Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
2019 HINO TRUCK Conventional 238 258LP 268 338 358 J08E VB J08E WU WORKSHOP MANUAL – PDF DOWNLOAD
Original price was: $95.95.$39.95Current price is: $39.95.
2019 HINO TRUCK Conventional 238 258LP 268 338 358 J08E VB J08E WU WORKSHOP MANUAL
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
2019 HINO TRUCK Conventional 238 258LP 268 338 358 J08E VB J08E WU WORKSHOP MANUAL
File Details:
2019 HINO TRUCK Conventional 238 258LP 268 338 358 J08E VB J08E WU WORKSHOP MANUAL
Language : English
Pages : 3556
Size : 108 MB
Downloadable : Yes
Format : PDF
2019 HINO TRUCK CONVENTIONAL 238 258LP 268 338 358 J08E VB J08E WU WORKSHOP MANUAL – PDF DOWNLOAD:
Image Preview:
Table of Contents:
2019 HINO TRUCK Conventional 238 258LP 268 338 358 J08E VB J08E WU WORKSHOP MANUAL
How to use ................................................................................................... 3 1 ........................................................................................................ 3 2 ........................................................................................................ 4 3 ........................................................................................................ 5 4 ........................................................................................................ 6 5 ........................................................................................................ 7 FOREWORD...................................................................................................... 8 CHAPTER REFERENCES............................................................................................ 9 INDEX......................................................................................................... 10 GENERAL INTRODUCTION (CHASSIS)................................................................................ 14 GENERAL INTRODUCTION...................................................................................... 15 GENERAL PRECAUTIONS................................................................................... 15 IDENTIFICATION INFORMATION............................................................................ 18 HOW TO USE THIS WORKSHOP MANUAL....................................................................... 26 PRECAUTIONS........................................................................................... 29 SEALANT ON THE TAPERED SCREW FOR PIPING............................................................... 32 NYLON TUBE REPLACEMENT METHOD......................................................................... 33 METRIC INFORMATION.................................................................................... 35 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.......................................................... 37 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS............................................................ 37 RECOMMENDED LUBRICANTS................................................................................ 39 VEHICLE LIFT AND SUPPORT LOCATIONS.................................................................... 41 INFORMATION DISPLAY................................................................................... 43 SYMPTOM SIMULATION.................................................................................... 48 GLOSSARY.............................................................................................. 50 GLOSSARY OF SAE AND HINO TERMS........................................................................ 53 CLUTCH MAIN UNIT (EATON 1402) ................................................................................ 56 CLUTCH ASSEMBLY (EATON SAS1402) .......................................................................... 57 DATA AND SPECIFICATIONS............................................................................... 57 DESCRIPTION........................................................................................... 57 TROUBLESHOOTING....................................................................................... 58 SPECIAL TOOL.......................................................................................... 60 COMPONENT LOCATOR..................................................................................... 61 OVERHAUL.............................................................................................. 62 CLUTCH ASSEMBLY (EATON SOLO1402) ......................................................................... 71 DATA AND SPECIFICATIONS............................................................................... 71 COMPONENT LOCATOR..................................................................................... 71 OVERHAUL.............................................................................................. 72 INSPECTION AND REPAIR................................................................................. 82 CLUTCH CONTROL................................................................................................ 85 CLUTCH CONTROL UNIT ...................................................................................... 86 DESCRIPTION........................................................................................... 86 INSPECTION AND ADJUSTMENT............................................................................. 87 CLUTCH PEDAL AND RELEASE UNIT ............................................................................ 90 COMPONENT LOCATOR..................................................................................... 90 OVERHAUL.............................................................................................. 91 INSPECTION AND REPAIR................................................................................. 93 CLUTCH MASTER CYLINDER ................................................................................... 94 COMPONENT LOCATOR..................................................................................... 94 OVERHAUL.............................................................................................. 95 INSPECTION AND REPAIR................................................................................. 95 TRANSMISSION MAIN UNIT (EATON FS 5406/6406)................................................................... 96 TRANSMISSION ASSEMBLY .................................................................................... 97 DATA AND SPECIFICATION................................................................................ 97 DISMOUNTING AND MOUNTING.............................................................................. 98 AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS, 2500HS) ........................................... 100 AUTOMATIC TRANSMISSION ASSEMBLY .......................................................................... 101 TROUBLESHOOTING....................................................................................... 101 SPECIAL TOOL.......................................................................................... 101 DISMOUNTING AND MOUNTING.............................................................................. 101 AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS)............................................................. 109 AUTOMATIC TRANSMISSION ASSEMBLY .......................................................................... 110 TROUBLESHOOTING....................................................................................... 110 SPECIAL TOOL.......................................................................................... 110 DISMOUNTING AND MOUNTING.............................................................................. 110 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION)..................................................... 117 TRANSMISSION CONTROL UNIT ................................................................................ 118 TROUBLESHOOTING....................................................................................... 118 COMPONENT LOCATOR..................................................................................... 119 OVERHAUL.............................................................................................. 120 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION) ............................................... 121 TRANSMISSION CONTROL UNIT ................................................................................ 122 TROUBLESHOOTING....................................................................................... 122 COMPONENT LOCATOR..................................................................................... 122 OVERHAUL.............................................................................................. 124 PROPELLER SHAFT (SPL 100, 140)................................................................................ 125 PROPELLER SHAFT ASSEMBLY ................................................................................. 126 DATA AND SPECIFICATIONS............................................................................... 126 DESCRIPTION........................................................................................... 126 TROUBLESHOOTING....................................................................................... 127 COMPONENT LOCATOR..................................................................................... 127 OVERHAUL.............................................................................................. 129 DIFFERENTIAL CARRIER (MERITOR MS17.19.21&RS23)................................................................ 145 DIFFERENTIAL CARRIER ASSEMBLY ............................................................................ 146 DATA AND SPECIFICATIONS............................................................................... 146 DESCRIPTION........................................................................................... 148 TROUBLESHOOTING....................................................................................... 151 SPECIAL TOOL.......................................................................................... 152 COMPONENT LOCATOR..................................................................................... 154 OVERHAUL.............................................................................................. 158 INSPECTION AND REPAIR................................................................................. 198 DRIVER-CONTROLLED MAIN DIFFERENTIAL LOCK.................................................................. 207 OVERHAUL.............................................................................................. 207 INSPECTION AND REPAIR................................................................................. 210 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)................................................................. 211 SERVICE BRAKE ASSEMBLY ................................................................................... 212 DESCRIPTION........................................................................................... 212 DIAGRAM............................................................................................... 213 TROUBLESHOOTING....................................................................................... 215 BRAKE SYSTEM AIR BLEEDING............................................................................. 220 POWER STEERING SYSTEM AIR BLEEDING.................................................................... 222 BRAKE TEST............................................................................................ 223 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE).................................................................. 224 SERVICE BRAKE ASSEMBLY ................................................................................... 225 DESCRIPTION........................................................................................... 225 DATA AND SPECIFICATIONS............................................................................... 226 DIAGRAM............................................................................................... 227 TROUBLESHOOTING....................................................................................... 228 SERVICE BRAKE (HYDRAULIC BRAKE)............................................................................... 230 AIR DRYER ................................................................................................ 231 DATA AND SPECIFICATIONS............................................................................... 231 DESCRIPTION........................................................................................... 231 COMPONENT LOCATOR..................................................................................... 232 OVERHAUL.............................................................................................. 233 INSPECTION AND REPAIR................................................................................. 235 HYDRAULIC BRAKE .......................................................................................... 236 INSPECTION AND ADJUSTMENT............................................................................. 236 HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER CYLINDER..................................................... 239 DATA AND SPECIFICATIONS............................................................................... 239 DESCRIPTION........................................................................................... 239 PRINCIPLE OF OPERATION................................................................................ 241 COMPONENT LOCATOR..................................................................................... 243 HYDRO-MAX BOOSTER ........................................................................................ 244 OVERHAUL.............................................................................................. 244 MASTER CYLINDER .......................................................................................... 250 OVERHAUL.............................................................................................. 250 PRESSURE TESTS........................................................................................ 252 ABS MODULATOR ............................................................................................ 253 DATA AND SPECIFICATIONS............................................................................... 253 DESCRIPTION........................................................................................... 253 WHEEL BRAKE (TYPE: 4 PISTON) ............................................................................. 254 DATA AND SPECIFICATIONS............................................................................... 254 DESCRIPTION........................................................................................... 255 TROUBLESHOOTING....................................................................................... 256 SERVICE BRAKE (FULL AIR BRAKE)................................................................................ 269 AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS) ..................................................... 270 DESCRIPTION........................................................................................... 270 AD-IS AIR DRYER RESERVOIR SYSTEM TROUBLESHOOTING CHART................................................ 281 CHECK VALVE .............................................................................................. 285 DATA AND SPECIFICATIONS............................................................................... 285 DESCRIPTION........................................................................................... 285 INSPECTION AND REPAIR................................................................................. 286 BRAKE PEDAL .............................................................................................. 288 OVERHAUL.............................................................................................. 288 BRAKE VALVE............................................................................................... 291 DATA AND SPECIFICATIONS............................................................................... 291 DESCRIPTION........................................................................................... 291 COMPONENT LOCATOR..................................................................................... 292 INSPECTION AND REPAIR................................................................................. 293 RELAY VALVE .............................................................................................. 297 DATA AND SPECIFICATIONS............................................................................... 297 DESCRIPTION........................................................................................... 297 INSPECTION AND REPAIR................................................................................. 297 SPRING BRAKE MODULATING VALVE ............................................................................ 301 DESCRIPTION........................................................................................... 301 COMPONENT LOCATOR..................................................................................... 302 INSPECTION AND REPAIR................................................................................. 303 SPRING BRAKE CONTROL VALVE ............................................................................... 305 DESCRIPTION........................................................................................... 305 COMPONENT LOCATOR..................................................................................... 306 INSPECTION AND REPAIR................................................................................. 307 BRAKE CHAMBER (FRONT)..................................................................................... 310 DATA AND SPECIFICATIONS............................................................................... 310 DESCRIPTION........................................................................................... 310 COMPONENT LOCATOR..................................................................................... 311 OVERHAUL.............................................................................................. 311 BRAKE CHAMBER (REAR)...................................................................................... 313 DATA AND SPECIFICATIONS............................................................................... 313 DESCRIPTION........................................................................................... 314 COMPONENT LOCATOR..................................................................................... 315 INSPECTION AND REPAIR................................................................................. 316 PROTECTION VALVE.......................................................................................... 327 DATA AND SPECIFICATIONS............................................................................... 327 DESCRIPTION........................................................................................... 327 INSPECTION............................................................................................ 328 WHEEL BRAKE............................................................................................... 330 DATA AND SPECIFICATIONS............................................................................... 330 DESCRIPTION........................................................................................... 331 COMPONENT LOCATOR..................................................................................... 332 OVERHAUL.............................................................................................. 334 INSPECTION AND REPAIR................................................................................. 351 AUTOMATIC SLACK ADJUSTER ................................................................................. 353 DESCRIPTION........................................................................................... 353 DIAGNOSTICS........................................................................................... 354 COMPONENT LOCATOR..................................................................................... 355 OVERHAUL.............................................................................................. 357 INSTALLING THE SLACK ADJUSTER ONTO THE CAMSHAFT....................................................... 365 CHECK & ADJUSTMENT.................................................................................... 367 ABS (ABS : HYDRAULIC (E VERSION))............................................................................. 374 ABS ...................................................................................................... 375 OVERVIEW.............................................................................................. 375 COMPOSITION AND OPERATION............................................................................. 376 FUNCTION.............................................................................................. 379 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS................................................... 380 OVERVIEW AND FUNCTION................................................................................. 381 ABS (ABS : FULL AIR).......................................................................................... 393 ABS ...................................................................................................... 394 OVERVIEW.............................................................................................. 394 COMPOSITION AND OPERATION............................................................................. 395 FUNCTION.............................................................................................. 398 PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS................................................... 399 OVERVIEW AND FUNCTION................................................................................. 400 INSPECTION (FRONT WHEEL BRAKE)........................................................................ 405 INSPECTION (REAR WHEEL BRAKE)......................................................................... 407 EXHAUST BRAKE................................................................................................. 413 EXHAUST BRAKE SYSTEM...................................................................................... 414 SYSTEM DIAGRAM........................................................................................ 414 TROUBLESHOOTING....................................................................................... 415 ADJUSTMENT............................................................................................ 415 BRAKE CYLINDER............................................................................................ 417 DATA AND SPECIFICATIONS............................................................................... 417 DESCRIPTION........................................................................................... 417 PARKING BRAKE (BOSCH 12")..................................................................................... 418 PARKING BRAKE ASSEMBLY.................................................................................... 419 DATA AND SPECIFICATIONS............................................................................... 419 DESCRIPTION........................................................................................... 419 TROUBLESHOOTING....................................................................................... 420 COMPONENT LOCATOR..................................................................................... 421 OVERHAUL.............................................................................................. 423 INSPECTION AND REPAIR................................................................................. 437 ADJUSTMENT............................................................................................ 438 FOREWORD...................................................................................................... 441 CHAPTER REFERENCES............................................................................................ 442 INDEX......................................................................................................... 443 STEERING EQUIPMENT............................................................................................ 447 STEERING SYSTEM .......................................................................................... 448 TROUBLESHOOTING....................................................................................... 448 STEERING UNIT................................................................................................. 452 STEERING LINKAGE ......................................................................................... 453 DESCRIPTION........................................................................................... 453 COMPONENT LOCATOR..................................................................................... 454 SPECIAL TOOL.......................................................................................... 455 OVERHAUL.............................................................................................. 456 INSPECTION AND REPAIR................................................................................. 461 POWER STEERING................................................................................................ 463 POWER STEERING GEAR UNIT.................................................................................. 464 DATA AND SPECIFICATIONS............................................................................... 464 DESCRIPTION........................................................................................... 465 OPERATION............................................................................................. 466 COMPONENT LOCATOR..................................................................................... 468 TORQUE CHART.......................................................................................... 470 HAZARD WARNING DEFINITIONS............................................................................ 470 DISCLAIMER............................................................................................ 471 PATENTS............................................................................................... 471 MAINTENANCE TIPS...................................................................................... 471 ON-VEHICLE SERVICE.................................................................................... 473 RESEAL & REPAIR....................................................................................... 483 POWER STEERING PUMP....................................................................................... 517 DATA AND SPECIFICATIONS............................................................................... 517 DESCRIPTION........................................................................................... 517 OPERATION............................................................................................. 518 COMPONENT LOCATOR..................................................................................... 519 OVERHAUL.............................................................................................. 521 INSPECTION AND REPAIR................................................................................. 526 FRONT AXLE (MFS).............................................................................................. 528 FRONT AXLE (MFS) ......................................................................................... 529 DATA AND SPECIFICATIONS............................................................................... 529 TROUBLESHOOTING....................................................................................... 531 COMPONENT LOCATOR..................................................................................... 533 SERVICE NOTES......................................................................................... 537 SPECIAL TOOLS......................................................................................... 538 INTRODUCTION.......................................................................................... 543 INSPECTION............................................................................................ 544 DISASSEMBLY........................................................................................... 550 PREPARE PARTS FOR ASSEMBLY............................................................................ 557 ASSEMBLY.............................................................................................. 565 ADJUSTMENT............................................................................................ 577 LUBRICATION AND MAINTENANCE........................................................................... 586 MAINTENANCE........................................................................................... 590 REAR AXLE..................................................................................................... 591 REAR AXLE ................................................................................................ 592 DATA AND SPECIFICATIONS............................................................................... 592 TROUBLESHOOTING....................................................................................... 599 COMPONENT LOCATOR..................................................................................... 600 SPECIAL TOOL.......................................................................................... 603 DISASSEMBLY........................................................................................... 605 PREPARE PARTS FOR ASSEMBLY............................................................................ 607 ASSEMBLY.............................................................................................. 611 ADJUSTMENT............................................................................................ 621 LUBRICATION AND MAINTENANCE........................................................................... 623 WHEEL & TIRE.................................................................................................. 625 WHEEL AND TIRE ........................................................................................... 626 DATA AND SPECIFICATIONS............................................................................... 626 TROUBLESHOOTING....................................................................................... 629 DESCRIPTION........................................................................................... 631 SPECIAL TOOL.......................................................................................... 632 PRECAUTIONS........................................................................................... 633 INSPECTION............................................................................................ 634 INSPECTION AND REPAIR................................................................................. 635 WHEEL .................................................................................................... 636 OVERHAUL.............................................................................................. 636 SUSPENSION.................................................................................................... 641 LEAF SUSPENSION ASSEMBLY ................................................................................. 642 DATA AND SPECIFICATIONS............................................................................... 642 DESCRIPTION........................................................................................... 644 TROUBLESHOOTING....................................................................................... 646 COMPONENT LOCATOR..................................................................................... 647 OVERHAUL.............................................................................................. 651 INSPECTION AND REPAIR................................................................................. 656 AIR SUSPENSION ASSEMBLY .................................................................................. 659 DATA AND SPECIFICATIONS............................................................................... 659 SYSTEM DIAGRAM FOR HEIGHT CONTROL..................................................................... 660 DESCRIPTION........................................................................................... 661 TROUBLESHOOTING....................................................................................... 662 COMPONENT LOCATOR..................................................................................... 663 OVERHAUL.............................................................................................. 665 INSPECTION AND REPAIR................................................................................. 669 CHASSIS FRAME................................................................................................. 671 CHASSIS FRAME ............................................................................................ 672 TROUBLESHOOTING....................................................................................... 672 INSPECTION............................................................................................ 672 REPAIRS............................................................................................... 673 CAB........................................................................................................... 678 CAB ASSEMBLY ............................................................................................. 679 DATA AND SPECIFICATIONS............................................................................... 679 TROUBLESHOOTING....................................................................................... 680 DISMOUNTING AND MOUNTING.............................................................................. 681 INSPECTION AND REPAIR................................................................................. 684 HOOD...................................................................................................... 685 COMPONENT LOCATOR..................................................................................... 685 OVERHAUL.............................................................................................. 686 FRP REPAIR PROCEDURE.................................................................................. 689 RADIATOR GRILLE .......................................................................................... 694 COMPONENT LOCATOR..................................................................................... 694 OVERHAUL.............................................................................................. 695 DOOR ..................................................................................................... 696 COMPONENT LOCATOR..................................................................................... 696 OVERHAUL.............................................................................................. 697 FLOOR MAT ................................................................................................ 700 COMPONENT LOCATOR..................................................................................... 700 DISMOUNTING AND MOUNTING.............................................................................. 701 SEAT ..................................................................................................... 702 COMPONENT LOCATOR..................................................................................... 702 INSTRUMENT PANEL ......................................................................................... 705 COMPONENT LOCATOR..................................................................................... 705 DISMOUNTING AND MOUNTING.............................................................................. 706 HEATER AND AIR CONDITIONER ............................................................................... 707 COMPONENT LOCATOR..................................................................................... 707 SPECIAL TOOL.......................................................................................... 707 AIR CONDITIONING SYSTEM .................................................................................. 708 SPECIFICATION DATA.................................................................................... 708 PRECAUTIONS REGARDING REFRIGERANT (HFC134a)........................................................... 708 PRECAUTIONS FOR REPLENISHING THE REFRIGERANT GAS...................................................... 709 TROUBLESHOOTING (FAULT DIAGNOSIS BY SYMPTOMS)......................................................... 710 GAS LEAKAGE INSPECTION................................................................................ 719 PRECAUTIONS FOR REMOVING/INSTALLING THE AIR CONDITIONER............................................... 722 RECOVERY AND REPLENISHMENT OF REFRIGERANT............................................................. 724 MAINTENANCE........................................................................................... 729 REPLACEMENT........................................................................................... 730 DISMOUNTING AND MOUNTING.............................................................................. 732 WINDSHIELD ............................................................................................... 733 COMPONENT LOCATOR..................................................................................... 733 REPLACEMENT........................................................................................... 734 AFFIXING WEATHERSTRIP PROCEDURE....................................................................... 735 FRONT BUMPER ............................................................................................. 739 COMPONENT LOCATOR..................................................................................... 739 ELECTRICAL EQUIPMENT.......................................................................................... 740 ELECTRICAL PARTS ......................................................................................... 741 DATA AND SPECIFICATIONS............................................................................... 741 COMPONENT LOCATOR..................................................................................... 742 TROUBLESHOOTING....................................................................................... 751 GENERAL INSTRUCTION................................................................................... 752 HANDLING PRECAUTION................................................................................... 757 INSPECTION............................................................................................ 758 INSPECTION AND ADJUSTMENT............................................................................. 776 SPEEDOMETER CONVERSION RATE LIST...................................................................... 777 ELECTRIC WIRE................................................................................................. 778 DIAGRAM .................................................................................................. 779 HOW TO USE THIS CHAPTER............................................................................... 779 SPECIFICATION SYMBOL LIST............................................................................. 785 DIAGRAM............................................................................................... 793 POSITION OF CONNECTOR................................................................................. 934 CONNECTOR............................................................................................. 959 PIN LIST OF WIRE TO WIRE CONNECTOR (IN THE BULK HEAD CONNECTOR BOX)................................... 985 PIN LIST OF WIRE TO WIRE CONNECTOR (OUT OF THE BULK HEAD CONNECTOR BOX)............................... 990 PIN LIST OF SIGNAL CHECK CONNECTOR.................................................................... 995 CONNECTOR LIST........................................................................................ 997 FOREWORD......................................................................................................1014 CHAPTER REFERENCES............................................................................................1015 INDEX.........................................................................................................1016 GENERAL INTRODUCTION (ENGINE).................................................................................1018 GENERAL INTRODUCTION (ENGINE) ............................................................................1019 GENERAL PRECAUTIONS...................................................................................1019 HOW TO USE THIS WORKSHOP MANUAL.......................................................................1022 IDENTIFICATION INFORMATION............................................................................1024 PRECAUTIONS...........................................................................................1025 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS..........................................................1028 DISMOUNTING AND MOUNTING..............................................................................1029 SYMPTOM SIMULATION....................................................................................1032 GLOSSARY OF SAE AND HINO TERMS........................................................................1034 ENGINE INTRODUCTION (J08E)....................................................................................1037 ENGINE ASSEMBLY ..........................................................................................1038 DATA AND SPECIFICATIONS...............................................................................1038 TROUBLESHOOTING.......................................................................................1040 TROUBLESHOOTING (COMMON RAIL SYSTEM)..................................................................1047 ENGINE TUNEUP.........................................................................................1048 SPECIAL TOOL..........................................................................................1054 OVERHAUL CRITERIA.....................................................................................1055 DISMOUNTING AND MOUNTING..............................................................................1056 LIQUID GASKET AND APPLICATION POINTS..................................................................1058 ENGINE MECHANICAL (J08E)......................................................................................1063 CYLINDER HEAD ............................................................................................1064 COMPONENT LOCATOR.....................................................................................1064 SPECIAL TOOL..........................................................................................1067 OVERHAUL..............................................................................................1068 INSPECTION AND REPAIR.................................................................................1079 CRANKSHAFT FRONT END .....................................................................................1083 COMPONENT LOCATOR.....................................................................................1083 SPECIAL TOOL..........................................................................................1084 OVERHAUL..............................................................................................1085 FLYWHEEL AND FLYWHEEL HOUSING ............................................................................1087 COMPONENT LOCATOR.....................................................................................1087 SPECIAL TOOL..........................................................................................1088 OVERHAUL..............................................................................................1088 INSPECTION AND REPAIR.................................................................................1094 TIMING GEAR ..............................................................................................1095 COMPONENT LOCATOR.....................................................................................1095 SPECIAL TOOL..........................................................................................1096 OVERHAUL..............................................................................................1097 INSPECTION AND REPAIR.................................................................................1099 MAIN MOVING PARTS AND CYLINDER BLOCK .....................................................................1101 COMPONENT LOCATOR.....................................................................................1101 SPECIAL TOOL..........................................................................................1104 OVERHAUL..............................................................................................1106 INSPECTION AND REPAIR.................................................................................1119 AIR INTAKE SYSTEM (J08E)......................................................................................1123 AIR INTAKE MANIFOLD AND PIPE .............................................................................1124 COMPONENT LOCATOR.....................................................................................1124 DISMOUNTING AND MOUNTING..............................................................................1125 AIR INTAKE ...............................................................................................1126 COMPONENT LOCATOR.....................................................................................1126 AIR CLEANER ..............................................................................................1127 DESCRIPTION...........................................................................................1127 OVERHAUL..............................................................................................1128 AIR HOSE .................................................................................................1129 COMPONENT LOCATOR.....................................................................................1129 OVERHAUL..............................................................................................1130 AIR FLOW SENSOR ..........................................................................................1131 COMPONENT LOCATOR.....................................................................................1131 REPLACEMENT...........................................................................................1132 BOOST PRESSURE SENSOR ....................................................................................1133 COMPONENT LOCATOR.....................................................................................1133 REPLACEMENT...........................................................................................1134 EXHAUST SYSTEM (J08E).........................................................................................1135 EXHAUST MANIFOLD AND PIPE ................................................................................1136 COMPONENT LOCATOR.....................................................................................1136 DISMOUNTING AND MOUNTING..............................................................................1137 EXHAUST PIPE AND MUFFLER UNIT ............................................................................1138 DESCRIPTION...........................................................................................1138 COMPONENT LOCATOR.....................................................................................1139 REPLACEMENT OF ATC....................................................................................1145 OVERHAUL..............................................................................................1147 DPR (DIESEL PARTICULATE ACTIVE REDUCTION SYSTEM) .........................................................1163 SYSTEM CONFIGURATION..................................................................................1163 STRUCTURE OF DPR-CLEANER..............................................................................1164 DPR INSPECTION........................................................................................1165 INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY..........1166 INSPECTION BY WAY OF HINO DX II.......................................................................1167 INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL)..........................1171 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX II.................................1174 CHECKING THE DPR STATE................................................................................1174 REPLACEMENT OF DPR FILTER.............................................................................1175 OVERALL OPERATION FLOW................................................................................1179 DIFFERENTIAL PRESSURE SENSOR .............................................................................1187 COMPONENT LOCATOR.....................................................................................1187 DISMOUNTING AND MOUNTING..............................................................................1188 INSPECTION AND REPAIR.................................................................................1188 AFTERTREATMENT FUEL INJECTOR .............................................................................1191 COMPONENT LOCATOR.....................................................................................1191 OVERHAUL..............................................................................................1192 EXHAUST CONTROL CYLINDER .................................................................................1202 SYSTEM CONFIGURATION..................................................................................1202 DPR INSPECTION CHECK SHEET............................................................................1203 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC UPSTREAM) AND EXHAUST GAS TEMPERATURE SENSOR 2 (ATC DOWNSTREAM) ....1206 COMPONENT LOCATOR.....................................................................................1206 OVERHAUL..............................................................................................1207 LUBRICATING SYSTEM (J08E).....................................................................................1208 LUBRICATING SYSTEM .......................................................................................1209 DIAGRAM...............................................................................................1209 OIL PUMP AND OIL STRAINER ................................................................................1211 COMPONENT LOCATOR.....................................................................................1211 OVERHAUL..............................................................................................1212 INSPECTION AND REPAIR.................................................................................1213 OIL FILTER AND OIL COOLER ................................................................................1215 COMPONENT LOCATOR.....................................................................................1215 SPECIAL TOOL..........................................................................................1216 DISMOUNTING AND MOUNTING..............................................................................1217 INSPECTION AND REPAIR.................................................................................1218 COOLING SYSTEM (J08E).........................................................................................1219 COOLING SYSTEM ...........................................................................................1220 DIAGRAM...............................................................................................1220 COOLANT PUMP .............................................................................................1221 COMPONENT LOCATOR.....................................................................................1221 THERMOSTAT ...............................................................................................1222 COMPONENT LOCATOR.....................................................................................1222 OVERHAUL..............................................................................................1223 RADIATOR AND INTERCOOLER .................................................................................1225 COMPONENT LOCATOR.....................................................................................1225 OVERHAUL..............................................................................................1225 RADIATOR .................................................................................................1227 COMPONENT LOCATOR.....................................................................................1227 SPECIAL TOOL..........................................................................................1228 OVERHAUL..............................................................................................1228 INSPECTION AND REPAIR.................................................................................1232 COOLING FAN ..............................................................................................1233 COMPONENT LOCATOR.....................................................................................1233 INSPECTION AND REPAIR.................................................................................1234 FUEL SYSTEM (J08E)............................................................................................1235 FUEL SYSTEM ..............................................................................................1236 DIAGRAM...............................................................................................1236 COMPONENT LOCATOR.....................................................................................1237 SUPPLY PUMP ..............................................................................................1238 DESCRIPTION...........................................................................................1238 COMPONENT LOCATOR.....................................................................................1239 SPECIAL TOOL..........................................................................................1239 OVERHAUL..............................................................................................1240 COMMON RAIL ..............................................................................................1249 DESCRIPTION...........................................................................................1249 INSPECTION............................................................................................1250 REPLACEMENT...........................................................................................1251 INJECTOR .................................................................................................1255 DESCRIPTION...........................................................................................1255 REPLACEMENT...........................................................................................1256 PRE FUEL FILTER ..........................................................................................1264 DESCRIPTION...........................................................................................1264 AIR BLEEDING..........................................................................................1265 FUEL FILTER ..............................................................................................1267 DESCRIPTION...........................................................................................1267 OVERHAUL..............................................................................................1268 FUEL TANK ................................................................................................1271 COMPONENT LOCATOR.....................................................................................1271 FUEL CUTOFF VALVE ........................................................................................1273 COMPONENT LOCATOR.....................................................................................1273 OVERHAUL..............................................................................................1274 TURBOCHARGER (J08E)...........................................................................................1275 TURBOCHARGER .............................................................................................1276 DESCRIPTION...........................................................................................1276 TROUBLESHOOTING.......................................................................................1277 REPLACEMENT...........................................................................................1286 INSPECTION AFTER MOUNTING.............................................................................1292 EMISSION CONTROL (J08E).......................................................................................1293 EGR VALVE AND EGR PIPE ...................................................................................1294 COMPONENT LOCATOR.....................................................................................1294 EGR VALVE ................................................................................................1295 DESCRIPTION...........................................................................................1295 DISMOUNTING AND MOUNTING..............................................................................1296 CLOSED VENTILATOR ........................................................................................1299 DESCRIPTION...........................................................................................1299 REPLACEMENT OF CLOSED VENTILATOR......................................................................1299 REPLACEMENT ..............................................................................................1300 REPLACING THE ELEMENT.................................................................................1300 SELECTIVE CATALYTIC REDUCTION (SCR) ......................................................................1301 GENERAL DESCRIPTION...................................................................................1301 COMPONENT LOCATOR.....................................................................................1303 INSPECTION............................................................................................1304 SPECIAL TOOL..........................................................................................1305 DISMOUNTING AND MOUNTING..............................................................................1306 INSPECTION AND REPAIR.................................................................................1324 ALTERNATOR (J08E: REMY 12V-130A,135A,180A,200A)...............................................................1325 ALTERNATOR ...............................................................................................1326 DATA AND SPECIFICATIONS...............................................................................1326 TROUBLESHOOTING.......................................................................................1326 COMPONENT LOCATOR.....................................................................................1327 OVERHAUL..............................................................................................1328 INSPECTION AND REPAIR.................................................................................1331 STARTER (J08E)................................................................................................1332 STARTER ..................................................................................................1333 DATA AND SPECIFICATIONS...............................................................................1333 DESCRIPTION...........................................................................................1333 TROUBLESHOOTING.......................................................................................1334 COMPONENT LOCATOR.....................................................................................1335 OVERHAUL..............................................................................................1336 INSPECTION AND REPAIR.................................................................................1340 AIR COMPRESSOR (J08E: 340 cm3)................................................................................1343 AIR COMPRESSOR ...........................................................................................1344 DATA AND SPECIFICATIONS...............................................................................1344 DESCRIPTION...........................................................................................1345 TROUBLESHOOTING.......................................................................................1346 COMPONENT LOCATOR.....................................................................................1347 SPECIAL TOOL..........................................................................................1348 OVERHAUL..............................................................................................1348 INSPECTION AND REPAIR.................................................................................1358 ENGINE CONTROL (J08E).........................................................................................1362 ACCELERATOR PEDAL.........................................................................................1363 DESCRIPTION...........................................................................................1363 ENGINE ECU ...............................................................................................1364 COMPONENT LOCATOR.....................................................................................1364 REPLACEMENT...........................................................................................1365 FOREWORD......................................................................................................1372 CHAPTER REFERENCES............................................................................................1373 INDEX.........................................................................................................1374 GENERAL INTRODUCTION..........................................................................................1375 GENERAL INTRODUCTION......................................................................................1376 GENERAL PRECAUTIONS...................................................................................1376 IDENTIFICATION INFORMATION............................................................................1379 HOW TO USE THIS WORKSHOP MANUAL.......................................................................1387 INTRODUCTION TO DESCRIPTIONS..........................................................................1387 PRECAUTIONS...........................................................................................1390 SEALANT ON THE TAPERED SCREW FOR PIPING...............................................................1393 METRIC INFORMATION....................................................................................1394 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS..........................................................1396 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS............................................................1397 RECOMMENDED LUBRICANTS................................................................................1398 INFORMATION DISPLAY...................................................................................1400 GLOSSARY..............................................................................................1405 GLOSSARY OF SAE AND HINO TERMS........................................................................1408 TROUBLE SHOOTING - COMPONENTS.................................................................................1411 ENGINE BASIC..............................................................................................1412 ENGINE ASSEMBLY.......................................................................................1412 ENGINE ASSEMBLY (COMMON RAIL SYSTEM)..................................................................1419 TURBOCHARGER (J08E).......................................................................................1420 TURBOCHARGER..........................................................................................1420 ALTERNATOR (J08E: REMY 12V-130A, 135A, 180A, 200A)........................................................1429 ALTERNATOR............................................................................................1429 STARTER (J08E)............................................................................................1430 STARTER...............................................................................................1430 AIR COMPRESSOR (J08E: 340 cm3)............................................................................1431 AIR COMPRESSOR........................................................................................1431 CLUTCH MAIN UNIT..........................................................................................1432 CLUTCH ASSEMBLY (EATON SAS1402).......................................................................1432 AUTOMATIC TRANSMISSION....................................................................................1434 AUTOMATIC TRANSMISSION ASSEMBLY.......................................................................1434 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) ................................................1435 TRANSMISSION CONTROL UNIT.............................................................................1435 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)............................................1436 TRANSMISSION CONTROL UNIT.............................................................................1436 PROPELLER SHAFT (SPL 100, 140)............................................................................1436 PROPELLER SHAFT ASSEMBLY..............................................................................1436 DIFFERENTIAL CARRIER (MERITOR MS-17, 19, 21 AND RS-23)....................................................1437 DIFFERENTIAL CARRIER ASSEMBLY.........................................................................1437 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE).............................................................1438 SERVICE BRAKE ASSEMBLY................................................................................1438 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)..............................................................1443 SERVICE BRAKE ASSEMBLY................................................................................1443 SERVICE BRAKE (HYDRAULIC BRAKE)...........................................................................1445 WHEEL BRAKE (TYPE: 4 PISTON)..........................................................................1445 SERVICE BRAKE (FULL AIR BRAKE)............................................................................1447 AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS)..................................................1447 EXHAUST BRAKE.............................................................................................1450 EXHAUST BRAKE SYSTEM..................................................................................1450 PARKING BRAKE (BOSCH 12)..................................................................................1451 PARKING BRAKE ASSEMBLY................................................................................1451 STEERING EQUIPMENT........................................................................................1452 STEERING SYSTEM.......................................................................................1452 FRONT AXLE (MFS)..........................................................................................1456 FRONT AXLE (MFS)......................................................................................1456 REAR AXLE.................................................................................................1458 REAR AXLE.............................................................................................1458 WHEEL AND TIRE............................................................................................1459 WHEEL AND TIRE........................................................................................1459 SUSPENSION................................................................................................1461 LEAF SUSPENSION ASSEMBLY..............................................................................1461 AIR SUSPENSION ASSEMBLY...............................................................................1461 CHASSIS FRAME.............................................................................................1462 CHASSIS FRAME.........................................................................................1462 CAB.......................................................................................................1463 AIR SUSPENSION DUMP SYSTEM............................................................................1463 CAB ASSEMBLY..........................................................................................1463 AIR CONDITIONING SYSTEM...............................................................................1465 ELECTRICAL EQUIPMENT......................................................................................1475 ELECTRICAL PARTS......................................................................................1475 TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM..................................................................1477 ABOUT HINO DX II..........................................................................................1478 About HINO DX II......................................................................................1478 BASIC PROCEDURE FOR TROUBLESHOOTING.......................................................................1480 BASIC PROCEDURE FOR TROUBLESHOOTING...................................................................1480 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE..........................................................1482 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE......................................................1482 SYMPTOM SIMULATION........................................................................................1485 SYMPTOM SIMULATION....................................................................................1485 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART.............................................................1487 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART.........................................................1487 ELECTRONIC CIRCUIT INSPECTION PROCEDURE...................................................................1488 ELECTRONIC CIRCUIT INSPECTION PROCEDURE...............................................................1488 INSPECTION PROCEDURE FOR MULTIPLE DTCS....................................................................1493 INSPECTION PROCEDURE FOR MULTIPLE DTCS................................................................1493 ENGINE CONTROL SYSTEM (J08E)..................................................................................1494 ENGINE CONTROL SYSTEM.....................................................................................1497 PRECAUTIONS FOR DIAGNOSIS.............................................................................1497 SYSTEM BLOCK DIAGRAM..................................................................................1499 SYSTEM DIAGRAM........................................................................................1500 PRECAUTIONS...........................................................................................1502 SENSOR LOCATION.......................................................................................1506 COMPUTER (ECU) PIN ASSIGNMENT.........................................................................1515 ENGINE ECU CONNECTOR..................................................................................1521 INSPECTION............................................................................................1525 DIAGNOSIS USING THE PC DIAGNOSIS TOOL.................................................................1526 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...................................................................1527 GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL........................................................1548 GROUP SHARING THE SENSOR GND TERMINAL.................................................................1549 ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET).........................................1550 NO DTC................................................................................................1554 SIMULTANEOUS MALFUNCTION OF MULTIPLE ELECTRIC SYSTEMS.................................................1557 MALFUNCTION OF STARTER................................................................................1561 MALFUNCTION OF ALTERNATOR.............................................................................1567 DTC: P0005............................................................................................1570 DTC: P0006 and P0007..................................................................................1574 DTC: P0016............................................................................................1579 DTC: P0027............................................................................................1582 DTC: P003A............................................................................................1587 DTC: P0045............................................................................................1592 DTC: P0047............................................................................................1597 DTC: P0048............................................................................................1602 DTC: P006E............................................................................................1607 DTC: P006F............................................................................................1611 DTC: P007B............................................................................................1615 DTC: P007C and P007D..................................................................................1628 DTC: P0088............................................................................................1636 DTC: P0096............................................................................................1645 DTC: P0097 and P0098 .................................................................................1656 DTC: P0101............................................................................................1664 DTC: P0104............................................................................................1671 DTC: P0106............................................................................................1677 DTC: P0107............................................................................................1683 DTC: P0108............................................................................................1690 DTC: P0111............................................................................................1696 DTC: P0112 and P0113..................................................................................1702 DTC: P0115............................................................................................1708 DTC: P0117 and P0118..................................................................................1716 DTC: P011A............................................................................................1724 DTC: P0122 and P0123..................................................................................1732 DTC: P0126............................................................................................1742 DTC: P0128............................................................................................1746 DTC: P0148 ...........................................................................................1751 DTC: P016E and P016F .................................................................................1762 DTC: P0182 and P0183 .................................................................................1772 DTC: P0191............................................................................................1779 DTC: P0192 and P0193 .................................................................................1784 DTC: P01A5............................................................................................1793 DTC: P01A6............................................................................................1800 DTC: P0200............................................................................................1807 DTC: P0201, P0202, P0203, P0204, P0205 and P0206......................................................1809 DTC: P0217............................................................................................1814 DTC: P0219............................................................................................1819 DTC: P0222 and P0223..................................................................................1825 DTC: P0234............................................................................................1835 DTC: P0263, P0266, P0269, P0272, P0275 and P0278......................................................1841 DTC: P026C and P026D..................................................................................1852 DTC: P0299............................................................................................1865 DTC: P0300............................................................................................1870 DTC: P0301, P0302, P0303, P0304, P0305 and P0306......................................................1878 DTC: P0335............................................................................................1886 DTC: P0336............................................................................................1891 DTC: P0340............................................................................................1897 DTC: P0341............................................................................................1902 DTC: P0381............................................................................................1909 DTC: P0401............................................................................................1914 DTC: P0402............................................................................................1928 DTC: P0404............................................................................................1938 DTC: P0405 and P0406..................................................................................1943 DTC: P041B............................................................................................1949 DTC: P041C and P041D..................................................................................1957 DTC: P0420............................................................................................1965 DTC: P0421............................................................................................1967 DTC: P0422............................................................................................1979 DTC: P0489 and P0490..................................................................................1982 DTC: P049D............................................................................................1988 DTC: P04D5 and P04D6..................................................................................1993 DTC: P04DA............................................................................................2001 DTC: P04DB............................................................................................2011 DTC: P0500 and P0501..................................................................................2019 DTC: P0504............................................................................................2025 DTC: P0506 and P0507..................................................................................2031 DTC: P0524............................................................................................2034 DTC: P0545 and P0546..................................................................................2039 DTC: P054E and P054F..................................................................................2048 DTC: P0562 and P0563..................................................................................2051 DTC: P0605............................................................................................2057 DTC: P0606............................................................................................2059 DTC: P0607............................................................................................2061 DTC: P0610............................................................................................2063 DTC: P0611............................................................................................2066 DTC: P0617............................................................................................2068 DTC: P0628 and P0629..................................................................................2072 DTC: P062F............................................................................................2079 DTC: P0630............................................................................................2083 DTC: P0642............................................................................................2086 DTC: P0643............................................................................................2090 DTC: P064C............................................................................................2095 DTC: P0652............................................................................................2100 DTC: P0653............................................................................................2105 DTC: P0671, P0672, P0675 and P0676 ...................................................................2110 DTC: P0683............................................................................................2120 DTC: P0686............................................................................................2125 DTC: P0698............................................................................................2129 DTC: P0699............................................................................................2131 DTC: P06A4............................................................................................2133 DTC: P06A5............................................................................................2135 DTC: P06D3 and P06D4..................................................................................2137 DTC: P0704............................................................................................2144 DTC: P073D............................................................................................2148 DTC: P081A............................................................................................2154 DTC: P081B............................................................................................2158 DTC: P0850............................................................................................2162 FOREWORD......................................................................................................2168 CHAPTER REFERENCES............................................................................................2169 INDEX.........................................................................................................2170 ENGINE CONTROL SYSTEM.........................................................................................2171 ENGINE CONTROL SYSTEM.....................................................................................2174 DTC: P104E............................................................................................2174 DTC: P104F............................................................................................2178 DTC: P1133............................................................................................2182 DTC: P119F............................................................................................2188 DTC: P1426............................................................................................2193 DTC: P1427............................................................................................2199 DTC: P1428............................................................................................2205 DTC: P1458............................................................................................2211 DTC: P1459............................................................................................2216 DTC: P146F............................................................................................2221 DTC: P14B0............................................................................................2226 DTC: P14B2............................................................................................2230 DTC: P14B3 and P14B4..................................................................................2234 DTC: P14B7 and P14B8..................................................................................2240 DTC: P14BC and P14BD..................................................................................2246 DTC: P14BF............................................................................................2252 DTC: P1515............................................................................................2257 DTC: P1530............................................................................................2262 DTC: P2002............................................................................................2266 DTC: P200C............................................................................................2286 DTC: P2032 and P2033..................................................................................2292 DTC: P203F............................................................................................2300 DTC: P204F............................................................................................2304 DTC: P206B............................................................................................2306 DTC: P207F............................................................................................2329 DTC: P2080............................................................................................2353 DTC: P2084............................................................................................2362 DTC: P20CD............................................................................................2370 DTC: P20CE............................................................................................2374 DTC: P20D8............................................................................................2378 DTC: P20DE............................................................................................2383 DTC: P20DF............................................................................................2387 DTC: P20E0............................................................................................2393 DTC: P20EE............................................................................................2399 DTC: P20EF............................................................................................2425 DTC: P2100............................................................................................2427 DTC: P2101............................................................................................2433 DTC: P2103............................................................................................2439 DTC: P2120............................................................................................2445 DTC: P2122 and P2123..................................................................................2449 DTC: P2127 and P2128..................................................................................2457 DTC: P2135............................................................................................2466 DTC: P2138............................................................................................2471 DTC: P2146............................................................................................2476 DTC: P2147 and P2148..................................................................................2483 DTC: P2149............................................................................................2491 DTC: P2150 and P2151..................................................................................2497 DTC: P2184 and P2185..................................................................................2505 DTC: P2201............................................................................................2513 DTC: P2227............................................................................................2552 DTC: P2228 and P2229..................................................................................2556 DTC: P2269............................................................................................2561 DTC: P226C............................................................................................2565 DTC: P229F............................................................................................2573 DTC: P22D3............................................................................................2613 DTC: P240F............................................................................................2617 DTC: P2428............................................................................................2626 DTC: P242B............................................................................................2630 DTC: P242C and P242D..................................................................................2638 DTC: P244A............................................................................................2646 DTC: P244B............................................................................................2663 DTC: P2457............................................................................................2694 DTC: P2458............................................................................................2708 DTC: P2459............................................................................................2718 DTC: P2463............................................................................................2720 DTC: P246F............................................................................................2725 DTC: P2470 and P2471..................................................................................2733 DTC: P2481 and P2482..................................................................................2741 DTC: P2483............................................................................................2749 DTC: P24A0............................................................................................2757 DTC: P24A1............................................................................................2760 DTC: P24A2............................................................................................2762 DTC: P24AE............................................................................................2772 DTC: P24AF............................................................................................2780 DTC: P24B0............................................................................................2785 DTC: P24B1............................................................................................2790 DTC: P24B4............................................................................................2793 DTC: P24B7............................................................................................2803 DTC: P24C7............................................................................................2806 DTC: P24D0............................................................................................2810 DTC: P24D1............................................................................................2815 DTC: P24DA............................................................................................2820 DTC: P24FE............................................................................................2825 DTC: P2563............................................................................................2843 DTC: P2564 and P2565..................................................................................2848 DTC: P259E............................................................................................2855 DTC: P259F............................................................................................2860 DTC: P2635............................................................................................2865 DTC: P268A and P2696..................................................................................2874 DTC: P2A00............................................................................................2880 DTC: P2A01............................................................................................2889 DTC: P2BA9............................................................................................2898 DTC: U0073............................................................................................2903 DTC: U010A............................................................................................2906 DTC: U010C............................................................................................2909 DTC: U010E............................................................................................2912 DTC: U029D............................................................................................2915 DTC: U029E............................................................................................2918 DTC: U02A2............................................................................................2921 DTC: U02A3 ...........................................................................................2924 DTC: U0301............................................................................................2927 DTC: U1001............................................................................................2930 DTC: U110A............................................................................................2933 FOREWORD......................................................................................................2937 CHAPTER REFERENCES............................................................................................2938 INDEX.........................................................................................................2939 DEF SCR SYSTEM (DCU)..........................................................................................2940 DEF SCR SYSTEM............................................................................................2941 PRECAUTIONS FOR DIAGNOSIS.............................................................................2941 SYSTEM BLOCK DIAGRAM..................................................................................2943 SYSTEM DIAGRAM........................................................................................2944 SENSOR LOCATION.......................................................................................2945 COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT..................................................2948 SIGNAL CHECK HARNESS..................................................................................2949 INSPECTION............................................................................................2949 MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN......................................................2950 DIAGNOSIS USING THE PC DIAGNOSIS TOOL.................................................................2951 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...................................................................2952 DTC: P0071............................................................................................2958 DTC: P0072............................................................................................2969 DTC: P0073............................................................................................2977 DTC: P0562............................................................................................2985 DTC: P0563............................................................................................2988 DTC: P060B............................................................................................2991 DTC: P060C............................................................................................2993 DTC: P062F............................................................................................2995 DTC: P0667............................................................................................2997 DTC: P068A............................................................................................2999 DTC: P06AD............................................................................................3004 DTC: P06AE............................................................................................3006 DTC: P142A............................................................................................3008 DTC: P142B............................................................................................3017 DTC: P14C1............................................................................................3027 DTC: P14C2............................................................................................3041 DTC: P14C3............................................................................................3046 DTC: P202E............................................................................................3052 DTC: P203C............................................................................................3057 DTC: P203D............................................................................................3060 DTC: P2044............................................................................................3063 DTC: P2045............................................................................................3066 DTC: P2047............................................................................................3069 DTC: P2048............................................................................................3073 DTC: P2049............................................................................................3078 DTC: P204B............................................................................................3084 DTC: P204C............................................................................................3087 DTC: P204D............................................................................................3093 DTC: P205B............................................................................................3099 DTC: P205C............................................................................................3108 DTC: P205D............................................................................................3111 DTC: P206C............................................................................................3114 DTC: P206D............................................................................................3117 DTC: P208A............................................................................................3120 DTC: P208B............................................................................................3124 DTC: P208C............................................................................................3127 DTC: P208D............................................................................................3131 DTC: P20A0............................................................................................3135 DTC: P20A1............................................................................................3141 DTC: P20A2............................................................................................3145 DTC: P20A3............................................................................................3151 DTC: P20B1............................................................................................3157 DTC: P20B2............................................................................................3162 DTC: P20B3............................................................................................3170 DTC: P20B4............................................................................................3175 DTC: P20BD, P20B9 and P20C1...........................................................................3180 DTC: P20C0, P20BC and P20C4...........................................................................3188 DTC: P20E8............................................................................................3194 DTC: P20E9............................................................................................3205 DTC: P20F4............................................................................................3210 DTC: P21C2............................................................................................3214 DTC: P21C3............................................................................................3219 DTC: P21C4............................................................................................3223 DTC: P2202............................................................................................3227 DTC: P2203............................................................................................3230 DTC: P2204............................................................................................3233 DTC: P2209............................................................................................3240 DTC: P22A0............................................................................................3247 DTC: P22A1............................................................................................3250 DTC: P22A2............................................................................................3253 DTC: P22A7............................................................................................3261 DTC: P2510............................................................................................3269 DTC: P2BAE............................................................................................3274 DTC: U0029............................................................................................3277 DTC: U0038............................................................................................3280 DTC: U0100............................................................................................3283 DTC: U029D............................................................................................3287 DTC: U029E............................................................................................3290 DTC: U02A2............................................................................................3293 BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION))..............................................................3296 ABS.......................................................................................................3297 TROUBLESHOOTING.......................................................................................3297 BRAKE CONTROL SYSTEM (ABS:FULL AIR)...........................................................................3319 ABS.......................................................................................................3320 TROUBLESHOOTING.......................................................................................3320 VEHICLE CONTROL SYSTEM (VCS)..................................................................................3349 VEHICLE CONTROL SYSTEM....................................................................................3350 PRECAUTIONS FOR DIAGNOSIS.............................................................................3350 SYSTEM BLOCK DIAGRAM..................................................................................3352 SIGNAL CHECK HARNESS..................................................................................3353 DIAGNOSIS USING THE PC DIAGNOSIS TOOL.................................................................3361 VEHICLE CONTROL ECU INSPECTION........................................................................3362 DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE...............................................3368 DTC: P0500............................................................................................3369 DTC: P0501............................................................................................3373 DTC: P0562............................................................................................3377 DTC: P0563............................................................................................3380 DTC: P0617............................................................................................3383 DTC: P0704............................................................................................3386 DTC: P0850............................................................................................3392 DTC: P1565............................................................................................3398 DTC: U0101............................................................................................3404 DTC: U0105 ...........................................................................................3407 DTC: U0155............................................................................................3410 NO ACTIVATION OF AUXILIARY BRAKE......................................................................3412 NO ACTIVATION/RELEASE OF ENGINE REVOLUTION CONTROL....................................................3418 NO ACTIVATION/RELEASE OF CRUISE FUNCTION..............................................................3423 NO ACTIVATION/RELEASE OF ECO MODE.....................................................................3431 CAN COMMUNICATION.............................................................................................3435 CAN COMMUNICATION TROUBLESHOOTING.........................................................................3436 Outline...............................................................................................3436 Definition of Terms...................................................................................3436 Troubleshooting Procedure.............................................................................3437 Work Flow.............................................................................................3437 ECU individual code list..............................................................................3438 CAN communication circuit diagram.....................................................................3439 CAN communication relation connector location.........................................................3442 ENGINE CAN COMMUNICATION LINE.............................................................................3446 ABNORMAL CAN COMMUNICATION DTC DETECTED...............................................................3446 CONNECTION DIAGRAM....................................................................................3446 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE...........................................3446 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE......................................................3448 DISCONNECTION INSPECTION FOR ENGINE CAN_H/L_COMMUNICATION LINE........................................3451 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE............................................................3457 INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE............................................................3466 INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE..................................................3475 INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE..................................................3480 INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE).............................3485 INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE....................................................3490 INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE....................................................3496 INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE......................................................3502 INSPECTION FOR PM SENSOR CAN COMMUNICATION LINE.......................................................3508 DIAGNOSIS CAN COMMUNICATION LINE..........................................................................3514 ABNORMAL CAN COMMUNICATION DTC DETECTED...............................................................3514 CONNECTION DIAGRAM....................................................................................3514 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE...........................................3514 PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE...................................................3516 DISCONNECTION INSPECTION FOR DIAGNOSIS CAN_H/L_COMMUNICATION LINE.....................................3519 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H-LINE..................................................3523 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN L-LINE..................................................3527 INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)..........................3532 INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE......................................................3536 CONTROL CAN COMMUNICATION LINE............................................................................3541 ABNORMAL CAN COMMUNICATION DTC DETECTED...............................................................3541 CONNECTION DIAGRAM (ALLISON AUTOMATIC TRANSMISSION)...................................................3541 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)..........3541 CONNECTION DIAGRAM (MANUAL TRANSMISSION)..............................................................3542 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION).....................3542 PRE-INSPECTION FOR CAN COMMUNICATION LINE.............................................................3543 DISCONNECTION INSPECTION FOR CAN_H/L_COMMUNICATION LINE...............................................3547 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE............................................................3550 INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE............................................................3552 INSPECTION FOR AUTOMATIC TRANSMISSION ECU CAN COMMUNICATION LINE......................................3554
Description:
2019 HINO TRUCK Conventional 238 258LP 268 338 358 J08E VB J08E WU WORKSHOP MANUAL
- FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
- Applicable for HINO 238, 258LP, 268, 338, 358 series, equipped with J08E-VB and J08E-WU 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
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]
