2016 hino 258 lp series truck service repair manual

FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 238, 258LP, 268, 338, 358 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 sys-
tems in these vehicles.
Manual Name Pub. No.
Chassis Workshop Manual S1-UNAE12A 2/2
J08E-VB, VC Engine Workshop Manual S5-UJ08E12A
Trouble Shooting Workshop Manual
S7-UNAE12A 1/3
S7-UNAE12A 2/3
S7-UNAE12A 3/3
MENU

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
CHAPTER
MANUAL NO. S1-UNAE12A 1/2 (U.S.A.), S1-CNAE12A 1/2 (CANADA)
MODELS HINO 238, 258LP, 268, 338, 358
Production Model
Code
NE8J, NF8J, NJ8J, NV8J, NH8J
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
TRANSMISSION/TRANSFER CONTROL TR06-001 TR06-002
PROPELLER SHAFT PP02-001
DIFFERENTIAL CARRIER DF02-001
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
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.

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
DIFFERENTIAL EQUIPMENT
DIFFERENTIAL CARRIER
INDEX: CHASSIS GROUP 1/4
PROPELLER SHAFT EQUIPMENT
BRAKE EQUIPMENT
SERVICE BRAKE
ABS
GENERAL INTRODUCTION
WORKSHOP
MANUAL

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

ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS

GENERAL INTRODUCTION (CHASSIS) GN02–1
GN02GENERAL INTRODUCTION (CHASSIS) GN02-001
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

GENERAL INTRODUCTION (CHASSIS)GN02–2
GENERAL INTRODUCTION
GENERAL PRECAUTIONS
EN00Z08020100001
Some recommended and standard maintenance services for your vehicle are included in this section. When performing main-
tenance 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 mainte-
nance, please consult your Hino dealer.
DEFINITION OF SAFETY TERMS
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.
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.

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 15q 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 emis-
sions control as the original parts; and
b. Any parameter adjustment or design element change is made only:
x In accordance with the original engine manufacturer's instructions; or
x 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.

(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 recom-
mended 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 emis-
sions-related control components including a listing of parts and components used, engine parameter adjustments, emis-
sions-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 die-
sel fuel, including a 15 ppm sulfur cap)."

IDENTIFICATION INFORMATION
EN00Z08020200001
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.
VIN
label

(1) VIN
See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page.
(2) P.S. (PRODUCTION SERIES) AND VEHICLE COMPONENTS
MODEL
(CLASS)
PRODUC-
TION CODE CLUTCH
SIZE
TRANS-
MIS-
SION
SERIES
TRANSMISSION RATIO REAR
AXLE
SERIES
SER-
VICE
BRAKE
PARK-
ING
BRAKE
SUSPEN-
SION
MODEL SERIES 1st 2nd 3rd 4th 5th 6th Rev.
HINO238
(6)
NE8J HBD -
2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
H D
L
or
A
RS19-145
2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
RS19-145
2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS17-145
RS19-145
HINO258
(6)
NE8J
GBD 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS17-145
H D
L
or
A
RS19-145
HBD
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
RS19-145
- 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
RS19-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS17-145
RS19-145
NJ8J
JBD 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS17-145
F W A
RS19-145
KBD
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
F W
L
or
A
RS19-145
- 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
RS19-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS17-145
RS19-145
PBD - 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS17-145
RS19-145

HINO268
(6)
NE8J
GBD 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS17-145
H D
L
or
A
RS19-145
HBD
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
RS19-145
- 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
RS19-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS17-145
RS19-145
NJ8J
JBD 350mm FS5406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS19-145
F W
L
or
A
KBD
- 2200HS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
RS19-145
- 2200RDS 3.10 1.81 1.41 1.00 0.71 0.61 4.49
RS17-145
RS19-145
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS17-145
RS19-145
PBD - 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS17-145
RS19-145
HINO268
(7)
NV8J
NBD 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS21-145
F W
L
or
A
RS23-160
PBD
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS21-145
RS23-160
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
RS21-145
RS23-160
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
RS21-145
RS23-160
TBD 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS21-145
RS23-160
SBD
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS21-145
RS23-160
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
RS21-145
RS23-160
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
RS21-145
RS23-160
MODEL
(CLASS)
PRODUC-
TION CODE CLUTCH
SIZE
TRANS-
MIS-
SION
SERIES
AXLE
SERIES
SER-
VICE
BRAKE
PARK-
ING
BRAKE
SUSPEN-
SION

HINO338
(7)
NF8J
DBD 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS21-145
H D
L
or
A
EBD - 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09 RS21-145
NV8J
NBD 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS21-145
F W
RS23-160
PBD
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS21-145
F W
L
or
A
RS23-160
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
RS21-145
RS23-160
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
RS21-145
RS23-160
TBD 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63
RS21-145
RS23-160
SBD
- 2500RDS 3.51 1.90 1.44 1.00 0.74 0.64 5.09
RS21-145
RS23-160
- 3000RDS 3.49 1.86 1.41 1.00 0.75 0.65 5.03
RS21-145
RS23-160
- 3500RDS 4.59 2.25 1.54 1.00 0.75 0.65 5.00
RS21-145
RS23-160
HINO358
(8)
NH8J
TBD 350mm FS6406 9.01 5.27 3.22 2.04 1.36 1.00 8.63 RS23-160
F W
L
or
ASBD
- 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
CODE SERVICE BRAKE
H: Hydraulic
F: Full air
PARKING BRAKE CONTROL CODE
D: ACTING ON DIFFERENTIAL
W: ACTING ON REAR WHEEL
SUSPENSION
L: LEAF
A: AIR
MODEL
(CLASS)
PRODUC-
TION CODE CLUTCH
SIZE
TRANS-
MIS-
SION
SERIES
AXLE
SERIES
SER-
VICE
BRAKE
PARK-
ING
BRAKE
SUSPEN-
SION

HINOVEHICLEIDENTIFICATIONNUMBER(VIN)STRUCTUREFORU.S.A.andCANADA(2016MY)
WMIVDSCDVIS
12345678910111213141516
5PVNJ8JT2G4S1000
17
1
MANUFACTURERTYPEMAKE,MODEL
LINE&CAB/BODYTYPE,
SERIES,BRAKESYSTEM
MODELYEAR
ASSEMBLYPLANTENGINEMODEL
WHEELBASE
CHECKDIGIT
MODIFICATION
SEQUENTIALNUMBER
CODE
JHA
JHB
TRUCK
INCOMPLETEVEHICLE
TYPEMANUFACTURER
HINOMOTORS,LTD.
HINOMOTORS,LTD.
5PVINCOMPLETEVEHICLE
HINOMOTORS
MANUFACTURING
U.S.A.,INC.
2AYINCOMPLETEVEHICLE
HINOMOTORS
CANADA,LTD.
CODE
P
CODE
2024
YEARYEAR
R2025
S2026
T2027L2021
M2022
N2023
I2018
J2019
K2020
G2016
H2017
CODE
8J
J08E-VC
MODEL
7.6LITERS,DIESEL220HP
J08E-VB7.6LITERS,DIESEL260HP
DESCRIPTIONMANUFACTURER
HINOMOTORS,LTD.
CODE
G3,861
LENGTH
NE-NV
mmin.
J4,445
L4,750
M5,207
N5,385
P5,512
R5,969
T6,426
V6,883
152
175
187
205
212
217
235
253
271
CODE
S
DESCRIPTION
ANEWLETTER
TWILLBEALLOTTED
UATEVERYMAJOR
...MODIFICATION
Z
CODE
1
ASSEMBLYPLANT
HINOMOTORS,LTD.
HINOPLANTINJAPAN
3CanadaPlant
4W.VPlantMODEL
CODE
MAKE
NFHYDRAULIC
LINE&CAB/BODYTYPE
INCOMPLETEVEHICLE
IntendedGVWRandVehicleClass
andClass
BRAKE
SYSTEMS
NV
FULLAIR
FULLAIR
INCOMPLETEVEHICLE
INCOMPLETEVEHICLE
INCOMPLETEVEHICLE
INCOMPLETEVEHICLE
NJ
10434kg.-11793kgorless
[23,001-26,000(lbs.)](CLASS6)
[30,001-33,000(lbs.)](CLASS7)
[30,001-33,000(lbs.)](CLASS7)
14969kg-15875kgorless
[33,001-35,000(lbs.)](CLASS8)
NE
HINO
HINO
NHHINO
HINO
HINO
[19,501-26,000(lbs.)](CLASS6)
HYDRAULIC
FULLAIR
SAPH00Z080200007

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 con-
forms to this low.
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
SAPH00Z080200008
SAPH00Z080200009
SAPH00Z080200010
SAPH00Z080200011
CARB § 1956.8. Exhaust Emission Standard and Test Procedure
(a) (b) Heavy-Duty Diesel Engine Idling Requirements

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.
VIN
label
Vehicle emission
control information
SAPH00Z080200012
For example
SAPH00Z080200013

HOW TO USE THIS WORKSHOP MANUAL
EN00Z08020200002
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.

MAIN CYLINDER
EXAMPLE:
Tightening torque Unit: N˜m {kgf˜cm, lbf˜ft}
In some cases, illustrations may be of parts which differ in some nonessen-
tial way from the parts found on your particular vehicle. In such cases, the
principle or procedure being illustrated applies regardless of such nones-
sential 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.
SAPH00Z080200014
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
7 Piston
A 2.5-4.4 {25-45, 1.8-3.2}

SAPH00Z080200015

PRECAUTIONS
EN00Z0802C100001
PRECAUTIONS FOR ELECTRICAL SYSTEM
1. REMOVING THE BATTERY CABLE
! WARNING
• Be sure to wait for at least ten minutes after the starter key is
turned to "LOCK" position before you disconnect the battery ter-
minals 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 vehi-
cle 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" posi-
tion. In this case, use HINO DX 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 degrada-
tion 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.
Loosen
SAPH00Z080200016
Incorrect
SAPH00Z080200017
Incorrect
Incorrect
Incorrect
SAPH00Z080200018

4. HANDLING OF CONNECTOR
(1) To remove a connector with lock, release the lock then pull it out.
(2) To remove a connector, hold the connector (indicated by an arrow in
the figure) to pull it out. Never pull the harness.
(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
! WARNING
• 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
! WARNING
• 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.
Incorrect
Incorrect
Correct
SAPH00Z080200019

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.
(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.
Computer
Battery
Chassis frame Chassis frame
Disconnect the ground terminal for
battery at the connecting point on the
frame and disconnect the ground for
computer as well.
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.
Alternator
etc.
ARC welding
machine
SAPH00Z080200020

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SEALANT ON THE TAPERED SCREW FOR
PIPING
EN00Z08020200003
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 assem-
ble in accordance with the tightening torque table below.
Wipe dirt off the mating part (female screw) before tightening it.
! WARNING
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: N˜m {kgf˜cm, lbf˜ft}
(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.
SAPH00Z080200021
SAPH00Z080200022
Screw diameter
1/8 1/4 3/8 1/2
Material
Steel
20r5
{200r50,
14.4r3.6}
49r10
{500r100,
36.2r7.2}
64r15 {650r150, 47r10}
Aluminum, brass
25r5
{250r50,
18.1r3.6}
34r5
{350r50,
25.3r3.6}
44r5
{450r50,
32.5r3.6}

NYLON TUBE REPLACEMENT METHOD
EN00Z08020200004
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 con-
ditions of the two types of joints; one-touch joints and caulking joints.
NOTICE
Since the function and quality of nylon tubes and joints are guaran-
teed 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
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 CAULK-
ING 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 dam-
aged 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 85-95q.
1. INSTALLATION OF A ONE-TOUCH JOINT
One-touch joint
Caulking joint
SAPH00Z080200023
Insertion length
Nylon tube
SAPH00Z080200024
DIAMETER
(Outside diameter x inside diam-
eter)
INSERTION LENGTH
mm {in.}
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}
SAPH00Z080200025
Less than 5˚
SAPH00Z080200026

• Before inserting the tube, mark the insertion length on the tube with a
white-out pen or similar implement, in accordance with the dimen-
sions, "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: N˜m {kgf˜cm, lbf˜ft}
NOTICE
Nuts must be tightened to 5q- 35qC.
4. ASSEMBLING THE CAULKING JOINT (AFTER THE TUBE HAS
FIRST BEEN REMOVED FROM THE JOINT AND THEN RE-
INSTALLED 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 60q 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 -40-90qC, 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 overbend-
ing.
NUT DIAMETERS TIGHTENING TORQUE
I1/4 in. 20-26 {200-270, 15-19}
I3.8 in. 35-45 {350-460, 26-33}
I1/2 in. 50-60 {500-610, 37-44}
Aligning marks
SAPH00Z080200027
OUTSIDE DIAMETER OF
TUBE
MINIMUM BENDING RADIUS DURING
HANDLING: R mm {in.}
I1/2 in. 30 {1.18}
I3/8 in. 65 {2.56}
I1/2 in. 70 {2.76}

METRIC INFORMATION
EN00Z08021200001
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 dam-
age 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 indi-
cating 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.
Metric system
M12-1.75 25
D T 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 corre-
spond to bolt strength. Increasing numbers rep-
resent increasing strength.
Nomenclature for bolts
Bolt strength identification
Bolt
SAPH00Z080200028

2016 hino 258 lp series truck service repair manual

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