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2020 HINO TRUCK Conventional 238 258 268 338 358 WORKSHOP MANUAL – PDF DOWNLOAD
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2020 HINO TRUCK Conventional 238 258 268 338 358 WORKSHOP MANUAL
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2020 HINO TRUCK Conventional 238 258 268 338 358 WORKSHOP MANUAL
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2020 HINO TRUCK CONVENTIONAL 238 258 268 338 358 WORKSHOP MANUAL – PDF DOWNLOAD:
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2020 HINO TRUCK Conventional 238 258 268 338 358 WORKSHOP MANUAL
How to use ................................................................................................... 2 1 ........................................................................................................ 2 2 ........................................................................................................ 3 3 ........................................................................................................ 4 4 ........................................................................................................ 5 5 ........................................................................................................ 6 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 REFRIGERANT 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............................................................................................ 760 INSPECTION AND ADJUSTMENT............................................................................. 778 SPEEDOMETER CONVERSION RATE LIST...................................................................... 779 ELECTRIC WIRE................................................................................................. 780 DIAGRAM .................................................................................................. 781 HOW TO USE THIS CHAPTER............................................................................... 781 SPECIFICATION SYMBOL LIST............................................................................. 787 DIAGRAM............................................................................................... 795 POSITION OF CONNECTOR................................................................................. 936 CONNECTOR............................................................................................. 961 PIN LIST OF WIRE TO WIRE CONNECTOR (IN THE BULK HEAD CONNECTOR BOX)................................... 987 PIN LIST OF WIRE TO WIRE CONNECTOR (OUT OF THE BULK HEAD CONNECTOR BOX)............................... 992 PIN LIST OF SIGNAL CHECK CONNECTOR.................................................................... 997 CONNECTOR LIST........................................................................................ 999 FOREWORD......................................................................................................1016 CHAPTER REFERENCES............................................................................................1017 INDEX.........................................................................................................1018 GENERAL INTRODUCTION (ENGINE).................................................................................1020 GENERAL INTRODUCTION (ENGINE) ............................................................................1021 GENERAL PRECAUTIONS...................................................................................1021 HOW TO USE THIS WORKSHOP MANUAL.......................................................................1024 IDENTIFICATION INFORMATION............................................................................1026 PRECAUTIONS...........................................................................................1027 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS..........................................................1030 DISMOUNTING AND MOUNTING..............................................................................1031 SYMPTOM SIMULATION....................................................................................1034 GLOSSARY OF SAE AND HINO TERMS........................................................................1036 ENGINE INTRODUCTION (J08E)....................................................................................1039 ENGINE ASSEMBLY ..........................................................................................1040 DATA AND SPECIFICATIONS...............................................................................1040 TROUBLESHOOTING.......................................................................................1042 TROUBLESHOOTING (COMMON RAIL SYSTEM)..................................................................1049 ENGINE TUNEUP.........................................................................................1050 SPECIAL TOOL..........................................................................................1056 OVERHAUL CRITERIA.....................................................................................1057 DISMOUNTING AND MOUNTING..............................................................................1058 LIQUID GASKET AND APPLICATION POINTS..................................................................1060 ENGINE MECHANICAL (J08E)......................................................................................1065 CYLINDER HEAD ............................................................................................1066 COMPONENT LOCATOR.....................................................................................1066 SPECIAL TOOL..........................................................................................1069 OVERHAUL..............................................................................................1070 INSPECTION AND REPAIR.................................................................................1081 CRANKSHAFT FRONT END .....................................................................................1085 COMPONENT LOCATOR.....................................................................................1085 SPECIAL TOOL..........................................................................................1086 OVERHAUL..............................................................................................1087 FLYWHEEL AND FLYWHEEL HOUSING ............................................................................1089 COMPONENT LOCATOR.....................................................................................1089 SPECIAL TOOL..........................................................................................1090 OVERHAUL..............................................................................................1090 INSPECTION AND REPAIR.................................................................................1097 TIMING GEAR ..............................................................................................1098 COMPONENT LOCATOR.....................................................................................1098 SPECIAL TOOL..........................................................................................1099 OVERHAUL..............................................................................................1100 INSPECTION AND REPAIR.................................................................................1102 MAIN MOVING PARTS AND CYLINDER BLOCK .....................................................................1104 COMPONENT LOCATOR.....................................................................................1104 SPECIAL TOOL..........................................................................................1107 OVERHAUL..............................................................................................1109 INSPECTION AND REPAIR.................................................................................1122 AIR INTAKE SYSTEM (J08E)......................................................................................1126 AIR INTAKE MANIFOLD AND PIPE .............................................................................1127 COMPONENT LOCATOR.....................................................................................1127 DISMOUNTING AND MOUNTING..............................................................................1128 AIR INTAKE ...............................................................................................1129 COMPONENT LOCATOR.....................................................................................1129 AIR CLEANER ..............................................................................................1130 DESCRIPTION...........................................................................................1130 OVERHAUL..............................................................................................1131 AIR HOSE .................................................................................................1132 COMPONENT LOCATOR.....................................................................................1132 OVERHAUL..............................................................................................1133 AIR FLOW SENSOR ..........................................................................................1134 COMPONENT LOCATOR.....................................................................................1134 REPLACEMENT...........................................................................................1135 BOOST PRESSURE SENSOR ....................................................................................1136 COMPONENT LOCATOR.....................................................................................1136 REPLACEMENT...........................................................................................1137 EXHAUST SYSTEM (J08E).........................................................................................1138 EXHAUST MANIFOLD AND PIPE ................................................................................1139 COMPONENT LOCATOR.....................................................................................1139 DISMOUNTING AND MOUNTING..............................................................................1140 EXHAUST PIPE AND MUFFLER UNIT ............................................................................1141 DESCRIPTION...........................................................................................1141 COMPONENT LOCATOR.....................................................................................1142 REPLACEMENT OF ATC....................................................................................1148 OVERHAUL..............................................................................................1150 DPR (DIESEL PARTICULATE ACTIVE REDUCTION SYSTEM) .........................................................1166 SYSTEM CONFIGURATION..................................................................................1166 STRUCTURE OF DPR-CLEANER..............................................................................1167 DPR INSPECTION........................................................................................1168 INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY..........1169 INSPECTION BY WAY OF HINO DX II.......................................................................1170 INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL)..........................1174 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX II.................................1177 CHECKING THE DPR STATE................................................................................1177 REPLACEMENT OF DPR FILTER.............................................................................1178 OVERALL OPERATION FLOW................................................................................1182 DIFFERENTIAL PRESSURE SENSOR .............................................................................1190 COMPONENT LOCATOR.....................................................................................1190 DISMOUNTING AND MOUNTING..............................................................................1191 INSPECTION AND REPAIR.................................................................................1192 AFTERTREATMENT FUEL INJECTOR .............................................................................1194 COMPONENT LOCATOR.....................................................................................1194 OVERHAUL..............................................................................................1195 EXHAUST CONTROL CYLINDER .................................................................................1206 SYSTEM CONFIGURATION..................................................................................1206 DPR INSPECTION CHECK SHEET............................................................................1207 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC UPSTREAM) AND EXHAUST GAS TEMPERATURE SENSOR 2 (ATC DOWNSTREAM) ....1210 COMPONENT LOCATOR.....................................................................................1210 OVERHAUL..............................................................................................1211 LUBRICATING SYSTEM (J08E).....................................................................................1212 LUBRICATING SYSTEM .......................................................................................1213 DIAGRAM...............................................................................................1213 OIL PUMP AND OIL STRAINER ................................................................................1215 COMPONENT LOCATOR.....................................................................................1215 OVERHAUL..............................................................................................1216 INSPECTION AND REPAIR.................................................................................1217 OIL FILTER AND OIL COOLER ................................................................................1219 COMPONENT LOCATOR.....................................................................................1219 SPECIAL TOOL..........................................................................................1220 DISMOUNTING AND MOUNTING..............................................................................1221 INSPECTION AND REPAIR.................................................................................1222 COOLING SYSTEM (J08E).........................................................................................1223 COOLING SYSTEM ...........................................................................................1224 DIAGRAM...............................................................................................1224 COOLANT PUMP .............................................................................................1225 COMPONENT LOCATOR.....................................................................................1225 THERMOSTAT ...............................................................................................1226 COMPONENT LOCATOR.....................................................................................1226 OVERHAUL..............................................................................................1227 RADIATOR AND INTERCOOLER .................................................................................1229 COMPONENT LOCATOR.....................................................................................1229 OVERHAUL..............................................................................................1230 RADIATOR .................................................................................................1231 COMPONENT LOCATOR.....................................................................................1231 SPECIAL TOOL..........................................................................................1232 OVERHAUL..............................................................................................1233 INSPECTION AND REPAIR.................................................................................1236 COOLING FAN ..............................................................................................1237 COMPONENT LOCATOR.....................................................................................1237 INSPECTION AND REPAIR.................................................................................1238 FUEL SYSTEM (J08E)............................................................................................1239 FUEL SYSTEM ..............................................................................................1240 DIAGRAM...............................................................................................1240 COMPONENT LOCATOR.....................................................................................1241 SUPPLY PUMP ..............................................................................................1242 DESCRIPTION...........................................................................................1242 COMPONENT LOCATOR.....................................................................................1243 SPECIAL TOOL..........................................................................................1243 OVERHAUL..............................................................................................1244 COMMON RAIL ..............................................................................................1253 DESCRIPTION...........................................................................................1253 INSPECTION............................................................................................1254 REPLACEMENT...........................................................................................1255 INJECTOR .................................................................................................1259 DESCRIPTION...........................................................................................1259 REPLACEMENT...........................................................................................1260 PRE FUEL FILTER ..........................................................................................1268 DESCRIPTION...........................................................................................1268 AIR BLEEDING..........................................................................................1269 FUEL FILTER ..............................................................................................1271 DESCRIPTION...........................................................................................1271 OVERHAUL..............................................................................................1272 FUEL TANK ................................................................................................1275 COMPONENT LOCATOR.....................................................................................1275 FUEL CUTOFF VALVE ........................................................................................1277 COMPONENT LOCATOR.....................................................................................1277 OVERHAUL..............................................................................................1278 TURBOCHARGER (J08E)...........................................................................................1279 TURBOCHARGER .............................................................................................1280 DESCRIPTION...........................................................................................1280 TROUBLESHOOTING.......................................................................................1281 REPLACEMENT...........................................................................................1290 INSPECTION AFTER MOUNTING.............................................................................1296 EMISSION CONTROL (J08E).......................................................................................1297 EGR VALVE AND EGR PIPE ...................................................................................1298 COMPONENT LOCATOR.....................................................................................1298 EGR VALVE ................................................................................................1299 DESCRIPTION...........................................................................................1299 DISMOUNTING AND MOUNTING..............................................................................1300 CLOSED VENTILATOR ........................................................................................1303 DESCRIPTION...........................................................................................1303 REPLACEMENT OF CLOSED VENTILATOR......................................................................1303 REPLACEMENT ..............................................................................................1304 REPLACING THE ELEMENT.................................................................................1304 SELECTIVE CATALYTIC REDUCTION (SCR) ......................................................................1305 GENERAL DESCRIPTION...................................................................................1305 COMPONENT LOCATOR.....................................................................................1307 INSPECTION............................................................................................1308 SPECIAL TOOL..........................................................................................1309 DISMOUNTING AND MOUNTING..............................................................................1310 INSPECTION AND REPAIR.................................................................................1328 ALTERNATOR (J08E: REMY 12V-130A,135A,180A,200A)...............................................................1329 ALTERNATOR ...............................................................................................1330 DATA AND SPECIFICATIONS...............................................................................1330 TROUBLESHOOTING.......................................................................................1330 COMPONENT LOCATOR.....................................................................................1331 OVERHAUL..............................................................................................1332 INSPECTION AND REPAIR.................................................................................1335 STARTER (J08E)................................................................................................1336 STARTER ..................................................................................................1337 DATA AND SPECIFICATIONS...............................................................................1337 DESCRIPTION...........................................................................................1337 TROUBLESHOOTING.......................................................................................1338 COMPONENT LOCATOR.....................................................................................1339 OVERHAUL..............................................................................................1340 INSPECTION AND REPAIR.................................................................................1344 AIR COMPRESSOR (J08E: 340 cm3)................................................................................1347 AIR COMPRESSOR ...........................................................................................1348 DATA AND SPECIFICATIONS...............................................................................1348 DESCRIPTION...........................................................................................1349 TROUBLESHOOTING.......................................................................................1350 COMPONENT LOCATOR.....................................................................................1351 SPECIAL TOOL..........................................................................................1352 OVERHAUL..............................................................................................1353 INSPECTION AND REPAIR.................................................................................1362 ENGINE CONTROL (J08E).........................................................................................1366 ACCELERATOR PEDAL.........................................................................................1367 DESCRIPTION...........................................................................................1367 ENGINE ECU ...............................................................................................1368 COMPONENT LOCATOR.....................................................................................1368 REPLACEMENT...........................................................................................1369 FOREWORD......................................................................................................1376 CHAPTER REFERENCES............................................................................................1377 INDEX.........................................................................................................1378 GENERAL INTRODUCTION..........................................................................................1379 GENERAL INTRODUCTION......................................................................................1380 GENERAL PRECAUTIONS...................................................................................1380 IDENTIFICATION INFORMATION............................................................................1383 HOW TO USE THIS WORKSHOP MANUAL.......................................................................1391 INTRODUCTION TO DESCRIPTIONS..........................................................................1391 PRECAUTIONS...........................................................................................1394 SEALANT ON THE TAPERED SCREW FOR PIPING...............................................................1397 METRIC INFORMATION....................................................................................1398 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS..........................................................1400 SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS............................................................1401 RECOMMENDED LUBRICANTS................................................................................1402 INFORMATION DISPLAY...................................................................................1404 GLOSSARY..............................................................................................1409 GLOSSARY OF SAE AND HINO TERMS........................................................................1412 TROUBLE SHOOTING - COMPONENTS.................................................................................1415 ENGINE BASIC..............................................................................................1416 ENGINE ASSEMBLY.......................................................................................1416 ENGINE ASSEMBLY (COMMON RAIL SYSTEM)..................................................................1423 TURBOCHARGER (J08E).......................................................................................1424 TURBOCHARGER..........................................................................................1424 ALTERNATOR (J08E: REMY 12V-130A, 135A, 180A, 200A)........................................................1433 ALTERNATOR............................................................................................1433 STARTER (J08E)............................................................................................1434 STARTER...............................................................................................1434 AIR COMPRESSOR (J08E: 340 cm3)............................................................................1435 AIR COMPRESSOR........................................................................................1435 CLUTCH MAIN UNIT..........................................................................................1436 CLUTCH ASSEMBLY (EATON SAS1402).......................................................................1436 AUTOMATIC TRANSMISSION....................................................................................1438 AUTOMATIC TRANSMISSION ASSEMBLY.......................................................................1438 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) ................................................1439 TRANSMISSION CONTROL UNIT.............................................................................1439 TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)............................................1440 TRANSMISSION CONTROL UNIT.............................................................................1440 PROPELLER SHAFT (SPL 100, 140)............................................................................1440 PROPELLER SHAFT ASSEMBLY..............................................................................1440 DIFFERENTIAL CARRIER (MERITOR MS-17, 19, 21 AND RS-23)....................................................1441 DIFFERENTIAL CARRIER ASSEMBLY.........................................................................1441 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE).............................................................1442 SERVICE BRAKE ASSEMBLY................................................................................1442 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)..............................................................1447 SERVICE BRAKE ASSEMBLY................................................................................1447 SERVICE BRAKE (HYDRAULIC BRAKE)...........................................................................1449 WHEEL BRAKE (TYPE: 4 PISTON)..........................................................................1449 SERVICE BRAKE (FULL AIR BRAKE)............................................................................1451 AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS)..................................................1451 EXHAUST BRAKE.............................................................................................1454 EXHAUST BRAKE SYSTEM..................................................................................1454 PARKING BRAKE (BOSCH 12)..................................................................................1455 PARKING BRAKE ASSEMBLY................................................................................1455 STEERING EQUIPMENT........................................................................................1456 STEERING SYSTEM.......................................................................................1456 FRONT AXLE (MFS)..........................................................................................1460 FRONT AXLE (MFS)......................................................................................1460 REAR AXLE.................................................................................................1462 REAR AXLE.............................................................................................1462 WHEEL AND TIRE............................................................................................1463 WHEEL AND TIRE........................................................................................1463 SUSPENSION................................................................................................1465 LEAF SUSPENSION ASSEMBLY..............................................................................1465 AIR SUSPENSION ASSEMBLY...............................................................................1465 CHASSIS FRAME.............................................................................................1466 CHASSIS FRAME.........................................................................................1466 CAB.......................................................................................................1467 AIR SUSPENSION DUMP SYSTEM............................................................................1467 CAB ASSEMBLY..........................................................................................1467 AIR CONDITIONING SYSTEM...............................................................................1469 ELECTRICAL EQUIPMENT......................................................................................1479 ELECTRICAL PARTS......................................................................................1479 TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM..................................................................1481 ABOUT HINO DX II..........................................................................................1482 About HINO DX II......................................................................................1482 BASIC PROCEDURE FOR TROUBLESHOOTING.......................................................................1484 BASIC PROCEDURE FOR TROUBLESHOOTING...................................................................1484 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE..........................................................1486 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE......................................................1486 SYMPTOM SIMULATION........................................................................................1489 SYMPTOM SIMULATION....................................................................................1489 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART.............................................................1491 TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART.........................................................1491 ELECTRONIC CIRCUIT INSPECTION PROCEDURE...................................................................1492 ELECTRONIC CIRCUIT INSPECTION PROCEDURE...............................................................1492 INSPECTION PROCEDURE FOR MULTIPLE DTCS....................................................................1497 INSPECTION PROCEDURE FOR MULTIPLE DTCS................................................................1497 ENGINE CONTROL SYSTEM (J08E)..................................................................................1498 ENGINE CONTROL SYSTEM.....................................................................................1501 PRECAUTIONS FOR DIAGNOSIS.............................................................................1501 SYSTEM BLOCK DIAGRAM..................................................................................1503 SYSTEM DIAGRAM........................................................................................1504 PRECAUTIONS...........................................................................................1506 SENSOR LOCATION.......................................................................................1510 COMPUTER (ECU) PIN ASSIGNMENT.........................................................................1519 ENGINE ECU CONNECTOR..................................................................................1525 INSPECTION............................................................................................1529 DIAGNOSIS USING THE PC DIAGNOSIS TOOL.................................................................1530 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...................................................................1531 GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL........................................................1552 GROUP SHARING THE SENSOR GND TERMINAL.................................................................1553 ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET).........................................1554 NO DTC................................................................................................1558 SIMULTANEOUS MALFUNCTION OF MULTIPLE ELECTRIC SYSTEMS.................................................1561 MALFUNCTION OF STARTER................................................................................1565 MALFUNCTION OF ALTERNATOR.............................................................................1572 DTC: P0005............................................................................................1575 DTC: P0006 and P0007..................................................................................1579 DTC: P0016............................................................................................1584 DTC: P0027............................................................................................1587 DTC: P003A............................................................................................1592 DTC: P0045............................................................................................1597 DTC: P0047............................................................................................1602 DTC: P0048............................................................................................1607 DTC: P006E............................................................................................1612 DTC: P006F............................................................................................1616 DTC: P007B............................................................................................1620 DTC: P007C and P007D..................................................................................1633 DTC: P0088............................................................................................1641 DTC: P0096............................................................................................1651 DTC: P0097 and P0098 .................................................................................1662 DTC: P0101............................................................................................1670 DTC: P0104............................................................................................1677 DTC: P0106............................................................................................1683 DTC: P0107............................................................................................1690 DTC: P0108............................................................................................1697 DTC: P0111............................................................................................1703 DTC: P0112 and P0113..................................................................................1709 DTC: P0115............................................................................................1716 DTC: P0117 and P0118..................................................................................1725 DTC: P011A............................................................................................1733 DTC: P0122 and P0123..................................................................................1742 DTC: P0126............................................................................................1751 DTC: P0128............................................................................................1755 DTC: P0148 ...........................................................................................1760 DTC: P016E and P016F .................................................................................1771 DTC: P0182 and P0183 .................................................................................1782 DTC: P0191............................................................................................1789 DTC: P0192 and P0193 .................................................................................1795 DTC: P01A5............................................................................................1804 DTC: P01A6............................................................................................1811 DTC: P0200............................................................................................1818 DTC: P0201, P0202, P0203, P0204, P0205 and P0206......................................................1820 DTC: P0217............................................................................................1825 DTC: P0219............................................................................................1830 DTC: P0222 and P0223..................................................................................1837 DTC: P0234............................................................................................1846 DTC: P0263, P0266, P0269, P0272, P0275 and P0278......................................................1852 DTC: P026C and P026D..................................................................................1863 DTC: P0299............................................................................................1876 DTC: P0300............................................................................................1882 DTC: P0301, P0302, P0303, P0304, P0305 and P0306......................................................1890 DTC: P0335............................................................................................1898 DTC: P0336............................................................................................1904 DTC: P0340............................................................................................1910 DTC: P0341............................................................................................1915 DTC: P0381............................................................................................1922 DTC: P0401............................................................................................1927 DTC: P0402............................................................................................1941 DTC: P0404............................................................................................1951 DTC: P0405 and P0406..................................................................................1956 DTC: P041B............................................................................................1962 DTC: P041C and P041D..................................................................................1970 DTC: P0420............................................................................................1978 DTC: P0421............................................................................................1980 DTC: P0422............................................................................................1993 DTC: P0489 and P0490..................................................................................1996 DTC: P049D............................................................................................2002 DTC: P04D5 and P04D6..................................................................................2007 DTC: P04DA............................................................................................2015 DTC: P04DB............................................................................................2025 DTC: P0500 and P0501..................................................................................2033 DTC: P0504............................................................................................2039 DTC: P0506 and P0507..................................................................................2045 DTC: P0524............................................................................................2048 DTC: P0545 and P0546..................................................................................2053 DTC: P054E and P054F..................................................................................2062 DTC: P0562 and P0563..................................................................................2065 DTC: P0605............................................................................................2071 DTC: P0606............................................................................................2073 DTC: P0607............................................................................................2075 DTC: P0610............................................................................................2077 DTC: P0611............................................................................................2080 DTC: P0617............................................................................................2082 DTC: P0628 and P0629..................................................................................2086 DTC: P062F............................................................................................2093 DTC: P0630............................................................................................2097 DTC: P0642............................................................................................2101 DTC: P0643............................................................................................2105 DTC: P064C............................................................................................2110 DTC: P0652............................................................................................2115 DTC: P0653............................................................................................2120 DTC: P0671, P0672, P0675 and P0676 ...................................................................2126 DTC: P0683............................................................................................2136 DTC: P0686............................................................................................2141 DTC: P0698............................................................................................2146 DTC: P0699............................................................................................2148 DTC: P06A4............................................................................................2150 DTC: P06A5............................................................................................2152 DTC: P06D3 and P06D4..................................................................................2154 DTC: P0704............................................................................................2161 DTC: P073D............................................................................................2165 DTC: P081A............................................................................................2171 DTC: P081B............................................................................................2175 DTC: P0850............................................................................................2179 FOREWORD......................................................................................................2185 CHAPTER REFERENCES............................................................................................2186 INDEX.........................................................................................................2187 ENGINE CONTROL SYSTEM.........................................................................................2188 ENGINE CONTROL SYSTEM.....................................................................................2191 DTC: P104E............................................................................................2191 DTC: P104F............................................................................................2195 DTC: P1133............................................................................................2199 DTC: P119F............................................................................................2205 DTC: P1426............................................................................................2211 DTC: P1427............................................................................................2218 DTC: P1428............................................................................................2224 DTC: P1458............................................................................................2230 DTC: P1459............................................................................................2235 DTC: P146F............................................................................................2240 DTC: P14B0............................................................................................2245 DTC: P14B2............................................................................................2249 DTC: P14B3 and P14B4..................................................................................2253 DTC: P14B7 and P14B8..................................................................................2259 DTC: P14BC and P14BD..................................................................................2265 DTC: P14BF............................................................................................2271 DTC: P1515............................................................................................2276 DTC: P1530............................................................................................2281 DTC: P2002............................................................................................2285 DTC: P200C............................................................................................2305 DTC: P2032 and P2033..................................................................................2312 DTC: P203F............................................................................................2320 DTC: P204F............................................................................................2324 DTC: P206B............................................................................................2326 DTC: P207F............................................................................................2349 DTC: P2080............................................................................................2373 DTC: P2084............................................................................................2382 DTC: P20CD............................................................................................2390 DTC: P20CE............................................................................................2394 DTC: P20D8............................................................................................2399 DTC: P20DE............................................................................................2404 DTC: P20DF............................................................................................2408 DTC: P20E0............................................................................................2414 DTC: P20EE............................................................................................2420 DTC: P20EF............................................................................................2446 DTC: P2100............................................................................................2448 DTC: P2101............................................................................................2454 DTC: P2103............................................................................................2460 DTC: P2120............................................................................................2466 DTC: P2122 and P2123..................................................................................2470 DTC: P2127 and P2128..................................................................................2478 DTC: P2135............................................................................................2487 DTC: P2138............................................................................................2492 DTC: P2146............................................................................................2497 DTC: P2147 and P2148..................................................................................2504 DTC: P2149............................................................................................2512 DTC: P2150 and P2151..................................................................................2518 DTC: P2184 and P2185..................................................................................2526 DTC: P2201............................................................................................2534 DTC: P2227............................................................................................2573 DTC: P2228 and P2229..................................................................................2577 DTC: P2269............................................................................................2582 DTC: P226C............................................................................................2586 DTC: P229F............................................................................................2594 DTC: P22D3............................................................................................2634 DTC: P240F............................................................................................2638 DTC: P2428............................................................................................2647 DTC: P242B............................................................................................2651 DTC: P242C and P242D..................................................................................2659 DTC: P244A............................................................................................2667 DTC: P244B............................................................................................2684 DTC: P2457............................................................................................2711 DTC: P2458............................................................................................2725 DTC: P2459............................................................................................2738 DTC: P2463............................................................................................2740 DTC: P246F............................................................................................2746 DTC: P2470 and P2471..................................................................................2754 DTC: P2481 and P2482..................................................................................2762 DTC: P2483............................................................................................2770 DTC: P24A0............................................................................................2778 DTC: P24A1............................................................................................2781 DTC: P24A2............................................................................................2783 DTC: P24AE............................................................................................2793 DTC: P24AF............................................................................................2802 DTC: P24B0............................................................................................2807 DTC: P24B1............................................................................................2812 DTC: P24B4............................................................................................2815 DTC: P24B7............................................................................................2827 DTC: P24C7............................................................................................2830 DTC: P24D0............................................................................................2834 DTC: P24D1............................................................................................2839 DTC: P24DA............................................................................................2844 DTC: P24FE............................................................................................2849 DTC: P2563............................................................................................2867 DTC: P2564 and P2565..................................................................................2872 DTC: P259E............................................................................................2879 DTC: P259F............................................................................................2884 DTC: P2635............................................................................................2889 DTC: P268A and P2696..................................................................................2898 DTC: P2A00............................................................................................2904 DTC: P2A01............................................................................................2913 DTC: P2BA9............................................................................................2922 DTC: U0073............................................................................................2927 DTC: U010A............................................................................................2930 DTC: U010C............................................................................................2933 DTC: U010E............................................................................................2936 DTC: U029D............................................................................................2939 DTC: U029E............................................................................................2942 DTC: U02A2............................................................................................2945 DTC: U02A3 ...........................................................................................2948 DTC: U0301............................................................................................2951 DTC: U1001............................................................................................2954 DTC: U110A............................................................................................2957 FOREWORD......................................................................................................2961 CHAPTER REFERENCES............................................................................................2962 INDEX.........................................................................................................2963 DEF SCR SYSTEM (DCU)..........................................................................................2964 DEF SCR SYSTEM............................................................................................2965 PRECAUTIONS FOR DIAGNOSIS.............................................................................2965 SYSTEM BLOCK DIAGRAM..................................................................................2967 SYSTEM DIAGRAM........................................................................................2968 SENSOR LOCATION.......................................................................................2969 COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT..................................................2972 SIGNAL CHECK HARNESS..................................................................................2973 INSPECTION............................................................................................2973 MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN......................................................2974 DIAGNOSIS USING THE PC DIAGNOSIS TOOL.................................................................2975 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...................................................................2976 DTC: P0071............................................................................................2982 DTC: P0072............................................................................................2992 DTC: P0073............................................................................................3000 DTC: P0562............................................................................................3008 DTC: P0563............................................................................................3011 DTC: P060B............................................................................................3014 DTC: P060C............................................................................................3016 DTC: P062F............................................................................................3018 DTC: P0667............................................................................................3020 DTC: P068A............................................................................................3022 DTC: P06AD............................................................................................3027 DTC: P06AE............................................................................................3029 DTC: P142A............................................................................................3031 DTC: P142B............................................................................................3040 DTC: P14C1............................................................................................3051 DTC: P14C2............................................................................................3065 DTC: P14C3............................................................................................3071 DTC: P202E............................................................................................3078 DTC: P203C............................................................................................3083 DTC: P203D............................................................................................3086 DTC: P2044............................................................................................3089 DTC: P2045............................................................................................3092 DTC: P2047............................................................................................3095 DTC: P2048............................................................................................3099 DTC: P2049............................................................................................3104 DTC: P204B............................................................................................3110 DTC: P204C............................................................................................3113 DTC: P204D............................................................................................3119 DTC: P205B............................................................................................3125 DTC: P205C............................................................................................3134 DTC: P205D............................................................................................3137 DTC: P206C............................................................................................3140 DTC: P206D............................................................................................3143 DTC: P208A............................................................................................3146 DTC: P208B............................................................................................3150 DTC: P208C............................................................................................3153 DTC: P208D............................................................................................3157 DTC: P20A0............................................................................................3161 DTC: P20A1............................................................................................3167 DTC: P20A2............................................................................................3171 DTC: P20A3............................................................................................3177 DTC: P20B1............................................................................................3183 DTC: P20B2............................................................................................3188 DTC: P20B3............................................................................................3197 DTC: P20B4............................................................................................3202 DTC: P20BD, P20B9 and P20C1...........................................................................3207 DTC: P20C0, P20BC and P20C4...........................................................................3215 DTC: P20E8............................................................................................3221 DTC: P20E9............................................................................................3232 DTC: P20F4............................................................................................3237 DTC: P21C2............................................................................................3241 DTC: P21C3............................................................................................3246 DTC: P21C4............................................................................................3251 DTC: P2202............................................................................................3256 DTC: P2203............................................................................................3259 DTC: P2204............................................................................................3262 DTC: P2209............................................................................................3269 DTC: P22A0............................................................................................3277 DTC: P22A1............................................................................................3280 DTC: P22A2............................................................................................3283 DTC: P22A7............................................................................................3291 DTC: P2510............................................................................................3299 DTC: P2BAE............................................................................................3304 DTC: U0029............................................................................................3307 DTC: U0038............................................................................................3310 DTC: U0100............................................................................................3313 DTC: U029D............................................................................................3317 DTC: U029E............................................................................................3320 DTC: U02A2............................................................................................3323 BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION))..............................................................3326 ABS.......................................................................................................3327 TROUBLESHOOTING.......................................................................................3327 BRAKE CONTROL SYSTEM (ABS:FULL AIR)...........................................................................3349 ABS.......................................................................................................3350 TROUBLESHOOTING.......................................................................................3350 VEHICLE CONTROL SYSTEM (VCS)..................................................................................3380 VEHICLE CONTROL SYSTEM....................................................................................3381 PRECAUTIONS FOR DIAGNOSIS.............................................................................3381 SYSTEM BLOCK DIAGRAM..................................................................................3383 SIGNAL CHECK HARNESS..................................................................................3384 DIAGNOSIS USING THE PC DIAGNOSIS TOOL.................................................................3392 VEHICLE CONTROL ECU INSPECTION........................................................................3393 DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE...............................................3399 DTC: P0500............................................................................................3400 DTC: P0501............................................................................................3404 DTC: P0562............................................................................................3408 DTC: P0563............................................................................................3411 DTC: P0617............................................................................................3414 DTC: P0704............................................................................................3417 DTC: P0850............................................................................................3423 DTC: P1565............................................................................................3429 DTC: U0101............................................................................................3435 DTC: U0105 ...........................................................................................3438 DTC: U0155............................................................................................3441 NO ACTIVATION OF AUXILIARY BRAKE......................................................................3443 NO ACTIVATION/RELEASE OF ENGINE REVOLUTION CONTROL....................................................3449 NO ACTIVATION/RELEASE OF CRUISE FUNCTION..............................................................3454 NO ACTIVATION/RELEASE OF ECO MODE.....................................................................3462 CAN COMMUNICATION.............................................................................................3466 CAN COMMUNICATION TROUBLESHOOTING.........................................................................3467 Outline...............................................................................................3467 Definition of Terms...................................................................................3467 Troubleshooting Procedure.............................................................................3468 Work Flow.............................................................................................3468 ECU individual code list..............................................................................3469 CAN communication circuit diagram.....................................................................3470 CAN communication relation connector location.........................................................3473 ENGINE CAN COMMUNICATION LINE.............................................................................3477 ABNORMAL CAN COMMUNICATION DTC DETECTED...............................................................3477 CONNECTION DIAGRAM....................................................................................3477 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE...........................................3477 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE......................................................3479 DISCONNECTION INSPECTION FOR ENGINE CAN_H/L_COMMUNICATION LINE........................................3482 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE............................................................3488 INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE............................................................3497 INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE..................................................3506 INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE..................................................3511 INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE).............................3516 INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE....................................................3521 INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE....................................................3527 INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE......................................................3533 INSPECTION FOR PM SENSOR CAN COMMUNICATION LINE.......................................................3539 DIAGNOSIS CAN COMMUNICATION LINE..........................................................................3545 ABNORMAL CAN COMMUNICATION DTC DETECTED...............................................................3545 CONNECTION DIAGRAM....................................................................................3545 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE...........................................3545 PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE...................................................3547 DISCONNECTION INSPECTION FOR DIAGNOSIS CAN_H/L_COMMUNICATION LINE.....................................3550 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H-LINE..................................................3554 INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN L-LINE..................................................3559 INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)..........................3564 INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE......................................................3568 CONTROL CAN COMMUNICATION LINE............................................................................3573 ABNORMAL CAN COMMUNICATION DTC DETECTED...............................................................3573 CONNECTION DIAGRAM (ALLISON AUTOMATIC TRANSMISSION)...................................................3573 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)..........3573 CONNECTION DIAGRAM (MANUAL TRANSMISSION)..............................................................3574 CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION).....................3574 PRE-INSPECTION FOR CAN COMMUNICATION LINE.............................................................3575 DISCONNECTION INSPECTION FOR CAN_H/L_COMMUNICATION LINE...............................................3579 INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE............................................................3582 INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE............................................................3584 INSPECTION FOR AUTOMATIC TRANSMISSION ECU CAN COMMUNICATION LINE......................................3586
Description:
2020 HINO TRUCK Conventional 238 258 268 338 358 WORKSHOP MANUAL
- 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 vehicles.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
2 reviews for 2020 HINO TRUCK Conventional 238 258 268 338 358 WORKSHOP MANUAL – PDF DOWNLOAD
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Brendan Junior –
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Had a download problem, customer service worked me through it, now works fine. Great product with volumes of information.