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2019 HINO TRUCK COE OWNERS WORKSHOP MANUAL
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2019 HINO TRUCK COE OWNERS WORKSHOP MANUAL
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2019 HINO TRUCK COE OWNERS WORKSHOP MANUAL
FOREWORD................................................................................................ 3 CHAPTER REFERENCES...................................................................................... 4 INDEX................................................................................................... 5 GENERAL INTRODUCTION (CHASSIS).......................................................................... 9 GENERAL INTRODUCTION................................................................................ 10 GENERAL PRECAUTIONS............................................................................. 10 IDENTIFICATION INFORMATION...................................................................... 13 HOW TO USE THIS WORKSHOP MANUAL................................................................. 17 PRECAUTIONS..................................................................................... 20 SEALANT ON THE TAPERED SCREW FORPIPING.......................................................... 23 NYLON TUBE REPLACEMENT METHOD................................................................... 24 METRIC INFORMATION.............................................................................. 26 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.................................................... 28 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS...................................................... 28 RECOMMENDED LUBRICANTS.......................................................................... 30 VEHICLE LIFT AND SUPPORT LOCATIONS.............................................................. 32 SYMPTOM SIMULATION.............................................................................. 34 GLOSSARY........................................................................................ 36 GLOSSARY OF SAE AND HINO TERMS.................................................................. 39 CLUTCH MAIN UNIT (EATON SOLO 1402)...................................................................... 42 CLUTCH ASSEMBLY (EATON SOLO1402).................................................................... 43 DATA AND SPECIFICATIONS......................................................................... 43 DESCRIPTION..................................................................................... 43 TROUBLESHOOTING................................................................................. 44 SPECIAL TOOL.................................................................................... 46 COMPONENT LOCATOR............................................................................... 47 OVERHAUL........................................................................................ 48 INSPECTION AND REPAIR........................................................................... 57 CLUTCH CONTROL.......................................................................................... 60 CLUTCH CONTROL UNIT................................................................................. 61 DESCRIPTION..................................................................................... 61 INSPECTION AND ADJUSTMENT....................................................................... 62 CLUTCH PEDAL AND RELEASE UNIT....................................................................... 65 COMPONENT LOCATOR............................................................................... 65 OVERHAUL........................................................................................ 66 INSPECTION AND REPAIR........................................................................... 68 CLUTCH MASTER CYLINDER.............................................................................. 69 COMPONENT LOCATOR............................................................................... 69 OVERHAUL........................................................................................ 70 INSPECTION AND REPAIR........................................................................... 70 TRANSMISSION MAIN UNIT(EATON FAO-14810C)................................................................ 71 TRANSMISSION ASSEMBLY............................................................................... 72 DATA AND SPECIFICATION.......................................................................... 72 DISMOUNTING AND MOUNTING........................................................................ 73 TRANSMISSION MAIN UNIT(EATON RTLO-16913A)............................................................... 75 TRANSMISSION ASSEMBLY............................................................................... 76 DATA AND SPECIFICATION.......................................................................... 76 DISMOUNTING AND MOUNTING........................................................................ 77 AUTOMATIC TRANSMISSION(ALLISON 3000RDS, 3500RDS, 3000HS)................................................ 79 AUTOMATIC TRANSMISSION ASSEMBLY..................................................................... 80 TROUBLESHOOTING................................................................................. 80 SPECIAL TOOL.................................................................................... 80 DISMOUNTING AND MOUNTING........................................................................ 80 TRANSMISSION/TRANSFER CONTROL(EATON MANUAL TRANSMISSION)................................................ 88 TRANSMISSION CONTROL UNIT........................................................................... 89 TROUBLESHOOTING................................................................................. 89 COMPONENT LOCATOR............................................................................... 90 OVERHAUL........................................................................................ 92 TRANSMISSION/TRANSFER CONTROL(ALLISON AUTOMATIC TRANSMISSION)........................................... 93 TRANSMISSION CONTROL UNIT........................................................................... 94 TROUBLESHOOTING................................................................................. 94 COMPONENT LOCATOR............................................................................... 94 PROPELLER SHAFT (SPL 140HD, 170)........................................................................ 96 PROPELLER SHAFT ASSEMBLY............................................................................ 97 DATA AND SPECIFICATIONS......................................................................... 97 DESCRIPTION..................................................................................... 97 TROUBLESHOOTING................................................................................. 98 COMPONENT LOCATOR............................................................................... 98 OVERHAUL........................................................................................ 99 BRAKE EQUIPMENT......................................................................................... 111 SERVICE BRAKE ASSEMBLY.............................................................................. 112 DESCRIPTION..................................................................................... 112 DATA AND SPECIFICATIONS......................................................................... 113 WHEEL BRAKE CHAMBER LAYOUT...................................................................... 114 DIAGRAM......................................................................................... 115 TROUBLESHOOTING (DRUM BRAKE).................................................................... 125 TROUBLESHOOTING (AIR DISC BRAKE)................................................................ 127 SERVICE BRAKE........................................................................................... 128 AIR DRYER AND RESERVOIR SYSTEM(MODEL: BENDIX AD-IS PuraGuard (Oil Coalescing))...................... 129 DESCRIPTION..................................................................................... 129 BENDIX AD-IS AIR DRYER AND RESERVOIR SYSTEMTROUBLESHOOTING CHART................................ 141 BRAKE PEDAL......................................................................................... 145 OVERHAUL........................................................................................ 145 BRAKE VALVE......................................................................................... 148 DATA AND SPECIFICATIONS......................................................................... 148 DESCRIPTION..................................................................................... 148 COMPONENT LOCATOR............................................................................... 149 INSPECTION AND REPAIR........................................................................... 150 mBSP VALVE PACKAGE.................................................................................. 154 FUNCTION........................................................................................ 154 SPRING BRAKE MODULATING VALVE....................................................................... 155 DESCRIPTION..................................................................................... 155 COMPONENT LOCATOR............................................................................... 156 INSPECTION AND REPAIR........................................................................... 157 SPRING BRAKE CONTROL VALVE.......................................................................... 159 DESCRIPTION..................................................................................... 159 COMPONENT LOCATOR............................................................................... 160 INSPECTION AND REPAIR........................................................................... 161 QR-L INLINE QUICK RELEASE VALVE..................................................................... 164 DESCRIPTION AND MAINTENANCE..................................................................... 164 DC-4 DOUBLE CHECK VALVE............................................................................. 167 DESCRIPTION AND MAINTENANCE..................................................................... 167 BRAKE CHAMBER (FRONT)............................................................................... 170 DATA AND SPECIFICATIONS......................................................................... 170 DESCRIPTION AND MAINTENANCE..................................................................... 171 SPRING BRAKE CHAMBER (DRUM BRAKE)................................................................... 175 DESCRIPTION AND MAINTENANCE..................................................................... 175 SPRING BRAKE CHAMBER (DISC BRAKE)................................................................... 183 DESCRIPTION AND MAINTENANCE..................................................................... 183 WHEEL BRAKE (DRUM BRAKE)............................................................................ 187 DATA AND SPECIFICATIONS......................................................................... 187 DESCRIPTION..................................................................................... 189 COMPONENT LOCATOR............................................................................... 190 INSPECTION AND REPAIR........................................................................... 194 AUTOMATIC SLACK ADJUSTER Bendix Versajust........................................................... 223 DESCRIPTION..................................................................................... 223 INSPECTION AND REPAIR........................................................................... 225 DIAGNOSTICS..................................................................................... 230 WHEEL BRAKE (Bendix ADB22X AIR DISC BRAKE).......................................................... 231 DESCRIPTION..................................................................................... 231 COMPONENT LOCATOR............................................................................... 234 INSPECTION AND REPAIR........................................................................... 236 TP-5 TRACTOR PROTECTION VALVE(TRAILER BRAKE CONNECTION)............................................. 269 DESCRIPTION AND MAINTENANCE..................................................................... 269 MV-3 DASH CONTROL MODULE(TRAILER BRAKE CONNECTION).................................................. 273 DESCRIPTION AND MAINTENANCE..................................................................... 273 TCS-9000 CONTROL BRAKE VALVE(TRAILER BRAKE CONNECTION).............................................. 279 DESCRIPTION AND MAINTENANCE..................................................................... 279 ABS (ASR, VSC).......................................................................................... 282 ABS (ASR, VSC)...................................................................................... 283 OVERVIEW........................................................................................ 283 COMPOSITION AND OPERATION....................................................................... 285 OVERVIEW AND FUNCTION........................................................................... 286 INSPECTION (FRONT WHEEL BRAKE).................................................................. 289 INSPECTION (REAR WHEEL BRAKE)................................................................... 291 DIAGNOSTICS, TROUBLESHOOTING AND TESTING........................................................ 296 WIRING DIAGRAMS AND CONNECTORS.................................................................. 302 SPN FMI FAULT CODES............................................................................. 307 STEERING EQUIPMENT...................................................................................... 370 STEERING SYSTEM..................................................................................... 371 TROUBLESHOOTING................................................................................. 371 STEERING UNIT........................................................................................... 375 STEERING LINKAGE.................................................................................... 376 DESCRIPTION..................................................................................... 376 COMPONENT LOCATOR............................................................................... 377 SPECIAL TOOL.................................................................................... 379 OVERHAUL........................................................................................ 380 INSPECTION AND REPAIR........................................................................... 385 POWER STEERING.......................................................................................... 387 POWER STEERING GEAR UNIT............................................................................ 388 DATA AND SPECIFICATIONS......................................................................... 388 DESCRIPTION..................................................................................... 389 OPERATION....................................................................................... 390 COMPONENT LOCATOR............................................................................... 392 TORQUE CHART.................................................................................... 394 HAZARD WARNING DEFINITIONS...................................................................... 394 DISCLAIMER...................................................................................... 395 PATENTS......................................................................................... 395 MAINTENANCE TIPS................................................................................ 395 ON-VEHICLE SERVICE.............................................................................. 397 RESEAL & REPAIR................................................................................. 407 POWER STEERING PUMP................................................................................. 441 DATA AND SPECIFICATIONS......................................................................... 441 DESCRIPTION..................................................................................... 441 OPERATION....................................................................................... 442 COMPONENT LOCATOR............................................................................... 443 OVERHAUL........................................................................................ 445 INSPECTION AND REPAIR........................................................................... 450 FRONT AXLE(E1252RW, E1462W, D-2000F).................................................................... 452 FRONT AXLE (E1252RW, E1462W, D-2000F)............................................................... 453 DESCRIPTION..................................................................................... 453 FOREWORD................................................................................................ 498 CHAPTER REFERENCES...................................................................................... 499 INDEX................................................................................................... 500 REAR AXLE(WITH DIFFERENTIAL CARRIER).................................................................... 504 AXLE MODEL [S21-140] (SINGLE DRIVE AXLE)............................................................ 505 INTRODUCTION.................................................................................... 505 AXLE MODEL [S21-172, S23-172] (SINGLE DRIVE AXLE)................................................... 546 INTRODUCTION.................................................................................... 546 AXLE MODEL [23060SH] (SINGLE DRIVE AXLE)............................................................ 618 INTRODUCTION.................................................................................... 618 AXLE MODEL [DSH-40] (TANDEM DRIVE AXLE)............................................................. 669 INTRODUCTION.................................................................................... 669 AXLE MODEL [D40-157] (TANDEM DRIVE AXLE)............................................................ 779 INTRODUCTION.................................................................................... 779 AXLE MODEL [D-46-172] (TANDEM DRIVE AXLE)........................................................... 870 INTRODUCTION.................................................................................... 870 AXLE MODEL [D40-145] (TANDEM DRIVE AXLE)............................................................ 965 INTRODUCTION.................................................................................... 965 FOREWORD................................................................................................1063 CHAPTER REFERENCES......................................................................................1064 INDEX...................................................................................................1065 WHEEL & TIRE............................................................................................1069 WHEEL AND TIRE......................................................................................1070 DATA AND SPECIFICATIONS.........................................................................1070 TROUBLESHOOTING.................................................................................1071 DESCRIPTION.....................................................................................1073 SPECIAL TOOL....................................................................................1074 PRECAUTIONS.....................................................................................1075 INSPECTION......................................................................................1076 INSPECTION AND REPAIR...........................................................................1077 WHEEL...............................................................................................1078 OVERHAUL........................................................................................1078 SUSPENSION..............................................................................................1083 LEAF SUSPENSION ASSEMBLY............................................................................1084 DATA AND SPECIFICATIONS.........................................................................1084 DESCRIPTION.....................................................................................1086 TROUBLESHOOTING.................................................................................1088 COMPONENT LOCATOR...............................................................................1089 OVERHAUL........................................................................................1093 INSPECTION AND REPAIR...........................................................................1098 AIR SUSPENSION ASSEMBLY.............................................................................1101 DATA AND SPECIFICATIONS.........................................................................1101 SYSTEM DIAGRAM FOR HEIGHT CONTROL...............................................................1102 DESCRIPTION.....................................................................................1103 TROUBLESHOOTING.................................................................................1105 COMPONENT LOCATOR...............................................................................1106 OVERHAUL........................................................................................1108 INSPECTION AND REPAIR...........................................................................1112 RUBBER SUSPENSION...................................................................................1114 DATA AND SPECIFICATIONS.........................................................................1114 OVERHAUL........................................................................................1115 CHASSIS FRAME...........................................................................................1173 CHASSIS FRAME.......................................................................................1174 DESCRIPTION.....................................................................................1174 TROUBLESHOOTING.................................................................................1175 INSPECTION......................................................................................1175 REPAIRS.........................................................................................1176 COUPLER (5TH WHEEL).....................................................................................1181 COUPLER (5TH WHEEL) (HOLLAND FW17)..................................................................1182 DESCRIPTION.....................................................................................1182 OVERHAUL........................................................................................1184 INSPECTION AND ADJUSTMENT.......................................................................1190 COUPLER (5TH WHEEL) (HOLLAND FW35)..................................................................1193 DESCRIPTION.....................................................................................1193 OVERHAUL........................................................................................1195 ADJUSTMENT......................................................................................1202 CAB.....................................................................................................1203 CAB ASSEMBLY........................................................................................1204 DATA AND SPECIFICATIONS.........................................................................1204 TROUBLESHOOTING.................................................................................1205 DISMOUNTING AND MOUNTING........................................................................1206 INSPECTION AND REPAIR...........................................................................1209 HOOD................................................................................................1210 COMPONENT LOCATOR...............................................................................1210 OVERHAUL........................................................................................1211 FRP REPAIR PROCEDURE............................................................................1214 RADIATOR GRILLE.....................................................................................1219 COMPONENT LOCATOR...............................................................................1219 OVERHAUL........................................................................................1220 DOOR................................................................................................1221 COMPONENT LOCATOR...............................................................................1221 OVERHAUL........................................................................................1222 FLOOR MAT...........................................................................................1227 COMPONENT LOCATOR...............................................................................1227 DISMOUNTING AND MOUNTING........................................................................1228 SEAT................................................................................................1229 COMPONENT LOCATOR...............................................................................1229 INSTRUMENT PANEL....................................................................................1232 COMPONENT LOCATOR...............................................................................1232 DISMOUNTING AND MOUNTING........................................................................1234 HEATER AND AIR CONDITIONER..........................................................................1235 COMPONENT LOCATOR...............................................................................1235 SPECIAL TOOL....................................................................................1235 AIR CONDITIONING SYSTEM.............................................................................1236 SPECIFICATION DATA..............................................................................1236 PRECAUTIONS REGARDING REFRIGERANT(HFC134a)......................................................1236 PRECAUTIONS FOR REPLENISHING THEREFRIGERANT GAS.................................................1237 TROUBLESHOOTING (FAULT DIAGNOSIS BY SYMPTOMS)...................................................1237 GAS LEAKAGE INSPECTION..........................................................................1246 PRECAUTIONS FOR REMOVING/INSTALLINGTHE AIR CONDITIONER..........................................1249 RECOVERY AND REPLENISHMENT OFREFRIGERANT........................................................1251 MAINTENANCE.....................................................................................1256 REPLACEMENT.....................................................................................1257 DISMOUNTING AND MOUNTING........................................................................1259 WINDSHIELD..........................................................................................1260 COMPONENT LOCATOR...............................................................................1260 REPLACEMENT.....................................................................................1261 AFFIXING WEATHERSTRIP PROCEDURE.................................................................1262 FRONT BUMPER........................................................................................1266 COMPONENT LOCATOR...............................................................................1266 ELECTRICAL EQUIPMENT....................................................................................1267 ELECTRICAL PARTS....................................................................................1268 DATA AND SPECIFICATIONS.........................................................................1268 COMPONENT LOCATOR...............................................................................1269 TROUBLESHOOTING.................................................................................1273 GENERAL INSTRUCTION.............................................................................1274 HANDLING PRECAUTION.............................................................................1279 INSPECTION......................................................................................1282 INSPECTION AND ADJUSTMENT.......................................................................1298 SPEEDOMETER CONVERSION RATE LIST................................................................1299 ELECTRIC WIRE...........................................................................................1301 DIAGRAM.............................................................................................1302 HOW TO USE THIS CHAPTER.........................................................................1302 SPECIFICATION SYMBOL LIST.......................................................................1306 DIAGRAM.........................................................................................1312 CONNECTOR LIST..................................................................................1480 OTHERS..................................................................................................1495 PCS.................................................................................................1496 DESCRIPTION.....................................................................................1496 Section 1: Introduction.........................................................................1502 Section 2: Diagnostics, Troubleshooting and Testing.............................................1507 Section 3: Component Replacement................................................................1539 Section 4: Frequently Asked Questions...........................................................1540 FOREWORD................................................................................................1544 CHAPTER REFERENCES......................................................................................1545 INDEX...................................................................................................1546 GENERAL INTRODUCTION....................................................................................1547 GENERAL INTRODUCTION................................................................................1548 GENERAL PRECAUTIONS.............................................................................1548 HOW TO USE THIS WORKSHOP MANUAL.................................................................1551 IDENTIFICATION INFORMATION......................................................................1553 PRECAUTIONS.....................................................................................1554 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....................................................1557 DISMOUNTING AND MOUNTING........................................................................1558 SYMPTOM SIMULATION..............................................................................1561 GLOSSARY OF SAE AND HINO TERMS..................................................................1563 ENGINE INTRODUCTION (A09C)..............................................................................1566 ENGINE ASSEMBLY.....................................................................................1567 REQUIRED ITEMS (A09C)...........................................................................1567 MEASUREMENT OF COMPRESSION PRESSURE.............................................................1569 ADJUSTING THE VALVE CLEARANCE...................................................................1571 REPLACEMENT.....................................................................................1571 ENGINE MECHANICAL (A09C)................................................................................1584 HEAD COVER..........................................................................................1585 COMPONENT LOCATOR...............................................................................1585 HEAD COVER......................................................................................1585 REPLACEMENT.....................................................................................1586 ENGINE RETARDER.....................................................................................1590 COMPONENT LOCATOR...............................................................................1590 ENGINE RETARDER.................................................................................1592 OVERHAUL........................................................................................1593 ROCKER ARM ASSEMBLY.................................................................................1599 COMPONENT LOCATOR...............................................................................1599 ROCKER ARM ASSEMBLY.............................................................................1600 OVERHAUL........................................................................................1601 CAMSHAFT ASSEMBLY...................................................................................1613 COMPONENT LOCATOR...............................................................................1613 CAM SHAFT ASSEMBLY..............................................................................1614 OVERHAUL........................................................................................1615 CYLINDER HEAD ASSEMBLY..............................................................................1622 COMPONENT LOCATOR...............................................................................1622 CYLINDER HEAD ASSEMBLY..........................................................................1623 REPLACEMENT.....................................................................................1624 OVERHAUL........................................................................................1636 VALVE SYSTEM........................................................................................1645 COMPONENT LOCATOR...............................................................................1645 VALVE SYSTEM....................................................................................1647 OVERHAUL........................................................................................1648 CRANKSHAFT DAMPER...................................................................................1656 COMPONENT LOCATOR...............................................................................1656 REPLACEMENT.....................................................................................1657 CRANKSHAFT FRONT OIL SEAL...........................................................................1661 COMPONENT LOCATOR...............................................................................1661 CRANKSHAFT FRONT OIL SEAL.......................................................................1662 REPLACEMENT.....................................................................................1663 FRONT TIMING GEAR COVER AND TIMING GEAR.............................................................1666 COMPONENT LOCATOR...............................................................................1666 FRONT TIMING GEAR COVER AND TIMING GEAR.........................................................1667 CONFIGURATION DIAGRAM...........................................................................1668 OVERHAUL........................................................................................1669 FLYWHEEL ASSEMBLY...................................................................................1679 COMPONENT LOCATOR...............................................................................1679 FLYWHEEL ASSEMBLY...............................................................................1680 OVERHAUL........................................................................................1681 CRANKSHAFT REAR OIL SEAL............................................................................1687 COMPONENT LOCATOR...............................................................................1687 CRANKSHAFT REAR OIL SEAL........................................................................1688 REPLACEMENT.....................................................................................1688 FLYWHEEL HOUSING....................................................................................1691 COMPONENT LOCATOR...............................................................................1691 FLYWHEEL HOUSING................................................................................1691 REPLACEMENT.....................................................................................1692 REAR TIMING GEAR AND CAM IDLE GEAR..................................................................1698 COMPONENT LOCATOR...............................................................................1698 REAR TIMING GEAR AND CAM IDLE GEAR..............................................................1699 CONFIGURATION DIAGRAM...........................................................................1700 OVERHAUL........................................................................................1701 PISTON AND CONNECTING ROD...........................................................................1714 COMPONENT LOCATOR...............................................................................1714 PISTON AND CONNECTING ROD.......................................................................1715 CRANKSHAFT......................................................................................1717 OVERHAUL........................................................................................1718 CRANKSHAFT..........................................................................................1733 COMPONENT LOCATOR...............................................................................1733 REPLACEMENT.....................................................................................1735 CYLINDER LINER......................................................................................1742 COMPONENT LOCATOR...............................................................................1742 CYLINDER LINER..................................................................................1743 REPLACEMENT.....................................................................................1744 CYLINDER BLOCK......................................................................................1747 COMPONENT LOCATOR...............................................................................1747 CYLINDER BLOCK..................................................................................1748 OVERHAUL........................................................................................1749 ENGINE MOUNTING AND BRACKET.........................................................................1759 COMPONENT LOCATOR...............................................................................1759 REPLACEMENT.....................................................................................1760 AIR INTAKE SYSTEM (A09C)................................................................................1763 INTAKE PIPE (INTAKE SIDE)...........................................................................1764 COMPONENT LOCATOR...............................................................................1764 REPLACEMENT.....................................................................................1765 INTAKE PIPE (EXHAUST SIDE)..........................................................................1768 COMPONENT LOCATOR...............................................................................1768 REPLACEMENT.....................................................................................1769 INTERCOOLER.........................................................................................1773 OVERHAUL........................................................................................1773 AIR CLEANER.........................................................................................1774 COMPONENT LOCATOR...............................................................................1774 OVERHAUL........................................................................................1776 BOOST PRESSURE SENSOR...............................................................................1779 COMPONENT LOCATOR...............................................................................1779 INSPECTION......................................................................................1780 REPLACEMENT.....................................................................................1780 AIR HOSE............................................................................................1782 COMPONENT LOCATOR...............................................................................1782 OVERHAUL........................................................................................1783 AIR FLOW SENSOR.....................................................................................1784 COMPONENT LOCATOR...............................................................................1784 REPLACEMENT.....................................................................................1785 INTAKE MANIFOLD TEMPERATURE SENSOR..................................................................1786 COMPONENT LOCATOR...............................................................................1786 REPLACEMENT.....................................................................................1787 AIR INTAKE HEATER...................................................................................1788 COMPONENT LOCATOR...............................................................................1788 REPLACEMENT.....................................................................................1789 INTAKE THROTTLE VALVE...............................................................................1792 COMPONENT LOCATOR...............................................................................1792 INSPECTION......................................................................................1793 REPLACEMENT.....................................................................................1793 EXHAUST SYSTEM (A09C)...................................................................................1794 EXHAUST MANIFOLD AND PIPE...........................................................................1795 COMPONENT LOCATOR...............................................................................1795 DISMOUNTING AND MOUNTING........................................................................1796 EXHAUST PIPE AND MUFFLER UNIT.......................................................................1797 DESCRIPTION.....................................................................................1797 COMPONENT LOCATOR...............................................................................1798 REPLACEMENT OF ATC..............................................................................1805 OVERHAUL........................................................................................1807 DPR (DIESEL PARTICULATE ACTIVE REDUCTION SYSTEM)....................................................1820 SYSTEM CONFIGURATION............................................................................1820 STRUCTURE OF DPR-CLEANER........................................................................1821 SPECIAL TOOL....................................................................................1822 DPR INSPECTION..................................................................................1823 INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY....1824 INSPECTION BY WAY OF HINO DX II.................................................................1825 INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL)....................1829 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX II...........................1832 CHECKING THE DPR STATE..........................................................................1832 REPLACEMENT OF DPR FILTER.......................................................................1833 OVERALL OPERATION FLOW..........................................................................1837 DIFFERENTIAL PRESSURE SENSOR........................................................................1845 COMPONENT LOCATOR...............................................................................1845 DISMOUNTING AND MOUNTING........................................................................1846 INSPECTION AND REPAIR...........................................................................1846 AFTERTREATMENT FUEL INJECTOR........................................................................1848 COMPONENT LOCATOR...............................................................................1848 SPECIAL TOOL....................................................................................1849 OVERHAUL........................................................................................1850 EXHAUST CONTROL CYLINDER............................................................................1860 COMPONENT LOCATOR...............................................................................1860 REPLACEMENT.....................................................................................1862 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET) AND EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET)......1865 COMPONENT LOCATOR...............................................................................1865 OVERHAUL........................................................................................1866 EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET) AND EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET).......1867 COMPONENT LOCATOR...............................................................................1867 OVERHAUL........................................................................................1868 EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET).......................................................1869 COMPONENT LOCATOR...............................................................................1869 OVERHAUL........................................................................................1870 EXHAUST GAS TEMPERATURE SENSOR (SCR INLET)..........................................................1871 COMPONENT LOCATOR...............................................................................1871 OVERHAUL........................................................................................1872 PM SENSOR...........................................................................................1873 COMPONENT LOCATOR...............................................................................1873 OVERHAUL........................................................................................1874 LUBRICATING SYSTEM (A09C)...............................................................................1875 LUBRICATING SYSTEM..................................................................................1876 LUBRICATING SYSTEM DIAGRAM......................................................................1876 OIL FILTER..........................................................................................1877 COMPONENT LOCATOR...............................................................................1877 REPLACEMENT.....................................................................................1878 OIL COOLER..........................................................................................1882 COMPONENT LOCATOR...............................................................................1882 OVERHAUL........................................................................................1884 OIL PUMP............................................................................................1891 COMPONENT LOCATOR...............................................................................1891 OVERHAUL........................................................................................1892 OIL PAN.............................................................................................1897 COMPONENT LOCATOR...............................................................................1897 REPLACEMENT.....................................................................................1898 OIL STRAINER AND PLATE..............................................................................1901 COMPONENT LOCATOR...............................................................................1901 REPLACEMENT.....................................................................................1903 OIL PRESSURE SWITCH.................................................................................1905 COMPONENT LOCATOR...............................................................................1905 REPLACEMENT.....................................................................................1906 OIL LEVEL GAUGE AND GUIDE...........................................................................1908 COMPONENT LOCATOR...............................................................................1908 REPLACEMENT.....................................................................................1909 COOLING SYSTEM (A09C)...................................................................................1911 COOLING SYSTEM......................................................................................1912 COOLING SYSTEM DIAGRAM..........................................................................1912 RADIATOR............................................................................................1913 COMPONENT LOCATOR...............................................................................1913 INSPECTION AND REPAIR...........................................................................1914 INTERCOOLER.........................................................................................1915 COMPONENT LOCATOR...............................................................................1915 OVERHAUL........................................................................................1916 INSPECTION AND REPAIR...........................................................................1917 THERMOSTAT CASE AND THERMOSTAT......................................................................1918 COMPONENT LOCATOR...............................................................................1918 OVERHAUL........................................................................................1919 COOLANT PUMP........................................................................................1924 COMPONENT LOCATOR...............................................................................1924 REPLACEMENT.....................................................................................1925 INSPECTION AND REPAIR...........................................................................1930 COOLING FAN AND FAN CLUTCH..........................................................................1931 COMPONENT LOCATOR...............................................................................1931 REPLACEMENT.....................................................................................1932 COOLANT TEMPERATURE SENSOR..........................................................................1934 COMPONENT LOCATOR...............................................................................1934 REPLACEMENT.....................................................................................1935 HEADER TANK AND WATER LEVEL SWITCH..................................................................1937 COMPONENT LOCATOR...............................................................................1937 REPLACEMENT.....................................................................................1938 FUEL SYSTEM (A09C)......................................................................................1940 FUEL SYSTEM.........................................................................................1941 FUEL SYSTEM DIAGRAM.............................................................................1941 FUEL TANK...........................................................................................1942 COMPONENT LOCATOR...............................................................................1942 FUEL FILTER AND CASE................................................................................1944 COMPONENT LOCATOR...............................................................................1944 OVERHAUL........................................................................................1946 PRE FUEL FILTER.....................................................................................1953 COMPONENT LOCATOR...............................................................................1953 SPECIAL TOOL....................................................................................1953 OVERHAUL........................................................................................1954 FUEL FILTER WATER LEVEL SENSOR......................................................................1962 COMPONENT LOCATOR...............................................................................1962 REPLACEMENT.....................................................................................1963 SUPPLY PUMP.........................................................................................1965 COMPONENT LOCATOR...............................................................................1965 INSPECTION......................................................................................1968 REPLACEMENT.....................................................................................1968 INJECTOR............................................................................................1981 COMPONENT LOCATOR...............................................................................1981 SPECIAL TOOL....................................................................................1983 REPLACEMENT.....................................................................................1984 COMMON RAIL.........................................................................................1990 COMPONENT LOCATOR...............................................................................1990 SPECIAL TOOL....................................................................................1991 INSPECTION......................................................................................1992 REPLACEMENT.....................................................................................1992 FUEL TEMPERATURE SENSOR.............................................................................1998 COMPONENT LOCATOR...............................................................................1998 REPLACEMENT.....................................................................................1999 FUEL CUTOFF VALVE...................................................................................2001 COMPONENT LOCATOR...............................................................................2001 OVERHAUL........................................................................................2002 TURBOCHARGER (A09C).....................................................................................2003 TURBOCHARGER ASSEMBLY...............................................................................2004 COMPONENT LOCATOR...............................................................................2004 SPECIAL TOOL....................................................................................2006 INSPECTION......................................................................................2007 REPLACEMENT.....................................................................................2009 TURBOCHARGER CONTROL COMPUTER.......................................................................2018 COMPONENT LOCATOR...............................................................................2018 REPLACEMENT.....................................................................................2019 EMISSION CONTROL (A09C).................................................................................2021 EGR VALVE AND EGR COOLER............................................................................2022 COMPONENT LOCATOR...............................................................................2022 DESCRIPTION.....................................................................................2023 SPECIAL TOOL....................................................................................2024 DISMOUNTING AND MOUNTING........................................................................2025 CLOSED VENTILATOR...................................................................................2031 DESCRIPTION.....................................................................................2031 REPLACEMENT OF CLOSED VENTILATOR................................................................2032 CLOSED VENTILATOR ELEMENT...........................................................................2034 REPLACING THE ELEMENT...........................................................................2034 INSPECTION AND REPAIR...........................................................................2034 SELECTIVE CATALYTIC REDUCTION (SCR).................................................................2035 GENERAL DESCRIPTION.............................................................................2035 COMPONENT LOCATOR...............................................................................2037 INSPECTION......................................................................................2038 SPECIAL TOOL....................................................................................2039 DISMOUNTING AND MOUNTING........................................................................2040 INSPECTION AND REPAIR...........................................................................2055 ALTERNATOR (A09C).......................................................................................2056 ALTERNATOR (REMY 12V-130A, 135A, 180A, 200A)........................................................2057 COMPONENT LOCATOR...............................................................................2057 REPLACEMENT.....................................................................................2058 STARTER (A09C)..........................................................................................2068 STARTER.............................................................................................2069 DATA AND SPECIFICATIONS.........................................................................2069 COMPONENT LOCATOR...............................................................................2069 OVERHAUL........................................................................................2071 INSPECTION AND REPAIR...........................................................................2075 AIR COMPRESSOR (A09C)...................................................................................2078 AIR COMPRESSOR (95x60)..............................................................................2079 COMPONENT LOCATOR...............................................................................2079 SPECIAL TOOL....................................................................................2081 OVERHAUL........................................................................................2081 ENGINE CONTROL (A09C)...................................................................................2099 ACCELERATOR PEDAL...................................................................................2100 DESCRIPTION.....................................................................................2100 REPLACEMENT.....................................................................................2101 INSPECTION......................................................................................2102 ENGINE ECU..........................................................................................2103 COMPONENT LOCATOR...............................................................................2103 REPLACEMENT.....................................................................................2104 FOREWORD................................................................................................2110 CHAPTER REFERENCES .....................................................................................2111 INDEX...................................................................................................2112 GENERAL INTRODUCTION....................................................................................2113 GENERAL INTRODUCTION................................................................................2114 GENERAL PRECAUTIONS.............................................................................2114 IDENTIFICATION INFORMATION......................................................................2117 HOW TO USE THIS WORKSHOP MANUAL.................................................................2121 INTRODUCTION TO DESCRIPTIONS....................................................................2121 PRECAUTIONS.....................................................................................2124 SEALANT ON THE TAPERED SCREW FOR PIPING.........................................................2127 METRIC INFORMATION..............................................................................2128 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....................................................2130 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS......................................................2131 RECOMMENDED LUBRICANTS..........................................................................2132 GLOSSARY........................................................................................2134 GLOSSARY OF SAE AND HINO TERMS..................................................................2137 TROUBLE SHOOTING - COMPONENTS...........................................................................2140 ENGINE BASIC........................................................................................2141 ENGINE ASSEMBLY.................................................................................2141 ENGINE ASSEMBLY (COMMON RAIL SYSTEM)............................................................2148 TURBOCHARGER (A09C).................................................................................2149 TURBOCHARGER....................................................................................2149 ALTERNATOR (A09C: REMY 12V-130A,135A, 180A, 200A)...................................................2158 ALTERNATOR......................................................................................2158 STARTER (A09C)......................................................................................2159 STARTER.........................................................................................2159 AIR COMPRESSOR (A09C: 95X60)........................................................................2160 AIR COMPRESSOR..................................................................................2160 CLUTCH MAIN UNIT....................................................................................2161 CLUTCH ASSEMBLY (EATON SOLO1402)................................................................2161 AUTOMATIC TRANSMISSION..............................................................................2163 AUTOMATIC TRANSMISSION ASSEMBLY.................................................................2163 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) ..........................................2164 TRANSMISSION CONTROL UNIT.......................................................................2164 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)......................................2165 TRANSMISSION CONTROL UNIT.......................................................................2165 PROPELLER SHAFT (SPL 140HD, 170)....................................................................2165 PROPELLER SHAFT ASSEMBLY........................................................................2165 DIFFERENTIAL CARRIER (DANA S21, S23,D40,D46,DSH40 AND 23060SH)......................................2166 DIFFERENTIAL CARRIER ASSEMBLY...................................................................2166 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)........................................................2167 SERVICE BRAKE ASSEMBLY (DRUM BRAKE).............................................................2167 SERVICE BRAKE ASSEMBLY (AIR DISK BRAKE).........................................................2169 SERVICE BRAKE (FULL AIR BRAKE)......................................................................2170 AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS PURA GUARD).................................2170 STEERING EQUIPMENT..................................................................................2174 STEERING SYSTEM.................................................................................2174 FRONT AXLE (E1254I, E1462I, D-2000F)................................................................2178 FRONT AXLE (E1254I, E1462I, D-2000F)............................................................2178 REAR AXLE...........................................................................................2180 REAR AXLE.......................................................................................2180 WHEEL AND TIRE......................................................................................2181 WHEEL AND TIRE..................................................................................2181 SUSPENSION..........................................................................................2183 LEAF SUSPENSION ASSEMBLY........................................................................2183 AIR SUSPENSION ASSEMBLY.........................................................................2183 CHASSIS FRAME.......................................................................................2184 CHASSIS FRAME...................................................................................2184 CAB.................................................................................................2185 AIR SUSPENSION DUMP SYSTEM......................................................................2185 CAB ASSEMBLY....................................................................................2185 AIR CONDITIONING SYSTEM.........................................................................2187 ELECTRICAL EQUIPMENT................................................................................2196 ELECTRICAL PARTS................................................................................2196 TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM............................................................2198 ABOUT HINO DX.......................................................................................2199 About HINO DXⅡ..................................................................................2199 BASIC PROCEDURE FOR TROUBLESHOOTING.................................................................2201 BASIC PROCEDURE FOR TROUBLESHOOTING.............................................................2201 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....................................................2203 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE................................................2203 SYMPTOM SIMULATION..................................................................................2206 SYMPTOM SIMULATION..............................................................................2206 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART.......................................................2208 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART...................................................2208 ELECTRONIC CIRCUIT INSPECTION PROCEDURE.............................................................2209 ELECTRONIC CIRCUIT INSPECTION PROCEDURE.........................................................2209 INSPECTION PROCEDURE FOR MULTIPLE DTCS..............................................................2214 INSPECTION PROCEDURE FOR MULTIPLE DTCS..........................................................2214 ENGINE CONTROL SYSTEM (A09C)............................................................................2215 ENGINE CONTROL SYSTEM...............................................................................2218 PRECAUTIONS FOR DIAGNOSIS.......................................................................2218 SYSTEM BLOCK DIAGRAM............................................................................2220 SYSTEM DIAGRAM..................................................................................2221 PRECAUTIONS.....................................................................................2223 SENSOR LOCATION.................................................................................2227 COMPUTER (ECU) PIN ASSIGNMENT...................................................................2232 ENGINE ECU CONNECTOR............................................................................2238 INSPECTION......................................................................................2242 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...........................................................2243 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.............................................................2244 GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL..................................................2271 GROUP SHARING THE SENSOR GND TERMINAL...........................................................2272 ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)...................................2273 NO DTC..........................................................................................2277 SIMULTANEOUS MALFUNCTION OF MULTIPLE ELECTRIC SYSTEMS...........................................2280 MALFUNCTION OF STARTER..........................................................................2284 MALFUNCTION OF ALTERNATOR.......................................................................2290 DTC: P0005......................................................................................2294 DTC: P0006 and P0007............................................................................2298 DTC: P0016......................................................................................2303 DTC: P0027......................................................................................2306 DTC: P003A......................................................................................2311 DTC: P0045......................................................................................2316 DTC: P0047......................................................................................2321 DTC: P0048......................................................................................2326 DTC: P0049......................................................................................2331 DTC: P006E......................................................................................2336 DTC: P006F......................................................................................2340 DTC: P007B......................................................................................2344 DTC: P007C and P007D............................................................................2357 DTC: P0088......................................................................................2365 DTC: P0096......................................................................................2374 DTC: P0097 and P0098 ...........................................................................2385 DTC: P0101......................................................................................2393 DTC: P0104......................................................................................2401 DTC: P0106......................................................................................2408 DTC: P0107......................................................................................2414 DTC: P0108......................................................................................2421 DTC: P0111......................................................................................2427 DTC: P0112 and P0113............................................................................2433 DTC: P0115......................................................................................2439 DTC: P0117 and P0118............................................................................2447 DTC: P011A......................................................................................2455 DTC: P0122 and P0123............................................................................2463 DTC: P0126......................................................................................2472 DTC: P0128......................................................................................2476 DTC: P0148 .....................................................................................2481 DTC: P016E and P016F ...........................................................................2492 DTC: P0187 and P0188............................................................................2503 DTC: P0191......................................................................................2511 DTC: P0192 and P0193 ...........................................................................2516 DTC: P01A5......................................................................................2525 DTC: P01A6......................................................................................2532 DTC: P0200......................................................................................2539 DTC: P0201, P0202, P0203, P0204, P0205 and P0206................................................2541 DTC: P0217......................................................................................2546 DTC: P0219......................................................................................2551 DTC: P0222 and P0223............................................................................2557 DTC: P0234......................................................................................2566 DTC: P0263......................................................................................2572 DTC: P0266......................................................................................2584 DTC: P0269......................................................................................2596 DTC: P026C and P026D............................................................................2608 DTC: P0272......................................................................................2620 DTC: P0275......................................................................................2632 DTC: P0278......................................................................................2644 DTC: P0299......................................................................................2656 DTC: P0300......................................................................................2661 DTC: P0301, P0302, P0303, P0304, P0305 and P0306................................................2669 DTC: P0335......................................................................................2677 DTC: P0336......................................................................................2682 DTC: P0340......................................................................................2688 DTC: P0341......................................................................................2693 DTC: P0381......................................................................................2700 DTC: P0401......................................................................................2705 DTC: P0402......................................................................................2720 DTC: P0404......................................................................................2730 DTC: P0405 and P0406............................................................................2735 FOREWORD................................................................................................2742 CHAPTER REFERENCES .....................................................................................2743 INDEX...................................................................................................2744 ENGINE CONTROL SYSTEM (A09C)............................................................................2745 ENGINE CONTROL SYSTEM...............................................................................2748 DTC: P041B......................................................................................2748 DTC: P041C and P041D............................................................................2756 DTC: P0420......................................................................................2764 DTC: P0421......................................................................................2766 DTC: P0422......................................................................................2778 DTC: P0483......................................................................................2781 DTC: P0489 and P0490............................................................................2788 DTC: P049D......................................................................................2794 DTC: P04D5 and P04D6............................................................................2799 DTC: P04DA......................................................................................2807 DTC: P04DB......................................................................................2817 DTC: P0500 and P0501............................................................................2826 DTC: P0504......................................................................................2832 DTC: P0506 and P0507............................................................................2838 DTC: P0524......................................................................................2841 DTC: P0527......................................................................................2846 DTC: P0528......................................................................................2851 DTC: P0545 and P0546............................................................................2856 DTC: P054E and P054F............................................................................2865 DTC: P0562 and P0563............................................................................2868 DTC: P0605......................................................................................2874 DTC: P0606......................................................................................2876 DTC: P0607......................................................................................2878 DTC: P0610......................................................................................2880 DTC: P0611......................................................................................2884 DTC: P0617......................................................................................2886 DTC: P0628 and P0629............................................................................2890 DTC: P062F......................................................................................2903 DTC: P0630......................................................................................2907 DTC: P0642......................................................................................2910 DTC: P0643......................................................................................2914 DTC: P0652......................................................................................2919 DTC: P0653......................................................................................2924 DTC: P0686......................................................................................2929 DTC: P0691......................................................................................2933 DTC: P0692......................................................................................2938 DTC: P0698......................................................................................2943 DTC: P0699......................................................................................2945 DTC: P06A4......................................................................................2947 DTC: P06A5......................................................................................2949 DTC: P06D3 and P06D4............................................................................2951 DTC: P073D......................................................................................2959 DTC: P081A......................................................................................2965 DTC: P081B......................................................................................2969 DTC: P0850......................................................................................2973 DTC: P104E......................................................................................2978 DTC: P104F......................................................................................2982 DTC: P1071......................................................................................2986 DTC: P1072......................................................................................2990 DTC: P1133......................................................................................2994 DTC: P119F......................................................................................3000 DTC: P1229......................................................................................3005 DTC: P1266......................................................................................3007 DTC: P1426......................................................................................3009 DTC: P1427......................................................................................3015 DTC: P1428......................................................................................3021 DTC: P1458......................................................................................3027 DTC: P1459......................................................................................3032 DTC: P1462......................................................................................3037 DTC: P1463......................................................................................3043 DTC: P1467......................................................................................3049 DTC: P1468......................................................................................3055 DTC: P14B0......................................................................................3061 DTC: P14B2......................................................................................3065 DTC: P14B3 and P14B4............................................................................3069 DTC: P14B7 and P14B8............................................................................3075 DTC: P14BC and P14BD............................................................................3081 DTC: P14BF......................................................................................3087 DTC: P1515......................................................................................3092 DTC: P1530......................................................................................3097 DTC: P2002......................................................................................3101 DTC: P200C......................................................................................3121 DTC: P2032 and P2033............................................................................3128 DTC: P203F......................................................................................3136 DTC: P204F......................................................................................3140 DTC: P206B......................................................................................3142 DTC: P207F......................................................................................3167 DTC: P2080......................................................................................3193 DTC: P2084......................................................................................3202 DTC: P20CD......................................................................................3210 DTC: P20CE......................................................................................3214 DTC: P20D8......................................................................................3218 DTC: P20DE......................................................................................3223 DTC: P20DF......................................................................................3227 DTC: P20E0......................................................................................3233 DTC: P20EE......................................................................................3239 FOREWORD................................................................................................3267 CHAPTER REFERENCES......................................................................................3268 INDEX...................................................................................................3269 ENGINE CONTROL SYSTEM (A09C)............................................................................3270 ENGINE CONTROL SYSTEM...............................................................................3273 DTC: P20EF......................................................................................3273 DTC: P2100......................................................................................3275 DTC: P2101......................................................................................3281 DTC: P2103......................................................................................3287 DTC: P2120......................................................................................3293 DTC: P2122 and P2123............................................................................3297 DTC: P2127 and P2128............................................................................3306 DTC: P2135......................................................................................3315 DTC: P2138......................................................................................3320 DTC: P2146......................................................................................3325 DTC: P2147 and P2148............................................................................3331 DTC: P2149......................................................................................3338 DTC: P2150 and P2151............................................................................3344 DTC: P2184 and P2185............................................................................3351 DTC: P2201......................................................................................3359 DTC: P2227......................................................................................3398 DTC: P2228 and P2229............................................................................3402 DTC: P2269......................................................................................3407 DTC: P226C......................................................................................3412 DTC: P229F......................................................................................3420 DTC: P22D3......................................................................................3461 DTC: P240F......................................................................................3465 DTC: P2428......................................................................................3475 DTC: P242B......................................................................................3479 DTC: P242C and P242D............................................................................3487 DTC: P244A......................................................................................3495 DTC: P244B......................................................................................3512 DTC: P2457......................................................................................3539 DTC: P2458......................................................................................3553 DTC: P2459......................................................................................3563 DTC: P2463......................................................................................3565 DTC: P246F......................................................................................3570 DTC: P2470 and P2471............................................................................3578 DTC: P2481 and P2482............................................................................3586 DTC: P2483......................................................................................3594 DTC: P24A0......................................................................................3602 DTC: P24A1......................................................................................3605 DTC: P24A2......................................................................................3607 DTC: P24A3......................................................................................3617 DTC: P24AE......................................................................................3622 DTC: P24AF......................................................................................3630 DTC: P24B0......................................................................................3635 DTC: P24B1......................................................................................3640 DTC: P24B4......................................................................................3643 DTC: P24B7......................................................................................3653 DTC: P24C7......................................................................................3656 DTC: P24D0......................................................................................3660 DTC: P24D1......................................................................................3665 DTC: P24DA......................................................................................3670 DTC: P24FE......................................................................................3675 DTC: P2562......................................................................................3693 DTC: P2563......................................................................................3699 DTC: P2564 and P2565............................................................................3704 DTC: P259E......................................................................................3711 DTC: P259F......................................................................................3716 DTC: P2633 and P2634............................................................................3721 DTC: P268A and P2696............................................................................3730 DTC: P2A00......................................................................................3736 DTC: P2A01......................................................................................3746 DTC: P2BA9......................................................................................3756 DTC: U0073......................................................................................3760 DTC: U010A......................................................................................3763 DTC: U010C......................................................................................3766 DTC: U010E......................................................................................3769 DTC: U029D......................................................................................3772 DTC: U029E......................................................................................3775 DTC: U02A2......................................................................................3778 DTC: U02A3 .....................................................................................3781 DTC: U0301......................................................................................3784 DTC: U1001......................................................................................3787 DTC: U110A......................................................................................3790 FOREWORD................................................................................................3794 CHAPTER REFERENCES......................................................................................3795 INDEX...................................................................................................3796 DEF SCR SYSTEM (DCU)....................................................................................3797 DEF SCR SYSTEM......................................................................................3798 PRECAUTIONS FOR DIAGNOSIS.......................................................................3798 SYSTEM BLOCK DIAGRAM............................................................................3800 SYSTEM DIAGRAM..................................................................................3801 SENSOR LOCATION.................................................................................3803 COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT............................................3806 SIGNAL CHECK HARNESS............................................................................3807 INSPECTION......................................................................................3807 MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN................................................3808 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...........................................................3809 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.............................................................3810 DTC: P0071......................................................................................3817 DTC: P0072......................................................................................3828 DTC: P0073......................................................................................3836 DTC: P0562......................................................................................3844 DTC: P0563......................................................................................3847 DTC: P060B......................................................................................3850 DTC: P060C......................................................................................3852 DTC: P062F......................................................................................3854 DTC: P0667......................................................................................3856 DTC: P068A......................................................................................3858 DTC: P06AD......................................................................................3863 DTC: P06AE......................................................................................3865 DTC: P142A......................................................................................3867 DTC: P142B......................................................................................3876 DTC: P14C1......................................................................................3886 DTC: P14C2......................................................................................3900 DTC: P14C3......................................................................................3905 DTC: P202E......................................................................................3911 DTC: P203C......................................................................................3916 DTC: P203D......................................................................................3919 DTC: P2044......................................................................................3922 DTC: P2045......................................................................................3925 DTC: P2047......................................................................................3928 DTC: P2048......................................................................................3932 DTC: P2049......................................................................................3937 DTC: P204B......................................................................................3943 DTC: P204C......................................................................................3946 DTC: P204D......................................................................................3952 DTC: P205B......................................................................................3958 DTC: P205C......................................................................................3967 DTC: P205D......................................................................................3970 DTC: P206C......................................................................................3973 DTC: P206D......................................................................................3976 DTC: P208A......................................................................................3979 DTC: P208B......................................................................................3983 DTC: P208C......................................................................................3986 DTC: P208D......................................................................................3990 DTC: P20A0......................................................................................3994 DTC: P20A1......................................................................................4000 DTC: P20A2......................................................................................4004 DTC: P20A3......................................................................................4010 DTC: P20B1......................................................................................4016 DTC: P20B2......................................................................................4021 DTC: P20B3......................................................................................4030 DTC: P20B4......................................................................................4035 DTC: P20BD and P20B9............................................................................4040 DTC: P20C0 and P20BC............................................................................4048 DTC: P20E8......................................................................................4054 DTC: P20E9......................................................................................4065 DTC: P20F4......................................................................................4070 DTC: P21C2......................................................................................4074 DTC: P21C3......................................................................................4079 DTC: P21C4......................................................................................4083 DTC: P2202......................................................................................4087 DTC: P2203......................................................................................4090 DTC: P2204......................................................................................4093 DTC: P2209......................................................................................4101 DTC: P22A0......................................................................................4108 DTC: P22A1......................................................................................4111 DTC: P22A2......................................................................................4114 DTC: P22A7......................................................................................4123 DTC: P2510......................................................................................4131 DTC: P2BAE......................................................................................4136 DTC: U0029......................................................................................4139 DTC: U0038......................................................................................4142 DTC: U0100......................................................................................4145 DTC: U029D......................................................................................4149 DTC: U029E......................................................................................4152 DTC: U02A2......................................................................................4155 SUSPENSION CONTROL......................................................................................4158 HEIGHT CONTROL......................................................................................4159 DIAGNOSTIC TROUBLE CODE (DTC) TABLE.............................................................4159 DTC: C17A0......................................................................................4160 DTC: C17A1......................................................................................4165 DTC: C17A2......................................................................................4169 DTC: C17A3......................................................................................4174 DTC: C17EA......................................................................................4175 DTC: P0500......................................................................................4176 DTC: U110A......................................................................................4180 VEHICLE CONTROL SYSTEM (VCS)............................................................................4181 VEHICLE CONTROL SYSTEM..............................................................................4182 PRECAUTIONS FOR DIAGNOSIS.......................................................................4182 SYSTEM BLOCK DIAGRAM............................................................................4184 SIGNAL CHECK HARNESS............................................................................4185 DIAGNOSIS USING THE PC DIAGNOSIS TOOL...........................................................4193 VEHICLE CONTROL ECU INSPECTION..................................................................4194 DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE.........................................4200 DTC: P0500......................................................................................4201 DTC: P0501......................................................................................4205 DTC: P0617......................................................................................4209 DTC: P0704......................................................................................4212 DTC: P0850......................................................................................4215 DTC: P1565......................................................................................4221 DTC: U0101......................................................................................4224 DTC: U0105 .....................................................................................4227 DTC: U0121......................................................................................4230 DTC: U0155......................................................................................4233 NO ACTIVATION OF AUXILIARY BRAKE................................................................4235 NO ACTIVATION/RELEASE OF CRUISE FUNCTION........................................................4241 NO ACTIVATION/RELEASE OF ECO MODE...............................................................4247 CAN COMMUNICATION.......................................................................................4251 CAN COMMUNICATION TROUBLESHOOTING...................................................................4252 Outline.........................................................................................4252 Definition of Terms.............................................................................4252 Troubleshooting Procedure.......................................................................4253 Work Flow.......................................................................................4253 ECU individual code list........................................................................4254 CAN communication circuit diagram...............................................................4255 ENGINE CAN COMMUNICATION LINE.......................................................................4258 ABNORMAL CAN COMMUNICATION DTC DETECTED.........................................................4258 CONNECTION DIAGRAM..............................................................................4258 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE.....................................4258 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE................................................4260 DISCONNECTION INSPECTION FOR ENGINE CAN H/L COMMUNICATION LINE..................................4264 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE......................................................4276 INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE............................................4305 INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE............................................4310 INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE).......................4315 INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE..............................................4320 INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE..............................................4326 INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE................................................4332 INSPECTION FOR PM SENSOR CAN COMMUNICATION LINE.................................................4338 DIAGNOSIS CAN COMMUNICATION LINE....................................................................4344 ABNORMAL CAN COMMUNICATION DTC DETECTED.........................................................4344 CONNECTION DIAGRAM..............................................................................4344 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE.....................................4344 PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE.............................................4346 DISCONNECTION INSPECTION FOR DIAGNOSIS CAN H/L COMMUNICATION LINE...............................4350 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H/L LINE..........................................4356 INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)....................4370 INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE................................................4374 CONTROL CAN COMMUNICATION LINE......................................................................4379 ABNORMAL CAN COMMUNICATION DTC DETECTED.........................................................4379 CONNECTION DIAGRAM..............................................................................4379 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)....4380 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION)...............4380 PRE-INSPECTION FOR CAN COMMUNICATION LINE.......................................................4381 DISCONNECTION INSPECTION FOR CAN H/L COMMUNICATION LINE.........................................4385 INSPECTION FOR SHORT-CIRCUIT IN CAN H/L-LINE....................................................4406
Description:
2019 HINO TRUCK COE OWNERS WORKSHOP MANUAL
- This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
- Applicable for HINO XL7, XL8, XL8-T series, equipped with A09C-VD, A09C-VE and A09C-VF 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]
