Hino 145-338 Series Chassis Workshop Manual PDF – J05D-TA J08E-TA J08E-TB Engines

Description

Hino 145-338 Series Chassis Workshop Manual PDF

This Hino chassis workshop manual is the repair and service reference for HINO 145, 165, 185, 238, 258, 268, 308 and 338 series trucks fitted with the J05D-TA, J08E-TA and J08E-TB engines. It works through the chassis systems those trucks share – anti-lock braking in both hydraulic and full-air form, parking brakes, steering and power steering, front and rear axles, wheels and tires, suspension, chassis frame, cab, and the electrical system with its complete wiring diagrams. Procedures are written around the components as they sit on these vehicles, with torque figures, service limits and adjustment values carried in the text rather than left to guesswork.

File Details

• Manual type: Chassis workshop manual
• Brand: Hino
• Publication number: S1-UNAE03A 2/2 (U.S.A.), S1-CNAE03A 2/2 (Canada)
• Series covered: HINO 145, 165, 185, 238, 258, 268, 308, 338
• Engines covered: J05D-TA, J08E-TA, J08E-TB
• Language: English
• File format: PDF
• Pages: 580
• Date of issue: February 2006
• Publisher: Hino Motors Sales U.S.A., Inc.

Models Covered

Coverage is broken out by model and production code so the manual can be matched to the truck on the lift:

• HINO 145 (NA6J)
• HINO 165 (NB6J)
• HINO 185 (NC6J)
• HINO 238, 258 (ND8J)
• HINO 268 (NE8J, NJ8J)
• HINO 308 (NF8J)
• HINO 338 (NV8J)

Chapters Covered

• General Introduction
• ABS & ASR – ABS (Hydraulic): Overview, Composition and Operation, Function, Precautions When Driving Vehicles Equipped with ABS, Overview and Function
• ABS & ASR – ABS (Full Air): Overview, Composition and Operation, Function, Precautions When Driving Vehicles Equipped with ABS, Overview and Function, Inspection (Front Wheel Brake), Inspection (Rear Wheel Brake)
• Parking Brake (Bosch 9 in.): Data and Specifications, Description, Troubleshooting, Component Locator, Overhaul, Inspection and Repair, Adjustment
• Parking Brake (Meritor 10 in. & 12 in.): Data and Specifications, Description, Troubleshooting, Component Locator, Overhaul, Inspection and Repair, Adjustment
• Steering Equipment: Steering System, Troubleshooting
• Steering Unit: Steering Linkage, Description, Component Locator, Special Tool, Overhaul, Inspection and Repair
• Power Steering: Power Steering Gear Unit, Data and Specifications, Description, Operation, Component Locator, Torque Chart, Hazard Warning Definitions, Maintenance Tips, On-Vehicle Service, Reseal and Repair
• Front Axle (MFS): Data and Specifications, Troubleshooting, Component Locator, Service Notes, Special Tools, Introduction, Inspection, Disassembly, Prepare Parts for Assembly, Assembly, Adjustment, Lubrication and Maintenance
• Rear Axle: Data and Specifications, Troubleshooting, Component Locator, Special Tools, Disassembly, Prepare Parts for Assembly, Assembly, Adjustment, Lubrication and Maintenance
• Wheel & Tire: Data and Specifications, Description, Troubleshooting, Special Tool, Precautions, Inspection, Inspection and Repair, SAE/JIS Type Wheel, Overhaul
• Suspension: Leaf Suspension Assembly, Air Suspension Assembly
• Chassis Frame: Troubleshooting, Inspection, Repairs
• Cab: Cab Assembly, Hood, Door, Seat, Instrument Panel, Heater and Air Conditioner, Windshield, Front Bumper
• Electrical Equipment: Electrical Parts, Component Locator, Troubleshooting, General Instruction, Handling Precaution, Inspection, Inspection and Adjustment, Speedometer Conversion Rate List
• Electric Wire: Diagram, How to Use This Chapter, Specification Symbol List, Position of Connector, Connector, Connector List
• Brake Control (ABS: Hydraulic): System Layout, System Components, Wiring Information, System Diagnostics, Blink Codes, Standard Component Testing, Component Removal and Installation
• Brake Control (ABS: Full Air): ABS Configuration, System Components, TOOLBOX Software, Blink Code Diagnostics, Pro-Link Diagnostics, Valve Tests, Component Removal and Installation, Wiring Diagram, Reconfiguration Procedure

What makes this Hino chassis workshop manual worth having is the level of mechanical detail behind those headings. It is not a quick-reference booklet – each system is taken apart from the specification table down to the individual component, then rebuilt in the order a technician actually works. The front axle section, for example, runs through knuckle vertical end play measurement, king pin bushing installation and reaming, tie rod end inspection and toe adjustment, each with the numbers you need to decide whether a part is reusable or scrap. The rear axle section follows the same pattern for wheel end disassembly, bearing end play adjustment and stud replacement. The power steering section goes past the usual reseal instructions and includes sector shaft adjustment, input shaft seal replacement using the vehicle pump, poppet readjustment and the full torque chart for the TAS40 and TAS65 gear units.

Brake and ABS Coverage in Detail

Braking is one of the strongest parts of this manual, because it covers both ABS architectures these trucks were built with. The hydraulic ABS material explains the composition of the system, the slip ratio relationship between tire friction and road surface, and how the modulator switches between pressure increase, pressure maintenance and pressure reduction modes. There are cutaway diagrams of the modulator showing exactly which port opens in each mode, and the fail-safe logic is documented so you understand what the warning lamp is telling you when the system drops back to normal braking. The full-air ABS chapter does the same job for the air-braked trucks, with the control valve internal construction, the pressure increase / pressure reduction / pressure maintenance cycle, wheel sensor and sensor ring inspection, and the inspection procedures for both front and rear wheel brakes.

Parking brake coverage is split by supplier – Bosch 9 in. units on the HINO 145, 165 and 185 with Eaton FS-4205 manual transmission, and Meritor 10 in. and 12 in. units on the larger models running the Allison 2200RDS/2500RDS automatic or Eaton FS5406 manual. Both chapters carry a troubleshooting table that links the symptom to the cause and the correction, which is often the fastest way into a complaint. Lining thickness limits, drum inside diameter limits, pull-up force figures and the burnishing procedure after a reline are all given, so the adjustment stage is not guesswork.

Steering, Axles, Suspension and Chassis

The steering unit chapter covers the linkage end to end, including steering wheel removal, pitman arm removal with the specified puller, drag link dust seal replacement and steering wheel free play measurement. Torque values are given separately for the HINO 145/165/185 group and the HINO 238/258/268/308/338 group, which matters because the two families use different fastener sizes at the pitman arm, drag link and ball studs. The suspension chapter handles both the taper-leaf front springs with double-acting shock absorbers and the semi-elliptic main and auxiliary helper-leaf rear springs, plus the Hendrickson AL-V air suspension used on the HINO 268 and 338, including vehicle height adjustment and transverse rod bushing replacement. The chassis frame chapter covers alignment checks, crack repair with the correct V-groove geometry, patch plate rules and welding conditions, with clear diagrams of correct and incorrect practice.

Cab, Electrical Equipment and Wiring Diagrams

The cab section documents the tilt hood with its torsion bars and oil damper, door hinge and striker adjustment with the body-to-door clearance figures, seat and instrument panel removal, and the air conditioning system including the HFC134a precautions, compressor oil requirements, refrigerant recovery and replenishment, and V-belt tension adjustment for both the J05D and J08E engines. The electrical equipment chapter lists where each part is installed, then gives inspection procedures with terminal continuity tables for the starter switch, combination switch, relays, sensors, warning buzzer, power window motors and blower circuits. The electric wire chapter is the largest single reference in the file: it explains the wiring colour coding, the specification symbol system used to differentiate circuits between models, then provides the connector positions, connector shapes with part numbers, and a full connector list indexed by diagram symbol.

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With this manual on hand you can diagnose an ABS fault from the blink codes and trace it to the correct wheel sensor or modulator valve, replace a leaking steering gear input shaft seal without pulling the gear, reset knuckle end play to specification, adjust parking brake pull-up force, repair a cracked chassis frame to the approved method, or trace an electrical fault through the connector list to the exact pin. Those jobs depend on having the correct torque figure, clearance and adjustment value in front of you – not on a general idea of how the system works. The file is delivered as an instant PDF download, no shipping and nothing to wait for, and it opens on a laptop, tablet or phone in the workshop. Keep it on the shop computer, print the pages you need for the job, and work from the same procedures the trucks were built around.