HINO 155 155h 195 195h 238 258LP 268 338 Truck Workshop Repair Service Manual 2016 PDF - MHINOMISC16OPES.zip

A thorough repair and service manual covering the HINO 155, 155h, 195, 195h, 238, 258LP, 268, and 338 Series trucks, packed with every bit of workshop data needed to maintain, troubleshoot, fix, and service these vehicles the way expert technicians do.

The HINO Trucks 155, 155h, 195, 195h & 238, 258LP, 268, 338 MY2016 workshop service repair manual contains (13,010 pages PDF):

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

2016 Hino-155-195-155h-195h Body Builder Book

2016 Hino-238-258LP-258ALP-268-268A-338 Body Builder Book

COE_HEV Service Manual

16MY COE Owners Manual_H1-L053E01.pdf

2016 COE Chassis DT_SA_BE_HEV_AC.pdf

2016 COE EWD.pdf

2016 COE Troubleshooting 1_ENG.pdf

2016 COE Troubleshooting 2_ENG.pdf

2016 COE Troubleshooting 3_ENG.pdf

2016 COE Troubleshooting 4_HEV_ATM_DT.pdf

2016 COE Troubleshooting 5_SA_BRAKE_ELEC.pdf

Conventional Service Manual

16MY Conv Owners Manual_H1-A036E01.pdf

2016 CONV Chassis 1_DT_ABS.pdf

2016 CONV Chassis 2_EWD.pdf

2016 CONV Troubleshooting 1_ELEC_ENG_DPF.pdf

2016 CONV Troubleshooting 2_ENGINE.pdf

2016 CONV Troubleshooting 3_DEF_DPF.pdf

Bulkhead JB Connector ID.pdf

Hybrid COE Safety Requirements.pdf

S1-UNAE12A-1.pdf

S1-UNAE12A-2.pdf

S5-UJ08E12A.pdf

S7-UNAE12A-1.pdf

S7-UNAE12A-2.pdf

S7-UNAE12A-3.pdf

SB-14-008 Hybrid COE Safety Tool and Accessory Requirements Final.pdf

Total Pages: 13,010 pages

File Format: PDF (Windows & Mac & Linux)

Language: English

Applicable for HINO 238, 258LP, 268, 338, 358 series, equipped with J08E-VB and J08E-VC engine

Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine

MAIN SECTIONS

TABLE OF CONTENTS

GENERAL INTRODUCTION

CLUTCH EQUIPMENT

CLUTCH MAIN UNIT

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

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

CAB EQUIPMENT

CAB

ELECTRICAL EQUIPMENT

ELECTRIC WIRE

HYBRID SYSTEM

2016 Hino-155-195-155h-195h Body Builder Book....2

US data....3

US RECORD....4

US WARNING....5

US XZU Chap01....6

Chapter 1....6

1. PURPOSE....7

2. RELATION TO OTHER HINO MANUALS....7

3. NON-GUARANTEE....7

4. CERTIFICATION AND COMPLIANCE WITH SAFETY REGULATIONS AND STANDARDS....8

5. INSTALLATION, MODIFICATION AND ALTERATION....8

6. CHANGE OF THIS BOOK....8

7. RELATION BETWEEN THIS BOOK AND THE VEHICLE WARRANTY....9

8. FURTHER INFORMATION....9

US XZU Chap02....10

Chapter 2....0

1. SAFETY STANDARDS....11

2. VEHICLE NOISE REGULATIONS INFORMATION....16

3. EMISSION CONTROL REGULATIONS....17

US XZU Chap03....19

Chapter 3....19

1. MODEL LINE-UP....20

2. WEIGHTS AND DIMENSIONS....21

3. WEIGHT DISTRIBUTION OF THE OPTION EQUIPMENT....30

4. BODY TYPES....31

US XZU Chap04....32

Chapter 4....32

1. GENERAL PRECAUTION....33

2. WEIGHT DISTRIBUTION AND CENTER OF GRAVITY....37

3. FIRE SHIELD....38

4. CLEARANCE BETWEEN CAB AND REAR BODY OR EQUIPMENT....39

5. SPACE FOR MAINTENANCE OF BATTERY....43

6. FUEL TANK....44

7. CAUTION LABEL OF FUEL TANK....45

8. INSTALLATION OF FENDER AND MUDGUARD....47

9. WELDING WORK....48

10. MINIMUM CLEARANCE WITH REAR SPRING AND REAR SPRING HANGER....61

11. HANDLING OF ABS....62

12. RE-PROGRAMMING VEHICLES CONTROL ECU....63

13. SYSTEM CONTROL COMPUTERS....65

14. REMOVING THE INSTRUMENT PANEL....67

15. REINSTALLING WASHER TANK INLET....71

16. ADDITIONAL WIRING IN THE ENGINE COMPARTMENT....73

17. EXHAUST SYSTEM....74

18. DPR MUFFLER....77

19. DEF - SCR SYSTEM....80

20. INSTALLATION OF FUEL INLET PIPE....84

21. THE FUEL HOSE AND PIPE....88

22. BODY MOUNTING WORK FOR HYBRID VEHICLE MODEL XFC SERIES ONLY....90

23. PROVISION FOR AM RADIO NOISE....94

24. INSTALLING EQUIPMENT ON THE CAB ROOF....96

25. VEHICLE STORAGE....97

US XZU Chap05....98

Chapter 5....98

1. GENERAL CAUTIONS....99

2. PRECAUTION FOR THE TIGHTENING BOLT AND NUT OF THE CHASSIS FRAME....101

3. MATERIAL FOR CHASSIS FRAME MODIFICATIONS....102

4. CHASSIS FRAME HOLE PATTERN....103

5. CHASSIS FRAME DRILLING....104

6. FLANGE CUTTING....105

7. CHASSIS FRAME WELDING....106

8. REAR OVERHANG EXTENSION....109

9. STIFFENING OF SIDE RAILS....110

10. PROPELLER SHAFT MODIFICATION AND ALTERATION....115

11. SERVICE BRAKE MODIFICATIONS....116

12. ELECTRIC WIRING MODIFICATIONS....132

13. ALTERATION OF EXHAUST SYSTEM....133

14. CAUTIONS NEEDED IN ADDITIONAL MACHINING AND ALTERATION OF THE CAB....134

US XZU Chap06....135

Chapter 6....135

1. MAIN SILL (SUB-FRAME)....136

2. REAR AXLE....142

3. REAR BODY LENGTH AND MAIN SILL (SUB-FRAME) DIMENSIONS....143

4. U-BOLTS....144

5. MOUNTING SUB-FRAME WITH U-BOLT....147

6. MOUNTING OF REAR FENDER AND MUDGUARD....148

US XZU Chap07....150

Chapter 7....150

1. WARNING....151

2. LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT....152

3. ADDITIONAL LAMP....157

4. THE INSTRUCTIONS OF LED LAMP FOR STOP LAMP....159

5. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK....168

6. INSTALLATION OF ADDITIONAL SWITCHES....175

7. ALTERNATOR OUTPUT CHARACTERISTIC....180

8. ELECTRICAL POWER SOURCES....181

9. BACK-UP BUZZER....190

10. HARNESS WIRING....191

US XZU Chap08....204

Chapter 8....204

1. GENERAL CAUTIONS....205

2. CAUTIONS FOR USE OF THINNER AND SOLVENTS CONTAINING THINNER....206

3. THE PARTS WHICH HAVE NO RESISTANCE TO HIGH TEMPERATURE AND THEIR TEMPERATURE LIMIT....208

4. CAUTIONS ON THE TOP COAT OF PAINT....209

5. CAUTIONS FOR FORCED DRYING....210

6. PRINCIPAL PARTS AND ALLOWABLE HEAT LIMIT....211

7. HOW TO DISMOUNTING AND REMOUNTING THE PARTS OF CAB....215

8. THE KIND AND THE ATTACHING POSITION OF MARK AND ORNAMENT....224

9. PRECAUTIONS FOR FITTING AND STORING THE CAUTION LABEL....226

10. HANDLING OF COMPUTERS (ECU)....227

11. CAUTIONS FOR PAINTING THE TIRE DISC WHEELS....228

12. PRECAUTION FOR INSTALLING TIRE DISC WHEEL ONTO THE VEHICLE....229

US XZU Chap09....230

Chapter 9....230

1. OUTLINE DIMENSIONS OF CHASSIS....231

2. CAB DRAWINGS....232

3. CAB BACK DRAWINGS....234

4. CHASSIS DRAWINGS....246

5. CHASSIS FRAME DRAWINGS....272

US XZU Chap10....294

Chapter 10....294

1. FUEL TANK....295

2. BATTERY....297

3. EXHAUST SYSTEM....299

US XZU Chap11....300

Chapter 11....300

1. HINO GENUINE P.T.O....301

2. TRANSMISSION MODELS TO BE INSTALLED HINOS VEHICLES....301

3. OTHER NOTICES....302

4. MOUNTING POSITION OF TRANSMISSION P.T.O. ASSY....303

5. ENGINE REV. CONTROL FOR MOUNTING OF BODY OR EQUIPMENT....304

US XZU Chap12....308

Chapter 12....308

1. DIAGRAM OF FRAME SECTION MODULUS....309

2. SUSPENSION DEFLECTION CHART....315

3. BRAKE PIPING DIAGRAM....322

4. ELECTRIC WIRING DIAGRAM....324

5. CONNECTORS....369

6. METRIC/U.S. CUSTOMARY UNIT EQUIVALENTS....414

US cover....415

COVER ....415

BACK COVER ....416

BACK COVER ....417

index.orig....418

2016 Hino-238-258LP-258ALP-268-268A-338 Body Builder Book....419

Hino_BBB_111815_update....420

Index....420

Cover....421

Production Code To Model Name Conversion Chart....422

Chapter 1 ....423

1. PURPOSE....424

2. RELATION TO OTHER HINO MANUALS....424

3. NON-GUARANTEE....424

4. CERTIFICATION AND COMPLIANCE WITH SAFETY REGULATIONSAND STANDARDS....425

5. INSTALLATION, MODIFICATION, AND ALTERATION....425

6. CHANGE OF THIS BOOK....425

7. RELATION BETWEEN THIS BOOK AND THE VEHICLE WARRANTY....426

8. FURTHER INFORMATION....426

Chapter 2....427

1. SAFETY STANDARDS....428

2. VEHICLE NOISE REGULATIONS INFORMATION....434

3. EMISSION CONTROL REGULATIONS....435

Chapter 3....437

1. MODEL LINE-UP....438

2. WEIGHTS AND DIMENSIONS....439

3. WEIGHT DISTRIBUTION OF THE OPTION EQUIPMENT....519

4. BODY TYPE....521

Chapter 4....522

1 . GENERAL PRECAUTION....523

2. WEIGHT DISTRIBUTION AND CENTER OF GRAVITY....528

3. THE TILT HOOD....529

4. FUEL TANK....530

5. THE FUEL HOSE....532

6. CAUTION LABEL OF FUEL TANK....533

7. INSTALLATION OF FENDER AND MUDGUARD....535

8. WELDING WORK....536

9. MINIMUM CLEARANCE WITH REAR SPRING AND REAR SPRING HANGER....541

10. SYSTEM CONTROL COMPUTERS....544

11. THE ANTENNA POSITION....546

12. REMOVING THE INSTRUMENT PANEL....547

13. ADDITIONAL WIRING IN THE ENGINE COMPARTMENT....548

14. RESETTING OF VEHICLE SPEED SENSORING PULSE CONVERTER....549

15. MAXIMUM VERTICAL TRAVEL RANGE OF LATERAL ROD(REAR AIR SUSPENSION MODEL)....550

16. LEVELING VALVE(REAR AIR SUSPENSION MODEL)....551

17. EXHAUST SYSTEM....553

18. DPR SYSTEM....556

19. DEF - SCR SYSTEM....559

20. VERTICAL EXHAUST TAIL PIPE....563

21. INSTALLING EQUIPMENT ON THE CAB ROOF....566

22. VEHICLE STORAGE....568

Chapter 5....569

1. GENERAL CAUTIONS....570

2. MATERIAL FOR CHASSIS FRAME MODIFICATIONS....571

3. CHASSIS FRAME DRILLING....572

4. FLANGE CUTTING....573

5. CHASSIS FRAME WELDING....574

6. REAR OVERHANG EXTENSION....578

7. STIFFENING OF SIDE RAILS....579

8. WHEELBASE MODIFICATIONS....581

9. PARKING BRAKE CONTROL CABLE MODIFICATION AND ALTERATION....585

10. PROPELLER SHAFT MODIFICATION AND ALTERATION....587

11. SERVICE BRAKE MODIFICATIONS....602

12. ELECTRIC WIRING MODIFICATIONS....627

13. ALTERATION OF EXHAUST SYSTEM....629

14. CAUTIONS NEEDED IN ADDITIONAL MACHINING AND ALTERATION OF THECAB....630

Chapter 6....631

1. MAIN SILL (SUB-FRAME)....632

2. REAR AXLE....636

3. REAR BODY LENGTH AND MAIN SILL (SUB-FRAME) DIMENSIONS....637

4. U-BOLTS....638

5. MOUNTING SUB-FRAME WITH U-BOLT....640

6. MOUNTING OF REAR FENDER AND MUDGUARD....641

Chapter 7....644

1. LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT....645

2. FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK....648

3. INSTALLATION OF ADDITIONAL SWITCHES....653

4. ALTERNATOR OUTPUT CHARACTERISTIC....655

5. INSTALLATION OF 180A OR 200A ALTERNATOR (OPT)....657

6. ELECTRICAL POWER SOURCES....661

7. BACK-UP ALARM (OPTIONAL EQUIPMENT)....674

8. HARNESS WIRING....675

9. INSTALLATION OF THE BATTERY DISCONNECT SWITCH....687

10. INSTALLATION OF FLASHER CUT HARNESS....689

Chapter 8....690

1. GENERAL CAUTIONS....691

2. CAUTIONS FOR USE OF THINNER AND SOLVENTS CONTAINING THINNER....692

3. CAB COLOR CODE CHART....694