Hino 238 Instruction manual

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-UNAE10A 1/2

S1-UNAE10A 2/2

J08E-VB, VC Engine Workshop Manual S5-UJ08E10A

Trouble Shooting Workshop Manual

S7-UNAE10C 1/4

S7-UNAE10C 3/4

S7-UNAE10C 4/4

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.

This manual does not contain items on half-tone dot meshing.

CHAPTER

MANUAL NO. S7-UNAE10C 2/4 (U.S.A.), S7-CNAE10C 2/4 (CANADA)

MODELS HINO 238, 258LP, 268, 338, 358

Production Code NE8J, NF8J, NJ8J, NV8J

GENERAL INTRODUCTION 1-001

TROUBLE SHOOTING - COMPONENTS 2-001

TROUBLE SHOOTING -

ELECTRICAL CONTROL SYSTEM 3-001

ENGINE CONTROL SYSTEM (J08E) 4-001

DEF SCR SYSTEM (DCU) 5-001

BURNER CONTROL SYSTEM (BCU) 6-001

BRAKE CONTROL SYSTEM 9-001

(ABS:HYDRAULIC (E VERSION))

9-002

(ABS:FULL AIR)

VEHICLE CONTROL SYSTEM (VCS) 11-001

CAN COMMUNICATION 12-001

DX MANUAL DX01-001 DX02-001 DX03-001 DX04-001 DX06-001 DX07-001

INDEX: TROUBLE SHOOTING

WORKSHOP

MANUAL

GENERAL INTRODUCTION

TROUBLE SHOOTING - COMPONENTS

TROUBLE SHOOTING -

ENGINE CONTROL SYSTEM (J08E)

DEF SCR SYSTEM (DCU)

BURNER CONTROL SYSTEM (BCU)

BRAKE CONTROL SYSTEM

VEHICLE CONTROL SYSTEM (VCS)

CAN COMMUNICATION

ELECTRICAL CONTROL SYSTEM

ENGINE CONTROL SYSTEM (J08E) 4–1

ENGINE CONTROL SYSTEM (J08E)

4-001

ENGINE CONTROL SYSTEM......................................4-3

PRECAUTIONS FOR DIAGNOSIS.........................4-3

SYSTEM BLOCK DIAGRAM...................................4-5

SYSTEM DIAGRAM................................................4-6

PRECAUTIONS ......................................................4-8

SENSOR LOCATION ............................................4-11

COMPUTER (ECU) PIN ASSIGNMENT...............4-20

ENGINE ECU CONNECTOR................................4-24

INSPECTION ........................................................4-28

DIAGNOSIS USING THE PC DIAGNOSIS

TOOL.....................................................................4-29

DIAGNOSTIC TROUBLE CODE (DTC)

TABLE ...................................................................4-30

GROUP SHARING THE SENSOR POWER SUPPLY

TERMINAL ............................................................4-45

GROUP SHARING THE SENSOR GND

TERMINAL ............................................................4-46

ENGINE BASIC INSPECTION SHEET

(ENGINE INSPECTION CHECK SHEET) ............4-47

NO DTC ................................................................4-50

DTC: P0016 ..........................................................4-53

DTC: P003A ..........................................................4-57

DTC: P0045 ..........................................................4-64

DTC: P0047 ..........................................................4-71

DTC: P0048 ..........................................................4-78

DTC: P006E ..........................................................4-85

DTC: P006F ..........................................................4-90

DTC: P007B ..........................................................4-95

DTC: P007C and P007D.....................................4-113

DTC: P0088 ........................................................4-122

DTC: P0096 ........................................................4-146

DTC: P0097 and P0098 ......................................4-161

DTC: P00AF........................................................4-170

DTC: P0101 ........................................................4-175

DTC: P0104 ........................................................4-187

DTC: P0106 ........................................................4-195

DTC: P0108 ........................................................4-202

DTC: P0112 and P0113 ......................................4-210

DTC: P0115 ........................................................4-219

DTC: P0117 and P0118 ......................................4-231

DTC: P011A ........................................................4-241

DTC: P011C........................................................4-252

DTC: P0122 and P0123 ......................................4-260

DTC: P0128 ........................................................4-273

DTC: P016E and P016F .....................................4-280

DTC: P0182 and P0183 ......................................4-304

DTC: P0191 ........................................................4-313

DTC: P0192 and P0193 ......................................4-335

DTC: P01A5 ........................................................4-346

DTC: P01A6 ........................................................4-355

DTC: P0200 ........................................................4-364

DTC: P0201, P0202, P0203, P0204, P0205 and

P0206..................................................................4-367

DTC: P0217 ........................................................4-376

DTC: P0219 ........................................................4-383

DTC: P0222 and P0223 ......................................4-390

DTC: P0234 ........................................................4-402

DTC: P0237 ........................................................4-409

DTC: P0263, P0266, P0269, P0272, P0275 and

P0278..................................................................4-418

DTC: P026C and P026D.....................................4-434

DTC: P0299 ........................................................4-452

DTC: P0300 ........................................................4-459

DTC: P0301, P0302, P0303, P0304, P0305 and

P0306..................................................................4-469

DTC: P0335 ........................................................4-481

DTC: P0336 ........................................................4-489

DTC: P0340 ........................................................4-497

DTC: P0341 ........................................................4-504

DTC: P0381 ........................................................4-512

DTC: P0401 ........................................................4-519

DTC: P0402 ........................................................4-537

DTC: P0404 ........................................................4-550

DTC: P0405 and P0406 ......................................4-557

DTC: P041B ........................................................4-564

DTC: P041C and P041D.....................................4-579

DTC: P0420 ........................................................4-589

DTC: P0489 and P0490 ......................................4-596

DTC: P049D........................................................4-603

DTC: P04D5 and P04D6.....................................4-610

DTC: P0500 and P0501 ......................................4-619

DTC: P0504 ........................................................4-627

DTC: P0519 ........................................................4-635

DTC: P0524 ........................................................4-639

DTC: P0562 and P0563 ......................................4-646

DTC: P05F1 ........................................................4-654

DTC: P0605 ........................................................4-664

DTC: P0606 ........................................................4-667

DTC: P0607 ........................................................4-670

DTC: P0610 ........................................................4-673

DTC: P0611 ........................................................4-677

DTC: P0617 ........................................................4-680

ENGINE CONTROL SYSTEM (J08E)4–2

DTC: P0628 and P0629 ......................................4-685

DTC: P062F ........................................................4-694

DTC: P0630.........................................................4-699

DTC: P0642.........................................................4-703

DTC: P0643.........................................................4-710

DTC: P064C ........................................................4-718

DTC: P0652.........................................................4-725

DTC: P0653.........................................................4-731

DTC: P0671, P0672, P0675 and P0676 .............4-738

DTC: P0683.........................................................4-750

DTC: P0686.........................................................4-757

DTC: P06D3 and P06D4 .....................................4-762

DTC: P0704.........................................................4-770

DTC: P073D ........................................................4-776

DTC: P081A ........................................................4-783

DTC: P081B ........................................................4-788

DTC: P0850.........................................................4-793

DTC: P1133.........................................................4-800

DTC: P119F ........................................................4-808

DTC: P141F ........................................................4-815

DTC: P1426.........................................................4-818

DTC: P1427.........................................................4-826

DTC: P1428.........................................................4-834

DTC: P1458.........................................................4-843

DTC: P1459.........................................................4-850

DTC: P14B0 ........................................................4-857

DTC: P14B2 ........................................................4-862

DTC: P14B3 and P14B4 .....................................4-867

DTC: P14B7 and P14B8 .....................................4-874

DTC: P14BC and P14BD ....................................4-881

DTC: P14BF ........................................................4-888

DTC: P1515.........................................................4-895

DTC: P1530.........................................................4-901

DTC: P1601.........................................................4-906

DTC: P200C ........................................................4-911

DTC: P203F ........................................................4-922

DTC: P204F ........................................................4-927

DTC: P207F ........................................................4-931

DTC: P20EE........................................................4-943

DTC: P2100.........................................................4-955

DTC: P2101.........................................................4-962

DTC: P2103.........................................................4-970

DTC: P2120.........................................................4-977

DTC: P2122 and P2123 ......................................4-982

DTC: P2127 and P2128 ......................................4-991

DTC: P2135.......................................................4-1002

DTC: P2138.......................................................4-1009

DTC: P2146.......................................................4-1015

DTC: P2147 and P2148 ....................................4-1023

DTC: P2149.......................................................4-1032

DTC: P2150 and P2151 ....................................4-1040

DTC: P2184 and P2185 ....................................4-1049

DTC: P2214.......................................................4-1058

DTC: P2227.......................................................4-1072

DTC: P2228 and P2229 ....................................4-1077

DTC: P2269.......................................................4-1082

DTC: P226C ......................................................4-1088

DTC: P22D3 ......................................................4-1097

DTC: P240F ......................................................4-1102

DTC: P242B ......................................................4-1115

DTC: P242C and P242D ...................................4-1125

DTC: P244A ......................................................4-1135

DTC: P244B ......................................................4-1161

DTC: P2457.......................................................4-1190

DTC: P2459.......................................................4-1207

DTC: P2463.......................................................4-1210

DTC: P246F ......................................................4-1224

DTC: P2470 and P2471 ....................................4-1234

DTC: P2563.......................................................4-1244

DTC: P2564 and P2565 ....................................4-1251

DTC: P259E ......................................................4-1260

DTC: P259F ......................................................4-1267

DTC: P2635.......................................................4-1274

DTC: P268A and P2696....................................4-1296

DTC: P2BA9......................................................4-1303

DTC: U0073 ......................................................4-1309

DTC: U010A ......................................................4-1313

DTC: U010C......................................................4-1316

DTC: U010E ......................................................4-1319

DTC: U029D......................................................4-1322

DTC: U029E ......................................................4-1325

DTC: U02A2 ......................................................4-1328

DTC: U0301 ......................................................4-1331

DTC: U1001 ......................................................4-1335

DTC: U110A ......................................................4-1338

DTC: U111E ......................................................4-1341

ENGINE CONTROL SYSTEM (J08E) 4–783

DTC: P081A

EN01H16F01030F03001098

P081A: Starter Disable Circuit Low

INFORMATION

1. Technical description

•The starter cut relay prevents further rotations of the starter when the starter switch is turned after start of the engine.

•Harness GND short-circuit or disconnection and relay unit failure are detected.

2. DTC set condition

(1) Check conditions

•Engine speed of 500 r/min or more. (Request starter cut relay operation)

•Starter switch ON.

•Battery voltage is in the range of 10 V to 16 V.

The conditions described above remain for 5 seconds or longer.

(2) Judgement criteria

•Output of the starter cut relay remains at 10 V or less for 3 seconds or longer.

3. Reset condition

•Just after restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

•MIL: OFF

•Diag lamp: OFF

5. Symptoms on the vehicle when the DTC is set

•–

•Starter operates even when the engine is running.

6. Pre-inspection work

•Check that the battery voltage is in the normal range.

%L9

(STA)

K01

(S+)

K04

(NC)

NK0

(NO)

(ST)

N6E

(CL2-)

%L7

(STA)

ATM starter relay

Starter cut relay

LL1K01

K0G%D7

K0G

(STCR)

LL1

Engine

ECU

SAPH16F010300632

ENGINE CONTROL SYSTEM (J08E)4–784

7. After-inspection work

•Clear all past DTCs.

•Check that no DTC is stored after test drive.

8. Estimated failure factors

•Harness disconnection or short-circuit

•Looseness or poor contact of connector

•starter cut relay failure

•Engine ECU failure

ENGINE CONTROL SYSTEM (J08E) 4–785

INSPECTION PROCEDURE: P081A

1. Set the starter switch to the "LOCK" position.

2. Disconnect the starter cut relay.

3. Set the starter switch to the "ON" position.

4. Select [Engine] and check if P081A has been detected in [Fault

Information].

NOYES

1. Check the connection of the starter cut relay connector (Loose-

ness and poor contact).

NOYES

1Check the DTC detected (Engine ECU) [Hino-DX]

Select

Engine

SAPH16F010300633

Has DTC P081A been detected?

Go to step 2. Replace the starter cut relay.

Perform "After-inspection work" of INFOR-

MATION section.

2Inspect the starter cut relay connector

Was any failure found?

Connect securely, repair if needed.

Perform "After-inspection work" of INFOR-

MATION section.

Go to step 3.

ENGINE CONTROL SYSTEM (J08E)4–786

1. Set the starter switch to the "LOCK" position.

2. Connect the signal check harness to the engine ECU.

3. Set the starter switch to the "ON" position.

4. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness).

NOYES

1. Set the starter switch to the "ON" position.

2. Select [Engine] and check if P081A has been detected in [Fault

Information].

NOYES

3Inspect for disconnection in wire harness of starter cut relay

A B

V80

SAPH16F010300634

Measurement

conditions Tester connections Standard values

Starter switch:

Engine ECU (signal

check harness)

STCR(V2) –PGD4(V80)



Do the measurements meet the standard value?

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-

MATION section.

4Check the DTC detected (Engine ECU) [Hino-DX]

Select

Engine

SAPH16F010300635

Has DTC P081A been detected?

Replace the engine ECU.

Perform "After-inspection work" of INFOR-

MATION section.

Procedure completed.

Perform "After-inspection work" of INFOR-

MATION section.

ENGINE CONTROL SYSTEM (J08E) 4–787

CHECKLIST: P081A

DTC: P081A Starter Disable Circuit Low Inspection procedure

Step Action Description Judgement Check

(Yes/No) Yes No

Check the

DTC detected

(Engine ECU)

[Hino-DX]

1. Disconnect the starter cut

relay.

2. Check if P081A has been

detected in [Engine].

DTC P081A

has been

detected: Go

to YES.

No DTC has

been detected:

Go to NO.

Go to step 2.

Replace the

starter cut

relay.

Perform "After-

inspection

work" of

INFORMA-

TION section.

Inspect the

starter cut

relay connec-

tor

Check the connection of the

starter cut relay connector

(Looseness and poor contact).

Failure found:

Go to YES.

No failure

found: Go to

NO.

Connect

securely,

repair if

needed.

Perform "After-

inspection

work" of

INFORMA-

TION section.

Go to step 3.

Inspect for dis-

connection in

wire harness

of starter cut

relay

Connect the signal check harness

to the engine ECU and measure

the resistance between the termi-

nals of the engine ECU (signal

check harness).

Engine ECU (signal check har-

ness)

STCR(V2) –PGD4(V80)



The measure-

ments meet

the standard

value: Go to

YES.

The measure-

ments do not

meet the stan-

dard value: Go

to NO.

Go to step 4.

Repair or

replace the

harness.

Perform "After-

inspection

work" of

INFORMA-

TION section.

Check the

DTC detected

(Engine ECU)

[Hino-DX]

Check if P081A has been

detected in [Engine].

DTC P081A

has been

detected. Go

to YES.

No DTC has

been detected.

Go to NO.

Replace the

engine ECU.

Perform "After-

inspection

work" of

INFORMA-

TION section.

Procedure

completed.

Perform "After-

inspection

work" of

INFORMA-

TION section.

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