Toyota HINO 145 Series Instruction manual

HINO MOTORS SALES U.S.A. INC.
WORKSHOP MANUAL
HINO 145, 165, 185, 238,
268, 338

FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 145, 165, 185, 238, 268, 338 series, equipped with J05D-TA, J08E-TA and J08E-TB engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the 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 service manuals for the components and systems
in these vehicles.
Manual Name Pub. No.
Chassis Workshop Manual S1-UNAE01B 1/4
Chassis Workshop Manual S1-UNAE01B 2/4
Chassis Workshop Manual S1-UNAE01B 3/4
J05D-TA Engine Workshop Manual S5-UJ05E01B
J08E-TA, TB Engine Workshop Manual S5-UJ08E01B
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CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
CHAPTER
MANUAL NO. S1-UNAE01B 4/4 (U.S.A.), S1-CNAE01B 4/4 (CANADA)
MODELS
(Production Model
Code)
HINO
145
(NA6J)
HINO
165
(NB6J)
HINO
185
(NC6J)
HINO
238
(ND8J)
HINO
268 HINO
308
(NF8J)
HINO
338
(NV8J)
(NE8J) (NJ8J)
GENERAL INTRODUCTION GN02-001
CLUTCH MAIN UNIT CL02-001 CL02-002
CLUTCH CONTROL CL03-001
TRANSMISSION MAIN UNIT TR02-001
AUTOMATIC TRANSMISSION TR04-001 TR04-002 TR04-003
TRANSMISSION/TRANSFER CONTROL TR06-001
PROPELLER SHAFT PP02-001
DIFFERENTIAL CARRIER DF02-001
BRAKE EQUIPMENT BR01-001 BR01-002 BR01-001 BR01-002
SERVICE BRAKE BR02-001 — BR02-001 —
ABS (ANTI-LOCK BRAKE SYSTEM) BR03-001 BR03-002 BR03-001 BR03-002
PARKING BRAKE BR07-001, BR07-002 —BR07-001,
BR07-002 —
STEERING EQUIPMENT SR01-001
STEERING UNIT SR02-001
POWER STEERING SR03-001
FRONT AXLE AX02-001
REAR AXLE AX03-001
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.
FOREWORD4.fm 2 ページ ２００４年５月２５日 火曜日 午前１０時６分

CLUTCH EQUIPMENT
CLUTCH MAIN UNIT
CLUTCH CONTROL
TRANSMISSION EQUIPMENT
TRANSMISSION MAIN UNIT
TRANSFER MAIN UNIT
AUTOMATIC TRANSMISSION
P.T.O. (POWER TAKE-OFF)
TRANSMISSION / TRANSFER CONTROL
PROPELLER SHAFT
DIFFERENTIAL EQUIPMENT
DIFFERENTIAL CARRIER
INDEX: CHASSIS GROUP 1/4
PROPELLER SHAFT EQUIPMENT
BRAKE EQUIPMENT
SERVICE BRAKE
ABS (ANTI-LOCK BRAKE SYSTEM)
ES START (EASY & SMOOTH START) SYSTEM
GENERAL INTRODUCTION
WORKSHOP
MANUAL
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INDEX4-1.fm 2 ページ ２００４年５月２６日 水曜日 午前９時４０分

EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
STEERING EQUIPMENT
STEERING UNIT
POWER STEERING
INDEX: CHASSIS GROUP 2/4
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
WHEEL & TIRE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
COUPLER (5TH WHEEL)
PINTLE HOOK
CAB EQUIPMENT
CAB
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INDEX4-2.fm 2 ページ ２００４年５月２６日 水曜日 午前９時４４分

ELECTRICAL EQUIPMENT
ELECTRIC WIRE
INDEX: CHASSIS GROUP 3/4
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INDEX4-2.fm 4 ページ ２００４年５月２６日 水曜日 午前９時４４分

ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
INDEX: CHASSIS GROUP 4/4
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INDEX4-2.fm 6 ページ ２００４年５月２６日 水曜日 午前９時４４分

SUSPENSION SU02–1
SU 02 SUSPENSION
SU02-001
LEAF SUSPENSION ASSEMBLY ............SU02-2
DATA AND SPECIFICATIONS ......................... SU02-2
DESCRIPTION ................................................ SU02-4
TROUBLESHOOTING ..................................... SU02-7
COMPONENT LOCATOR................................ SU02-8
OVERHAUL ................................................... SU02-13
INSPECTION AND REPAIR .......................... SU02-17
AIR SUSPENSION ASSEMBLY .............SU02-19
DATA AND SPECIFICATIONS ....................... SU02-19
DESCRIPTION .............................................. SU02-20
TROUBLESHOOTING ................................... SU02-21
COMPONENT LOCATOR.............................. SU02-22
OVERHAUL ................................................... SU02-23
INSPECTION AND REPAIR .......................... SU02-27
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SUSPENSIONSU02–2
LEAF SUSPENSION ASSEMBLY
DATA AND SPECIFICATIONS
EN09ABC02I200001
FRONT SUSPENSION Unit: mm {in.}
REAR SUSPENSION Unit: mm {in.}
Model HINO 145
(NA6J)
HINO 165
(NB6J)
HINO 185
(NC6J)
HINO 238
(ND8J)
HINO 268
(NE8J)
(NJ8J)
HINO 308
(NF8J)
HINO 338
(NV8J)
Type Taper-leaf springs with double acting shock absorber
Dimensions
of leaf
springs:
Span 1,200 {47.24} 1,200 {47.24} 1,200 {47.24} 1,470 {57.88} 1,470 {57.88}
Width 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00}
Thickness
of leaves
16.76 {0.66} 16.76 {0.66} 16.76 {0.66} 20.01 {0.788} 20.01 {0.788}
16.76 {0.66} 16.76 {0.66} 16.76 {0.66} 20.01 {0.788} 20.01 {0.788}
— — — — 20.01 {0.788}
Shock
absorbers:
Type Double acting Double acting Double acting Double acting Double acting
Stroke 208 {8.19} 208 {8.19} 208 {8.19} 255 {10.04} 255 {10.04}
Min. length 420 {16.53} 420 {16.53} 420 {16.53} 390 {15.35} 390 {15.35}
Max. length 628 {24.72} 628 {24.72} 628 {24.72} 645 {25.4} 645 {25.4}
Stabilizer
(opt):
Type Torsion ber Torsion ber Torsion ber — —
Diameter 32 {1.26} 32 {1.26} 32 {1.26} — —
Length 289.5 {11.40} 289.5 {11.40} 289.5 {11.40} — —
Model HINO 145
(NA6J)
HINO 165
(NB6J)
HINO 185
(NC6J)
HINO 238
(ND8J)
HINO 268
(NE8J)
(NJ8J)
HINO 308
(NF8J)
HINO 338
(NV8J)
HINO 338
(NV8J)
Type Semi-elliptic main and auxiliary helper-leaf spring
Dimensions
of main leaf
springs:
Span 1,300 {51.18} 1,300 {51.18} 1,300 {51.18} 1,300 {51.18} 1,300 {51.18} 1,300 {51.18}
Width 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00}
Thickness of
leaves
10.7 {0.423} 12.0 {0.473} 13.4 {0.527} 14.17{0.558} 14.99 {0.590} 15.88 {0.625 }
10.2 {0.401} 10.7 {0.423} 12.0 {0.473} 13.4 {0.527} 9.65{0.380} —
— 10.2 {0.401} 10.7 {0.423} 9.65{0.383} 10.2 {0.401} 10.2 {0.401}
— 9.14 {0.360} 10.2 {0.401} 10.2 {0.401} — —
Dimensions
of auxiliary
leaf springs:
Span 900 {35.44} 900 {35.44} 900 {35.44} 900 {35.44} 900 {35.44} 900 {35.44}
Width 76.2{3.00} 76.2{3.00} 76.2{3.00} 76.2{3.00} 76.2{3.00} 76.2{3.00}
Thickness 17.83 {0.702} 17.83 {0.702} 17.83 {0.702} 17.83 {0.702} 17.83 {0.702} 17.83 {0.702}
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SUSPENSION SU02–3
Shock
absorbers
(opt):
Type Double act-
ing
Double act-
ing
Double act-
ing
Double act-
ing
Double act-
ing
Double act-
ing
Stroke 280 {11.02} 280 {11.02} 280 {11.02} 242 {9.53} 242 {9.53} 242 {9.53}
Min. length 389 {15.31} 389 {15.31} 389 {15.31} 432 {17.01} 432 {17.01} 432 {17.01}
Max. length 689 {27.12} 689 {27.12} 689 {27.12} 674 {26.53} 674 {26.53} 674 {26.53}
Stabilizer
(opt):
Type — — — Torsion ber Torsion ber Torsion ber
Diameter — — — 48 {1.89} 48 {1.89} 48 {1.89}
Length — — — 550 {21.65} 550 {21.65} 550 {21.65}
Model HINO 145
(NA6J)
HINO 165
(NB6J)
HINO 185
(NC6J)
HINO 238
(ND8J)
HINO 268
(NE8J)
(NJ8J)
HINO 308
(NF8J)
HINO 338
(NV8J)
HINO 338
(NV8J)
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SUSPENSIONSU02–4
DESCRIPTION
EN09ABC02C100001
FRONT SUSPENSION
REAR SUSPENSION
SAPH09ABC0200001
1 Leaf spring assembly 5 Shackle
2 Shock absorber 6 Spring pin
3 Spring bumper 7 Stabilizer (Opt.)
4U-bolt
SAPH09ABC0200002
1 Spring pin 4 Main leaf spring assembly
2 Auxiliary leaf spring assembly 5 Spring pad
3 U-bolt 6 Shock absorber (Opt.)
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SUSPENSION SU02–5
FRONT SUSPENSION
REAR SUSPENSION
SAPH09ABC0200003
1 Leaf spring assembly 4 U-bolt
2 Shock absorber 5 Shackle
3 Spring bumper 6 Spring pin
SAPH09ABC0200004
1 Spring pin 4 Main leaf spring assembly
2 Auxiliary leaf spring assembly 5 Spring pad
3 U-bolt 6 Shock absorber (Opt.)
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SUSPENSIONSU02–6
FRONT SUSPENSION
REAR SUSPENSION
SAPH09ABC0200005
1 Leaf spring assembly 4 U-bolt
2 Shock absorber 5 Shackle
3 Spring bumper 6 Spring pin
SAPH09ABC0200006
1 Stabilizer (Opt.)
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SUSPENSION SU02–7
TROUBLESHOOTING
EN09ABC02F300001
Symptom Possible cause Remedy/Prevention
Rough ride Broken leaves Replace the leaves. Check the load
capacity rating.
Cracked or damaged Replace the leaves. Check the load
capacity rating.
Overloading Decrease the load.
Heavy sway Inoperative shock absorber Replace the shock absorber.
Leaves broken at the center bolt
hole
Loosen U-bolts Replace the leaves and tighten the U-
bolts to specified torque.
Squeaking of the leaves Friction between the leaves Apply chassis grease between leaves.
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SUSPENSIONSU02–8
COMPONENT LOCATOR
EN09ABC02D100001
FRONT SUSPENSION
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}
1 U-bolt 11 Shock absorber bracket
2 Spring bumper 12 Shock absorber pin
3 Spring pad 13 Cushion (If so equipped)
4 Lock nut 14 Cushion washer (If so equipped)
5 Spring pin 15 Holder sub assembly (If so equipped)
6 U-bolt nut 16 Holder (If so equipped)
7 Caster shim 17 Stabilizer sub assembly (If so equipped)
8 Leaf spring assembly 18 Rubber bushing (If so equipped)
9 Shackle 19 Stabilizer lever (If so equipped)
10 Shock absorber
A 472-502 {4813-5118, 348-370} D 370-472 {3773-4813, 273-348} for HINO238-338 (ND-
NV)
B 107-147 {1091-1498, 79-108} for HINO145-185 (NA-
NC)
E 180-240 {1836-2447, 133-177}
B 169-227 {1724-2314, 125-167} for HINO238-338 (ND-
NV)
F 91-149 {928-1519, 67-109}
12
C
Standard front suspension
for Hino 145,165,185 (NA,NB,NC)
SAPH09ABC0200007
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SUSPENSION SU02–9
C 210-294 {2142-2998, 155-216} G 73-109 {745-1111, 54-80}
D 223-335 {2274-3416, 165-247} for HINO145-185 (NA-
NC)
H 35-51 {357-520, 26-37}
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