Hino 600 Workshop Manual
MENU
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 238, 258LP, 268, 338 series, equipped with J08E-VB and J08E-VC engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Driver’s / Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.
Please note that the publications below have also been prepared as relevant workshop manuals for the components and systems in these vehicles.
Manual Name Pub. No.
Chassis Workshop Manual S1-UNAE11A 2/2
J08E-VB, VC Engine Workshop Manual S5-UJ08E11A
S7-UNAE11A 1/3
Trouble Shooting Workshop Manual
S7-UNAE11A 2/3
S7-UNAE11A 3/3
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S1-UNAE11A 1/2 (U.S.A.), S1-CNAE11A 1/2 (CANADA)
CHAPTER
GENERAL INTRODUCTION GN02-001
CLUTCH MAIN UNIT CL02-001 CL02-002
CLUTCH CONTROL CL03-001
TRANSMISSION MAIN UNIT TR02-001
AUTOMATIC TRANSMISSION
TRANSMISSION/TRANSFER CONTROL
PROPELLER SHAFT
DIFFERENTIAL CARRIER
BRAKE EQUIPMENT BR01-001 BR01-002
SERVICE BRAKE BR02-001 BR02-002
ABS (ANTI-LOCK BRAKE SYSTEM) BR03-001 BR03-002
EXHAUST BRAKE BR05-001
PARKING BRAKE BR07-001
MODELS HINO 238, 258LP, 268, 338, 358
Production Model
Code
TR04-001
TR06-001
NE8J, NF8J, NJ8J, NV8J
PP02-001
DF02-001
TR04-002
TR06-002
STEERING EQUIPMENT SR01-001
STEERING UNIT SR02-001
POWER STEERING SR03-001
FRONT AXLE AX02-001
REAR AXLE
WHEEL & TIRE AX04-001
SUSPENSION SU02-001
CHASSIS FRAME FC02-001
CAB CA02-001
ELECTRICAL EQUIPMENT EL01-001
ELECTRIC WIRE EL02-001
This manual does not contain items on half-tone dot meshing.
AX03-001
INDEX: CHASSIS GROUP 1/4
GENERAL INTRODUCTION
CLUTCH EQUIPMENT
CLUTCH MAIN UNIT
WORKSHOP
MANUAL
CLUTCH CONTROL
TRANSMISSION EQUIPMENT
TRANSMISSION MAIN UNIT
TRANSFER MAIN UNIT
AUTOMATIC TRANSMISSION
PTO (POWER TAKE-OFF)
TRANSMISSION / TRANSFER CONTROL
PROPELLER SHAFT EQUIPMENT
PROPELLER SHAFT
DIFFERENTIAL EQUIPMENT
DIFFERENTIAL CARRIER
BRAKE EQUIPMENT
SERVICE BRAKE
ABS
INDEX: CHASSIS GROUP 2/4
ES START (EASY & SMOOTH START) SYSTEM
EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
STEERING EQUIPMENT
STEERING UNIT
POWER STEERING
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
WHEEL & TIRE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
COUPLER (5TH WHEEL)
PINTLE HOOK
INDEX: CHASSIS GROUP 3/4
CAB EQUIPMENT
CAB
ELECTRICAL EQUIPMENT
ELECTRIC WIRE
HYBRID SYSTEM
INDEX: CHASSIS GROUP 4/4
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
GENERAL INTRODUCTION (CHASSIS) GN02–1
GN0 2
GENERAL INTRODUCTION (CHASSIS)
GENERAL INTRODUCTION.....................GN02-2
GENERAL PRECAUTIONS.............................GN02-2
IDENTIFICATION INFORMATION ...................GN02-5
HOW TO USE
THIS WORKSHOP MANUAL.........................GN02-12
PRECAUTIONS.............................................GN02-15
SEALANT ON THE TAPERED SCREW
FOR PIPING ..................................................GN02-18
NYLON TUBE REPLACEMENT METHOD ...GN02-19
METRIC INFORMATION ...............................GN02-21
SPECIFIED TORQUE
FOR STANDARD BOLTS AND NUTS ...........GN02-23
SPECIFIED TORQUE
FOR FLANGE BOLTS AND NUTS ................GN02-23
RECOMMENDED LUBRICANTS ..................GN02-25
VEHICLE LIFT
AND SUPPORT LOCATIONS........................GN02-27
INFORMATION DISPLAY ..............................GN02-29
SYMPTOM SIMULATION ..............................GN02-34
GLOSSARY ...................................................GN02-36
GLOSSARY OF SAE AND HINO TERMS.....GN02-39
GN02-001
GENERAL INTRODUCTION (CHASSIS)GN02–2
GENERAL INTRODUCTION
GENERAL PRECAUTIONS
EN00Z00020100001
Some recommended and standard maintenance services for your vehicle are included in this section. When performing maintenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a malfunction
of the vehicle which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your Hino dealer.
WARNING
When working on your vehicle, observe the following general precautions to prevent death, personal injury and/or
property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chapter.
• Always wear safety glasses or goggles to protect your eyes.
• Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.
• Bind long hair securely behind the head.
• When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and
block the wheels.
• Always turn off the starter switch to stop the engine, unless the operation requires the engine running. Remov-
ing the key from the switch is recommended.
• To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radia-
tor, muffler, exhaust pipe and tail pipe.
• Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.
• Take utmost care when working on the battery. It contains corrosive sulfuric acid.
• Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which
can result in personal injury and/or property damage.
• Read carefully and observe the instructions specified on the jack before using it.
• Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a
vehicle supported only by a jack.
• If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly
applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.
• Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.
• Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when
the engine is running.
• Be careful not to damage lines and hoses by stepping or holding your feet on them.
• Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can
cause personal injury.
DEFINITION OF SAFETY TERMS
Indicates an extremely hazardous situation if proper procedures are not followed and could
result in death or serious injury.
Indicates a potential hazardous situation if proper procedures are not followed and could
result in death or serious injury.
Indicates a hazardous situation if proper procedures are not followed and could result in
serious injury or damage to parts/equipment.
Indicates the need to follow proper procedures and to pay attention to precautions so that
efficient service is provided.
Provides additional information to help you to perform the repair efficiently.
GENERAL INTRODUCTION (CHASSIS) GN02–3
TOWING
• When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to
protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near
the No. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with
the bumper.
1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle shaft is
defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and
entry of dirt or foreign matter.
(2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the frame.
(3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15 in horizontal and vertical
directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in towing a
vehicle trapped in a gutter.
(4) Keep the gear shift lever in Neutral.
(5) Make sure that the starter switch is kept in the "ON" position, if the engine is not running.
(6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum will be
available for the brake. This is dangerous, as the brake system does not function if the engine is not running.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to turn,
making it impossible to control the vehicle.
(7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
(8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.
2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed
for that purpose.
(1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the
transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of axle
lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed for vehicles
equipped with either manual or automatic transmission, and for even short distance towing. After being towed, check and
refill the rear axle housing with lubricant if necessary.
(2) Rear end towing
When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight-ahead
position.
CLEAN AIR ACT
1. Heavy-duty engine rebuilding practices.
§ 86.004-40
• The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and are
applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of
engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reassembly, and also
may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine. Any deviation
from the provisions contained in this section is a prohibited act under section 203(a) (3) of the Clean Air Act (42 U.S.C.
7522(a) (3)).
(1) When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical basis for
knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configuration (i.e., tolerances,
calibrations, specifications) and the model year(s) of the resulting engine configuration must be identified. A reasonable
basis would exist if:
a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and func-
tion of motor vehicle engines would reasonably believe that the parts perform the same function with respect to emissions control as the original parts; and
b. Any parameter adjustment or design element change is made only:
In accordance with the original engine manufacturer's instructions; or
Where data or other reasonable technical basis exists that such parameter adjustment or design element change,
when performed on the engine or similar engines, is not expected to adversely affect in-use emissions.
(2) When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a configu-
ration of the same or later model year as the original engine. When an engine is being replaced, the replacement engine
must be an engine of (or rebuilt to) a configuration of the same or later model year as the original engine.
GENERAL INTRODUCTION (CHASSIS)GN02–4
(3) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or reset with-
out diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are installed to
satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface. Diagnostic systems must be
free of all such codes when the rebuilt engine is returned to service. Such signals may not be rendered inoperative during
the rebuilding process.
(4) When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt engine, all
critical emissions-related components listed in § 86.004-25(2) not otherwise addressed by paragraphs (1) through (3) of
this section must be checked and cleaned, adjusted, repaired, or replaced as necessary, following manufacturer recommended practices.
(5) Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The records
shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the engine and emissions-related control components including a listing of parts and components used, engine parameter adjustments, emissions-related codes or signals responded to and reset, and work performed under paragraph (4) of this section.
a. Parties may keep records in whatever format or system they choose as long as the records are understandable to an
EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an understandable format
when requested.
b. Parties are not required to keep records of information that is not reasonably available through normal business prac-
tices including information on activities not conducted by themselves or information that they cannot reasonably
access.
c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual engine
rebuilt in cases where those rebuild practices are followed routinely.
d. Records must be kept for a minimum of two years after the engine is rebuilt.
2. Maintenance instructions.
§ 86.010-38
(1) For each new diesel-fueled engine subject to the standards prescribed in § 86.007-11, as applicable, the manufacturer
shall furnish or cause to be furnished to the ultimate purchaser a statement that
"This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for highway diesel fuel, including a 15 ppm sulfur cap)."
GENERAL INTRODUCTION (CHASSIS) GN02–5
VIN
label
IDENTIFICATION INFORMATION
EN00Z00020200001
1. VEHICLE IDENTIFICATION NUMBER
• VEHICLE IDENTIFICATION NUMBER (VIN) is comprised of 17 digits and letters. The VIN label is affixed to the left pillar
of the cab.
These numbers are used for identification purposes when you have a vehicle registered or inspected. Please quote these
numbers when ordering spare parts or reporting technical matter to receive prompt service attention.
• The following is an explanation of the items that are listed on the VIN label.
GENERAL INTRODUCTION (CHASSIS)GN02–6
(1) VIN
See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page.
(2) P.S. (PRODUCTION SERIES) AND VEHICLE COMPONENTS
MODEL
(CLASS)
HINO238
(6)
HINO258
(6)
PRODUC-
TION CODE
MODEL SERIES
CLUTCH
NE8J HBC -
GBC 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
NE8J
HBC
JBC 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
SIZE
TRANS-
MIS-
SION
SERIES
TRANSMISSION RATIO REAR
1st 2nd 3rd 4th 5th 6th Rev.
2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
- 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
AXLE
SERIES
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
SERVICE
BRAKE
PARK-
ING
BRAKE
SUSPEN-
SION
HDLor
A
HDLor
A
FWA
HINO268
(6)
NJ8J
NE8J
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
KBC
- 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
GBC 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
HBC
- 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
FWLor
A
HDLor
A
GENERAL INTRODUCTION (CHASSIS) GN02–7
MODEL
(CLASS)
HINO268
(6)
PRODUC-
TION CODE
MODEL SERIES
JBC 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
NJ8J
KBC
NBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
PBC
CLUTCH
SIZE
TRANS-
MIS-
SION
SERIES
TRANSMISSION RATIO REAR
1st 2nd 3rd 4th 5th 6th Rev.
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
- 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
AXLE
SERIES
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS17-145
RS19-145
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
SER-
VICE
BRAKE
PARK-
ING
BRAKE
FW
SUSPEN-
SION
L
or
A
HINO268
(7)
HINO338
(7)
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
NV8J
TBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
SBC
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
DBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS21-145
NF8J
EBC - 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09 RS21-145
NV8J NBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
FWLor
HD
or
FW
A
L
A
GENERAL INTRODUCTION (CHASSIS)GN02–8
MODEL
(CLASS)
HINO338
(7)
PRODUC-
TION CODE
MODEL SERIES
PBC
NV8J
TBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
SBC
CLUTCH
SIZE
TRANS-
MIS-
SION
SERIES
TRANSMISSION RATIO REAR
1st 2nd 3rd 4th 5th 6th Rev.
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
AXLE
SERIES
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
RS21-145
RS23-160
SERVICE
BRAKE
PARK-
ING
BRAKE
FWLor
SUSPEN-
SION
A
NBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS23-160
PBC
HINO358
(8)
NH8J
TBC 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS23-160
SBC
CODE SERVICE BRAKE
H: Hydraulic
F: Full air
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03 RS23-160
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00 RS23-160
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03 RS23-160
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00 RS23-160
PARKING BRAKE CONTROL CODE
D: ACTING ON DIFFERENTIAL
W: ACTING ON REAR WHEEL
FWLor
A
FWLor
A
SUSPENSION
L: LEAF
A: AIR
GENERAL INTRODUCTION (CHASSIS) GN02–9
HINO VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE FOR U.S.A. and CANADA (2015MY)
WMI VDS CD VIS
12 3 4 56 78 9 10111213141516
5P V NJ 8 J T 4 F4S10 0 0
17
1
MANUFACTURER TYPE
MAKE, MODEL
LINE & CAB/BODY TYPE,
SERIES, BRAKE SYSTEM
MODEL YEAR
ASSEMBLY PLANT
ENGINE MODEL
WHEEL BASE
CHECK DIGIT
MODIFICATION
SEQUENTIAL NUMBER
CODE
JHA
JHB
TRUCK
INCOMPLETE VEHICLE
TYPEMANUFACTURER
HINO MOTORS, LTD.
HINO MOTORS, LTD.
5PV INCOMPLETE VEHICLE
HINO MOTORS
MANUFACTURING
U.S.A., INC.
2AY INCOMPLETE VEHICLE
HINO MOTORS
CANADA, LTD.
CODE
P
CODE
2023
YEARYEAR
R 2024
S 2025
T 2026L 2020
M 2021
N 2022
H 2017
J 2018
K 2019
F 2015
G 2016
CODE
8J
J08E-VC
MODEL
7.6 LITERS, DIESEL 220HP
J08E-VB 7.6 LITERS, DIESEL 260HP
DESCRIPTIONMANUFACTURER
HINO MOTORS, LTD.
CODE
G 3,861
LENGTH
NE - NV
mm in.
J
4,445L4,750M5,207N5,385P5,512R5,969T6,426V6,883
152
175
187
205
212
217
235
253
271
CODE
S
DESCRIPTION
A NEW LETTER
T WILL BE ALLOTTED
U AT EVERY MAJOR
...
MODIFICATION
Z
CODE
1
ASSEMBLY PLANT
HINO MOTORS, LTD.
HINO PLANT IN JAPAN
3 Canada Plant
4 W.V Plant
MODEL
CODE
MAKE
NF
HYDRAULIC
LINE & CAB/BODY TYPE
INCOMPLETE VEHICLE
Intended GVWR and Vehicle Class
and Class
BRAKE
SYSTEMS
NV
FULL AIR
FULL AIR
INCOMPLETE VEHICLE
INCOMPLETE VEHICLE
INCOMPLETE VEHICLE
INCOMPLETE VEHICLE
NJ
10434 kg. - 11793 kg or less
[23,001 - 26,000 (lbs.)] (CLASS 6)
13609 kg. - 14968 kg or less
[30,001 - 33,000 (lbs.)] (CLASS 7)
13609 kg. - 14968 kg or less
[30,001 - 33,000 (lbs.)] (CLASS 7)
14969 kg - 15875 kg or less
[33,001 - 35,000 (lbs.) ] (CLASS 8)
NE
HINO
HINO
NHHINO
HINO
HINO
8846 kg. - 11793 kg or less
[19,501 - 26,000 (lbs.)] (CLASS 6)
HYDRAULIC
FULL AIR
SHTS00Z000200007
GENERAL INTRODUCTION (CHASSIS)GN02–10
VEHICLE NOISE EMISSION CONTROL INFORMATION
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE
EMISSION APPLICABLE TO MEDIUM AND HEAVY TRUCKS.
THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE
PROHIBITED BY THE NOISE CONTROL ACT OF 1972.
(A)THE REMOVAL OR RENDERING INOPERATIVE. OTHER THAN FOR
PURPOSES OF MAINTENANCE, REPAIR, OR REPLACEMENT, OF ANY
NOISE CONTROL DEVICE OR ELEMENT OF DESIGN (LISTED IN THE
OWNER' S MANUAL) INCORPORATED INTO THIS VEHICLE IN
COMPLIANCE WITH THE NOISE CONTROL ACT.
(B)THE USE OF THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF
DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE.
MFD BY:HINO MOTORS, LTD. DATE OF MANUFACTURE 03/2009
For all models
SHTS00Z000200010
SHTS00Z000200011
SHTS00Z000200012
SHTS00Z000200013-C
2. VEHICLE NOISE EMISSION CONTROL INFORMATION
• The Vehicle Noise Emission Control Information is affixed to the side
of the left door. The name of manufacturer, production year and
month, and noise emission applicable to medium and heavy trucks in
conformity with U.S. EPA Regulations are displayed.
3. ENGINE SERIAL NUMBERS.
• Please quote these numbers when ordering spare parts or reporting
technical matter to receive prompt service attention.
The engine serial number is engraved on the engine cylinder block.
4. CHASSIS SERIAL NUMBER
• Chassis serial number is engraved on the left side frame near the
front wheel.
5. CLEAN IDLE CERTIFIED LABEL FOR U.S.
• Make sure that the following clean engine idling certified label is
affixed to the outside of the left door.
By the CARB below, the label must be affixed there to prove that the
new vehicle with diesel engine manufactured from Jan., 2008 conforms to this low.
CARB § 1956.8. Exhaust Emission Standard and Test Procedure
(a) (b) Heavy-Duty Diesel Engine Idling Requirements
GENERAL INTRODUCTION (CHASSIS) GN02–11
GN02-13-1-0
For example
GN02-13-1-1
VIN
label
Vehicle emission
control information
6. VEHICLE EMISSION CONTROL INFORMATION
• The Vehicle Emission Control Information is affixed to the side of the
left door. The name of manufacturer, production year and month, and
emission applicable to medium and heavy trucks in conformity with
U.S. EPA Regulations are displayed.
GENERAL INTRODUCTION (CHASSIS)GN02–12
HOW TO USE THIS WORKSHOP MANUAL
EN00Z00020200002
This workshop manual is designed as a guide for servicing the vehicle.
An INDEX is provided on the first page of each chapter.
TROUBLESHOOTING is dealt with in each chapter.
When beginning operations, refer to the TROUBLESHOOTING section for
a guide to appropriate diagnosis.
SPECIAL TOOL is dealt with in each chapter.
When ordering a special tool, confirm the part number with the applicable
parts catalog.
• RERAIR PROCEDURES
Repair procedures when self-explanatory, such as simple installation
and removal of parts, have been omitted. Illustrations, such as the
one below, have been provided to make such simple procedures
clear. Only essential procedures requiring specific directions have
been dealt with explicitly.
GENERAL INTRODUCTION (CHASSIS) GN02–13
SHTS00Z000200014
MAIN CYLINDER
EXAMPLE:
1 Clevis 8 Return spring
2 Lock nut 9 Body
3 Push rod 10 Hose joint
4 Boot 11 O-ring
5 Retainer ring 12 Soft washer
6 Thrust washer 13 Bolt
7Piston
Tightening torque Unit: Nm {kgfcm, lbfft}
A 2.5-4.4 {25-45, 1.8-3.2}
In some cases, illustrations may be of parts which differ in some nonessential way from the parts found on your particular vehicle. In such cases, the
principle or procedure being illustrated applies regardless of such nonessential differences.
• DEFINITION OF TERMS
Definition of vehicle right and left.
Right and left refers to the left and right sides of the vehicle as seen
while looking down the center line from the rear towards the front.
GENERAL INTRODUCTION (CHASSIS)GN02–14
SHTS00Z000200015C
GENERAL INTRODUCTION (CHASSIS) GN02–15
! WARNING
Loosen
saph00z000200008
Incorrect
saph00z000200009
Incorrect
Incorrect
Incorrect
saph00z000200010
PRECAUTIONS
EN00Z0002C100001
PRECAUTIONS FOR ELECTRICAL SYSTEM
1. REMOVING THE BATTERY CABLE
• Be sure to wait for at least ten minutes after the starter key is
turned to "LOCK" position before you disconnect the battery terminals from the battery, as the vehicle data is recorded on ECU
and DCU starts working for the exhaust gas after treatment after
the starter key is turned to "LOCK" position. Otherwise, the vehicle data will not be recorded on ECU properly and DCU will not
complete working properly, which may result in the malfunction
of DPR system and DEF-SCR system.
• The MIL (malfunction indicator light) may come on when the
starter key is turned to "ON" position again, even if you wait for
at least ten minutes before disconnecting the battery terminals
from the battery after the starter key is turned to "LOCK" position. In this case, use HINO DX Ⅱ to clear the DTC (P204F and
P068A), to turn off the MIL and to conduct DPR regeneration
manually.
(1) Before electrical system work, remove the cable from the minus termi-
nal of the battery in order to avoid burning caused by short-circuiting.
(2) To remove the battery cable, fully release the nut to avoid damage to
the battery terminal. Never twist the terminal.
2. HANDLING OF ELECTRONIC PARTS
(1) Never give an impact to electronic parts of a computer or relay.
(2) Keep electronic parts away from high temperatures and humidity.
(3) Never splash water onto electronic parts in washing the vehicle.
(4) Do not remove the harness connector, electric component box, and
cover except for repair and inspection.
If removal is necessary, pay attention that water and foreign matters
do not attach or enter to the connector, terminals, electric component
box, and cover.
In restoration, make sure there is no attachment or entry of water and
foreign matters and mount them properly, because it causes degradation of waterproof function.
3. HANDLING OF WIRE HARNESS
(1) Perform marking on a clamp and a clip and secure then in original
position so that the wire harness will not interfere with the end and
acute angle section of the body and a bolt.
(2) To attach a part, take care not to bite the wire harness.
GENERAL INTRODUCTION (CHASSIS)GN02–16
! WARNING
! WARNING
Incorrect
Incorrect
Correct
saph00z000200011
4. HANDLING OF CONNECTOR
(1) To remove a connector, hold the connector (indicated by an arrow in
the figure) to pull it out. Never pull the harness.
(2) To remove a connector with lock, release the lock then pull it out.
(3) To connect a connector with lock, insert it until it clicks.
(4) To insert a test lead into the connector, insert it from behind the con-
nector.
(5) In case it is difficult to insert a test lead from behind the connector,
prepare a harness for inspection and perform inspection.
5. INSTALLATION OF BATTERY DISCONNECT SWITCH
• Installation of the battery disconnect switch on the power supply
circuit for the dosing control unit of DEF-SCR (DCU) may dam-
age or result in the malfunction of DEF-SCR system.
• Be sure to read and follow the procedures and instructions on
the service bulletin before the installation of the battery discon-
nect switch.
6. HANDLING OF BATTERY DISCONNECT SWITCH
• Wait for at least one minute before using the battery disconnect
switch after the starter key is turned to "LOCK" position.
Otherwise, the vehicle data will not be recorded on ECU properly,
which may result in the malfunction of DPR system.
GENERAL INTRODUCTION (CHASSIS) GN02–17
saph00z000200012
PRECAUTIONS FOR ELECTRIC WELDING
1. PRECAUTION FOR ELECTRIC WELDING
Electrical components such as the alternator and tachograph are
directly connected to the battery and one end is earthed to the
chassis frame. Under these conditions, welding current will flow
back along the earth circuit if electric welding is carried out and
damage may be caused to the alternator, tachograph, electrical
components, etc. Consequently, the following precautions are
always to be taken during welding.
(1) Disconnect the earth terminal of the battery at the frame fitment and
earth the welding equipment securely to the frame itself. (Do not fit the
welding equipment earth to such things as the tire rims, brake pipes
or fuel pipes and leaf spring, etc.)
a. Turn the starter switch off.
b. Disconnect the negative terminal of the battery.
c. Earth welding equipment securely, near to the area to be welded.
d. Put back battery negative ground as original condition.
e. Finally check the functioning of all instruments.
Alternator
etc.
ARC welding
machine
Computer
Battery
Disconnect the ground terminal for
battery at the connecting point on the
frame and disconnect the ground for
computer as well.
Chassis frame Chassis frame
Connect the ground of the ARC welding
machine near the place on the frame to be
welded but not connect it to plated parts such
as fuel pipes, brake pipes and leaf spring.
(2) In order to prevent damage to ancillary equipment components from
sparks during welding, take steps such as putting fire-resistant covers
over things like the engine, meters, steering wheel, hoses, tubes, leaf
spring and tires.
GENERAL INTRODUCTION (CHASSIS)GN02–18
! WARNING
SHTS00Z000200021
SHTS00Z000200022
SEALANT ON THE TAPERED SCREW FOR PIPING
EN00Z00020200003
To the tapered thread of the air pipe joint is applied the sealant "LOC-TITE
#575". Follow the procedure below to remove/attach the piping.
1. REMOVAL
(1) The sealant (LOCTITE #575) has a high sealing capability. The return
torque of taper joint is about 1.5 times as high as the initial tightening
torque. To remove the joint, use a longer wrench.
(2) For replacement of joint in a place with poor workability, remove the
auxiliaries with the joint attached then remove the joint.
2. ATTACHING
(1) To apply sealant (LOCTITE #575), use waste and thinner to wipe the
dirt off the sealing section, directly apply the sealant by a quarter turn
(three ridges) starting from the second ridge from the tip, then assemble in accordance with the tightening torque table below.
Wipe dirt off the mating part (female screw) before tightening it.
In case the sealant has entered your eye or attached to your skin,
wash it away in running water.
Tightening torque of tapered joint Unit: Nm {kgfcm, lbfft}
Screw diameter
Material
1/8 1/4 3/8 1/2
4910
Steel
Aluminum, brass
205
{20050,
14.43.6}
{500100,
36.27.2}
255
{25050,
18.13.6}
6415 {650150, 4710}
345
{35050,
25.33.6}
445
{45050,
32.53.6}
(2) To replace vulcanized tape with sealant, remove the tape before-
hand, same as (1).
NOTICE
Take special care not to let dirt and foreign matters enter the piping.
(3) In the event of air leakage after sealant is applied and piping attached,
retightening cannot check the air leakage. Follow the steps (1) and (2)
to reassemble the piping.
GENERAL INTRODUCTION (CHASSIS) GN02–19
One-touch joint
Caulking joint
SHTS00Z000200023
Insertion length
Nylon tube
SHTS00Z000200024
SHTS00Z000200025
Less than 5˚
SHTS00Z000200026
NYLON TUBE REPLACEMENT METHOD
EN00Z00020200004
NYLON TUBE REPLACEMENT METHOD
• In this vehicle, nylon tubes are used for all the air tubes except those
on the charge line and the rear axle, the tubing for the wheel power
signal, a portion of the accessory system tubing, and for the unloader
tubing, and it is also used in joints, depending on the connection conditions of the two types of joints; one-touch joints and caulking joints.
NOTICE
Since the function and quality of nylon tubes and joints are guaranteed as tube and joint sets, the use of parts other than Hino Genuine
Parts must be avoided.
1. ONE-TOUCH JOINT NYLON TUBE INSERTION LENGTH
DIAMETER
(Outside diameter x inside diam-
eter)
1/4 in. 14-19 {0.55-0.75}
3/8 in. 18-23 {0.71-0.91}
1/2 in. 21-26 {0.83-1.02}
INSERTION LENGTH
mm {in.}
2. REMOVAL OF A ONE-TOUCH JOINT
(1) Make sure there is no dirt or grease stuck to the connector end. If the
end is dirty, clean it thoroughly by air blowing or other means.
(2) Using the special tool for removing the nylon tube to push the connec-
tor end, pull off the nylon tube with your hand in one stroke, without
stopping partway, pulling the tube in the connector axial direction.
SST:
Puller (S0942-11490)
INSTALLATION OF A ONE-TOUCH JOINT AND CAULKING JOINT
• Make sure the joint interior is free of dirt grease. If the interior is dirty,
clean it thoroughly by air blowing or other means.
• Cut off the tube end where the tube surface is scarred by the joint
pinch marks, and make sure that the part of the tube inserted into the
joint has no surface damage. If the tube is damaged, cut off the damaged part (provided that the tube length is more than sufficient).
NOTICE
Use the special nylon tube cutter when cutting the nylon tube, and cut
the tube so that the angle of the cut end to the axial center is 85-95.
1. INSTALLATION OF A ONE-TOUCH JOINT
GENERAL INTRODUCTION (CHASSIS)GN02–20
Aligning marks
SHTS00Z000200027
•
Before inserting the tube, mark the insertion length on the tube with a
white-out pen or similar implement, in accordance with the dimensions, "ONE-TOUCH JOINT NYLON TUBE INSERTION LENGTH."
Then insert the tube firmly in place as far as the marked point.
2. INSTALLATION OF A CAULKING JOINT
• Press in the tube so that it does not move (will not come out), and
tighten the sleeve nut with the tightening tool to the torque shown in
the following table.
3. NYLON TUBE NUT TIGHTENING TORQUE
Unit: Nm {kgfcm, lbfft}
NUT DIAMETERS TIGHTENING TORQUE
1/4 in. 20-26 {200-270, 15-19}
3.8 in. 35-45 {350-460, 26-33}
1/2 in. 50-60 {500-610, 37-44}
NOTICE
Nuts must be tightened to 5- 35C.
4. ASSEMBLING THE CAULKING JOINT (AFTER THE TUBE HAS
FIRST BEEN REMOVED FROM THE JOINT AND THEN REINSTALLED IN THE SAME PLACE)
(1) Make aligning marks on the connector and union to mark their posi-
tions before loosening the nut.
(2) When re-assembling the joint, tighten the nut until the pre-disassem-
bly position (position of aligning marks) is reached, and then tighten
the nut 60 more.
(3) Always check air leakage after assembling the joint. If air is leaking
from the joint, continue tightening the sleeve nut until the leak stops.
(4) If the air leak does not stop, replace the tube, sleeve, and insert with
new parts. If the air leak still continues, replace the nut and connector
/ union.
NOTICE
• During repair or other work, make sure the temperature limit of
the nylon tube is within -40-90C, especially during paint drying
work.
• During boring, welding, sanding, and other work, protect nylon
tubes from tools, cuts, heat sources, and sparks, or remove the
nylon tubes beforehand.
• Do not attach a welding equipment clamp near the nylon tube.
• Do not pour battery fluid or other acidic fluid on the nylon tube.
• Do not bend the nylon tube beyond the nylon tube bending
radius R values shown in the following table. Also, do not use
the remaining portion of a tube that has broken due to overbending.
OUTSIDE DIAMETER OF
TUBE
MINIMUM BENDING RADIUS DURING
HANDLING: R mm {in.}
1/2 in. 30 {1.18}
3/8 in. 65 {2.56}
1/2 in. 70 {2.76}
GENERAL INTRODUCTION (CHASSIS) GN02–21
Metric system
M12-1.75 25
DT L
P
7
T
L
D
7
9
D- Nominal Diameter P- Property Class
(millimeters) (bolt strength)
L- Length (millimeters) T- Thread Pitch (thread
width crest to crest
millimeters)
Metric Bolts P Identification class numbers correspond to bolt strength. Increasing numbers represent increasing strength.
Nomenclature for bolts
Bolt strength identification
Bolt
SHTS00Z000200028
METRIC INFORMATION
EN00Z00021200001
METRIC FASTENERS
1. Most threaded fasteners on the Hino trucks series are metric.
Be careful not to mix them up with threaded fasteners using the
inch system.
Mismatched or incorrect bolts, nuts and screws can cause damage or malfunction, resulting in personal injury and/or property
damage.
2. When bolts, nuts and screws are removed from the vehicle, they
should be kept for reuse whenever possible.
If they are not re-usable, parts that are equivalent to the original
parts in dimensions, strength, and thread pitch must be
selected.
3. Most original bolts are marked with identification numbers indicating the strength of the bolts. The markings are shown below.
4. When replacing bolts, be careful to use bolts with the same
markings as the original bolts.
GENERAL INTRODUCTION (CHASSIS)GN02–22
DECIMAL AND METRIC EQUIVALENTS
Fractions Decimal In. Metric mm. Fractions Decimal In. Metric mm.
1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 17/32 0.53125 13.494
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.09375 2.381 19/32 0.59375 15.081
7/64 0.109375 2.778 39/64 0.609375 15.478
1/8 0.125 3.175 5/8 0.625 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.763 11/16 0.6875 17.463
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.250 6.35 3/4 0.750 19.05
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.54 51/64 0.796875 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.375 9.525 7/8 0.875 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.500 12.7 1 1.00 25.4
GENERAL INTRODUCTION (CHASSIS) GN02–23
No Mark
7
q
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS
Class 4T 7T 9T
Representation
Diameter
M6
M8 11.5-16.5 {114-172, 8.3-12.4}
M10
M12
M14
M16
{976-1,464, 70.6-105.8}
4.4-6.6
{45-67, 3.3-4.8}
22.0-32.0
{221-331, 16.0-23.9}
38.5-57.5
{392-588, 28.4-42.5}
62.0-92.0
{629-943, 45.5-68.1}
96.0-144.0
{976-1,464, 70.6-105.8}
{1,552-2,328, 112.3-168.3}
7.2-10.8
{74-110, 5.4-7.9}
18.0-26.0
{179-269, 13.0-19.4}
34.5-51.5
{351-527, 25.4-38.1}
61.0-91.0
{621-931, 44.9-67.3}
96.0-144.0
152.0-228.0
{816-1,224, 59.0-88.5}
{1,304-1,956, 94.3-141.4}
{2,040-3,060, 147.5-221.2}
EN00Z00023200001
Unit: Nm {kgfcm, lbfft.}
9.5-13.5
{94-140, 6.8-10.1}
23.5-34.5
{237-355, 17.2-25.6}
46.0-68.0
{466-698, 33.7-50.4}
80.0-120.0
128.0-192.0
200.0-300.0
M18
M20
M22
M24
132.0-198.0
{1,344-2,016, 97.2-145.7}
188.0-282.0
{1,920-2,880, 138.8-208.2}
256.0-384.0
{2,616-3,924, 189.2-283.7}
324.0-486.0
{3,304-4,956, 238.9-358.3}
{2,120-3,180, 153.3-229.9}
{3,024-4,536, 218.7-327.9}
{4,120-6,180, 297.9-446.8}
{5,220-7,840, 377.5-566.8}
208.0-312.0
296.0-444.0
405.0-605.0
515.0-765.0
SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS
Diameter
M8
M10
M12
Class
{184-265, 13.3-19.2}
{421-631, 30.5-45.6}
{744-1,116, 53.8-80.7}
7T 9T 12T Shape
18.0-26.0
41.5-61.5
{560-840, 40.5-60.7}
73.0-109.0
{979-1,469, 70.8-106.2}
——
55.0-82.0
96.0-114.0
—
—
276.0-414.0
{2,816-4,224, 203.6-305.4}
392.0-588.0
{4,000-6,000, 289.3-433.8}
540.0-800.0
{5,470-8,210, 395.5-593.6}
680.0-1,010.0
{6,900-10,340, 499.0-747.6}
EN00Z0002C100002
Unit: Nm {kgfcm, lbfft.}
M14 — —
86.0-142.0
{877-1,448, 63.4-104.7}
GENERAL INTRODUCTION (CHASSIS)GN02–24
With new flange (w/o grooves)
Unit: Nm {kgfcm, lbfft.}
Diameter
Class
M8
M10
M12
M14 —
{221-411, 16.0-29.7}
{250-464, 18.1-33.6}
{450-835, 32.5-60.4}
8.8T 10.9T Shape
21.7-40.3
24.5-45.5
44.1-81.9
27.3-50.7
{278-517, 20.1-37.4}
32.7-60.3
{333-615, 24.1-44.5}
57.4-106.6
{585-1087, 42.3-78.6}
91-169
{928-1723, 67.1-124.6}
104-156*
{106-1590, 76.7-115.1}
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