................2758 DTC: P20A3......................................................................................2763 DTC: P20B1......................................................................................2768 DTC: P20B2......................................................................................2772 DTC: P20B3......................................................................................2780 DTC: P20B4......................................................................................2784 DTC: P20BD, P20B9 and P20C1.....................................................................2788 DTC: P20C0, P20BC and P20C4.....................................................................2794 DTC: P20FC......................................................................................2801 DTC: P20FD......................................................................................2805 DTC: P20FE......................................................................................2808 DTC: P20E8......................................................................................2811 DTC: P20E9......................................................................................2822 DTC: P20F4......................................................................................2827 DTC: P2201......................................................................................2831 DTC: P2202......................................................................................2840 DTC: P2203......................................................................................2843 DTC: P2204......................................................................................2846 DTC: P2209......................................................................................2853 DTC: P2212......................................................................................2860 DTC: P2215......................................................................................2868 DTC: P2216......................................................................................2871 DTC: P2222......................................................................................2874 DTC: P2481......................................................................................2882 DTC: P2482......................................................................................2886 DTC: P2483......................................................................................2891 DTC: P2510......................................................................................2904 DTC: P2BAE......................................................................................2909 DTC: U0029......................................................................................2916 DTC: U0038......................................................................................2919 DTC: U0100......................................................................................2922 DTC: U029D......................................................................................2926 DTC: U029E......................................................................................2929 DTC: U02A2......................................................................................2932 DTC: U0597......................................................................................2935 BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION)) .......................................................2937 ABS.................................................................................................2938 TROUBLESHOTTING.................................................................................2938 BRAKE CONTROL SYSTEM (ABS:FULL AIR) ....................................................................2960 ABS.................................................................................................2961 TROUBLESHOTTING.................................................................................2961 VEHICLE CONTROL SYSTEM (VCS) ...........................................................................2990 VEHICLE CONTROL SYSTEM..............................................................................2991 PRECAUTIONS FOR DIAGNOSIS.......................................................................2991 SYSTEM BLOCK DIAGRAM............................................................................2993 SIGNAL CHECK HARNESS............................................................................2994 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...........................................................3002 VEHICLE CONTROL ECU INSPECTION..................................................................3003 DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE.........................................3009 DTC: P0500......................................................................................3010 DTC: P0501......................................................................................3014 DTC: P0562......................................................................................3018 DTC: P0563......................................................................................3021 DTC: P0617......................................................................................3024 DTC: P0704......................................................................................3027 DTC: P0850......................................................................................3033 DTC: P1565......................................................................................3039 DTC: U0101......................................................................................3045 DTC: U0105 .....................................................................................3048 DTC: U0155......................................................................................3051 NO ACTIVATION OF AUXILIARY BRAKE................................................................3053 NO ACTIVATION/RELEASE OF ENGINE REVOLUTION CONTROL..............................................3059 NO ACTIVATION/RELEASE OF CRUISE FUNCTION........................................................3064 NO ACTIVATION/RELEASE OF ECO MODE...............................................................3072 CAN COMMUNICATION.......................................................................................3076 CAN COMMUNICATION TROUBLESHOOTING...................................................................3077 Outline.........................................................................................3077 Definition of Terms.............................................................................3077 Troubleshooting Procedure.......................................................................3078 Work Flow.......................................................................................3078 ECU individual code list........................................................................3079 CAN communication circuit diagram...............................................................3080 CAN communication relation connector location...................................................3083 ENGINE CAN COMMUNICATION LINE.......................................................................3087 ABNORMAL CAN COMMUNICATION DTC DETECTED.........................................................3087 CONNECTION DIAGRAM..............................................................................3087 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE.....................................3087 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE................................................3089 DISCONNECTION INSPECTION FOR ENGINE CAN_H/L_COMMUNICATION LINE..................................3092 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE......................................................3096 INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE......................................................3104 INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE............................................3112 INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE............................................3117 INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE).......................3122 INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE..............................................3127 INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE..............................................3133 INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE................................................3139 DIAGNOSIS CAN COMMUNICATION LINE....................................................................3145 ABNORMAL CAN COMMUNICATION DTC DETECTED.........................................................3145 CONNECTION DIAGRAM..............................................................................3145 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE.....................................3145 PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE.............................................3147 DISCONNECTION INSPECTION FOR DIAGNOSIS CAN_H/ L_COMMUNICATION LINE..............................3150 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H-LINE............................................3154 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN L-LINE............................................3158 INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)....................3163 INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE................................................3167 CONTROL CAN COMMUNICATION LINE......................................................................3172 ABNORMAL CAN COMMUNICATION DTC DETECTED.........................................................3172 CONNECTION DIAGRAM (ALLISON AUTOMATIC TRANSMISSION).............................................3172 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)....3172 CONNECTION DIAGRAM (MANUAL TRANSMISSION)........................................................3173 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION)...............3173 PRE-INSPECTION FOR CAN COMMUNICATION LINE.......................................................3174 DISCONNECTION INSPECTION FOR CAN_H/L_COMMUNICATION LINE.........................................3178 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE......................................................3181 INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE......................................................3183 INSPECTION FOR AUTOMATIC TRANSMISSION ECU CAN COMMUNICATION LINE................................3185
Description:
2015 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]
