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2018 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL – PDF DOWNLOAD
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2018 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
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2018 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
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2018 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
Language : English
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2018 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL – PDF DOWNLOAD:
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Table of Contents:
2018 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
FOREWORD.................................................................................................................. 1 CHAPTER REFERENCES........................................................................................................ 2 INDEX..................................................................................................................... 3 GENERAL INTRODUCTION...................................................................................................... 5 HOW TO IDENTIFY VEHICLE TYPE.......................................................................................... 6 HOW TO IDENTIFY VEHICLE TYPE...................................................................................... 6 VEHICLE MODEL................................................................................................. 6 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE................................................................. 7 APPEARANCE OF VEHICLE................................................................................................. 8 APPEARANCE........................................................................................................ 8 APPEARANCE OF VEHICLE......................................................................................... 8 SAFETY INSTRUCTIONS AND READINESS TO WORK............................................................................. 9 WARNING........................................................................................................... 9 GENERAL PRECAUTIONS........................................................................................... 9 IDENTIFICATION INFORMATION.................................................................................... 13 SAFETY INSTRUCTIONS FOR WORK...................................................................................... 16 PRECAUTIONS................................................................................................... 16 INTRODUCTION TO WORKSHOP MANUAL................................................................................... 20 GENERAL....................................................................................................... 20 INTRODUCTION TO DESCRIPTIONS.................................................................................. 21 DEFINITION OF TERM............................................................................................ 23 TIGHTENING OF BOLTS AND NUTS...................................................................................... 24 BOLTS AND NUTS................................................................................................ 24 PURPOSES OF TIGHTENING TORQUE................................................................................. 24 CAUTIONS TO PREVENT LOOSENESS................................................................................. 24 TYPES AND IDENTIFICATION...................................................................................... 25 COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)............................................................ 26 STRENGTH CLASSES AND SYMBOLS.................................................................................. 27 PART No....................................................................................................... 28 LIST OF TIGHTENING TORQUE..................................................................................... 29 TIGHTENING OF FLARE NUTS AND HOSES............................................................................ 31 HANDLING OF LIQUID GASKET......................................................................................... 32 LIQUID GASKET................................................................................................. 32 GLOSSARY.............................................................................................................. 33 DEFINITION OF ABBREVIATION IN THIS MANUAL......................................................................... 33 LIST OF ABBREVIATION.......................................................................................... 33 GLOSSARY OF SAE AND HINO TERMS................................................................................ 36 LUBRICANTS............................................................................................................ 39 LUBRICANTS........................................................................................................ 39 RECOMMENDED LUBRICANTS........................................................................................ 39 HYBRID.................................................................................................................... 41 STANDARD VALUE........................................................................................................ 42 HYBRID SYSTEM..................................................................................................... 42 SERVICE PLUG.................................................................................................. 42 PCU........................................................................................................... 42 HV BATTERY.................................................................................................... 43 HV BATTERY COOLING FAN........................................................................................ 43 HV BATTERY ECU................................................................................................ 43 SYSTEM MAIN RELAY JUNCTION BLOCK.............................................................................. 43 INVERTER...................................................................................................... 44 HV-ECU........................................................................................................ 44 HYBRID JUNCTION BLOCK......................................................................................... 44 WATER PUMP.................................................................................................... 45 INVERTER RADIATOR............................................................................................. 45 COOLANT....................................................................................................... 45 MOTOR CABLE................................................................................................... 45 REQUIRED ITEMS........................................................................................................ 46 HYBRID SYSTEM..................................................................................................... 46 HYBRID SYSTEM................................................................................................. 46 SERVICE PLUG.................................................................................................. 46 COOLANT....................................................................................................... 46 HYBRID SYSTEM......................................................................................................... 47 HYBRID SYSTEM..................................................................................................... 47 CAUTIONS...................................................................................................... 47 SERVICE PLUG...................................................................................................... 51 COMPONENT LOCATOR............................................................................................. 51 UNIT CHECK.................................................................................................... 51 REPLACEMENT................................................................................................... 52 PCU............................................................................................................... 54 COMPONENT LOCATOR............................................................................................. 54 REPLACEMENT................................................................................................... 58 HV BATTERY........................................................................................................ 63 COMPONENT LOCATOR............................................................................................. 63 REPLACEMENT................................................................................................... 65 HV BATTERY COOLING FAN............................................................................................ 70 COMPONENT LOCATOR............................................................................................. 70 REPLACEMENT................................................................................................... 72 HV BATTERY ECU.................................................................................................... 75 COMPONENT LOCATOR............................................................................................. 75 REPLACEMENT................................................................................................... 76 SYSTEM MAIN RELAY JUNCTION BLOCK.................................................................................. 79 COMPONENT LOCATOR............................................................................................. 79 REPLACEMENT................................................................................................... 80 INVERTER.......................................................................................................... 82 COMPONENT LOCATOR............................................................................................. 82 REPLACEMENT................................................................................................... 83 HV-ECU............................................................................................................ 87 COMPONENT LOCATOR............................................................................................. 87 REPLACEMENT................................................................................................... 88 HYBRID JUNCTION BLOCK............................................................................................. 90 COMPONENT LOCATOR............................................................................................. 90 REPLACEMENT................................................................................................... 91 WATER PUMP........................................................................................................ 94 COMPONENT LOCATOR............................................................................................. 94 REPLACEMENT................................................................................................... 95 INVERTER RADIATOR................................................................................................. 98 COMPONENT LOCATOR............................................................................................. 98 REPLACEMENT................................................................................................... 99 COOLANT........................................................................................................... 102 REPLACEMENT................................................................................................... 102 MOTOR CABLE....................................................................................................... 104 COMPONENT LOCATOR............................................................................................. 104 REPLACEMENT................................................................................................... 107 TRANSMISSION (A465)....................................................................................................... 113 STANDARD VALUE........................................................................................................ 114 ATTACHING AND DETACHING THE TRANSMISSION.......................................................................... 114 AUTOMATIC TRANSMISSION ASSEMBLY............................................................................... 114 TRANSMISSION CONTROL.............................................................................................. 116 SHIFT LEVER ASSEMBLY.......................................................................................... 116 TRANSMISSION MECHANICAL........................................................................................... 116 TURBINE SENSOR................................................................................................ 116 SPEED SENSOR.................................................................................................. 116 NEUTRAL SWITCH................................................................................................ 117 EOP........................................................................................................... 117 VALVE BODY ASSEMBLY........................................................................................... 117 REQUIRED ITEMS........................................................................................................ 118 ATTACHING AND DETACHING THE TRANSMISSION.......................................................................... 118 AUTOMATIC TRANSMISSION ASSEMBLY............................................................................... 118 NEUTRAL SWITCH................................................................................................ 118 FRONT OIL SEAL................................................................................................ 118 ATTACHING AND DETACHING THE TRANSMISSION.............................................................................. 119 AUTOMATIC TRANSMISSION ASSEMBLY................................................................................... 119 REPLACEMENT................................................................................................... 119 TRANSMISSION CONTROL.................................................................................................. 160 CONTROL COMPUTER ASSEMBLY ........................................................................................ 160 COMPONENT LOCATOR............................................................................................. 160 OVERHAUL...................................................................................................... 161 SHIFT LEVER ASSEMBLY.............................................................................................. 167 COMPONENT LOCATOR............................................................................................. 167 OVERHAUL...................................................................................................... 168 TRANSMISSION MECHANICAL............................................................................................... 172 OIL PAN GASKET.................................................................................................... 172 COMPONENT LOCATOR............................................................................................. 172 OVERHAUL...................................................................................................... 173 REAR CASE GASKET.................................................................................................. 175 COMPONENT LOCATOR............................................................................................. 175 OVERHAUL...................................................................................................... 176 TURBINE SENSOR.................................................................................................... 179 COMPONENT LOCATOR............................................................................................. 179 OVERHAUL...................................................................................................... 180 SPEED SENSOR...................................................................................................... 181 COMPONENT LOCATOR............................................................................................. 181 OVERHAUL...................................................................................................... 182 NEUTRAL SWITCH.................................................................................................... 183 COMPONENT LOCATOR............................................................................................. 183 OVERHAUL...................................................................................................... 184 EOP............................................................................................................... 186 OVERHAUL...................................................................................................... 186 VALVE BODY ASSEMBLY............................................................................................... 193 OVERHAUL...................................................................................................... 193 FRONT OIL SEAL.................................................................................................... 202 OVERHAUL...................................................................................................... 202 PROPELLER SHAFT (LD)...................................................................................................... 204 STANDARD VALUE........................................................................................................ 205 PROPELLER SHAFT MECHANICAL........................................................................................ 205 PROPELLER SHAFT ASSEMBLY...................................................................................... 205 REQUIRED ITEMS........................................................................................................ 206 PROPELLER SHAFT MECHANICAL........................................................................................ 206 PROPELLER SHAFT ASSEMBLY...................................................................................... 206 PROPELLER SHAFT MECHANICAL............................................................................................ 208 PROPELLER SHAFT ASSEMBLY.......................................................................................... 208 COMPONENT LOCATOR............................................................................................. 208 PROPELLER SHAFT ASSEMBLY.......................................................................................... 210 OVERHAUL...................................................................................................... 210 AXLE...................................................................................................................... 225 STANDARD VALUE........................................................................................................ 226 FRONT AXLE........................................................................................................ 226 STEERING KNUCKLE.............................................................................................. 226 FRONT AXLE HUB................................................................................................ 227 REAR AXLE......................................................................................................... 228 REAR AXLE HUB................................................................................................. 228 REAR AXLE SHAFT............................................................................................... 229 REQUIRED ITEMS........................................................................................................ 230 FRONT AXLE........................................................................................................ 230 STEERING KNUCKLE.............................................................................................. 230 FRONT AXLE HUB................................................................................................ 231 REAR AXLE......................................................................................................... 234 REAR AXLE HUB................................................................................................. 234 REAR AXLE SHAFT............................................................................................... 235 WHEEL AND TIRE................................................................................................ 236 FRONT AXLE............................................................................................................ 237 STEERING KNUCKLE.................................................................................................. 237 COMPONENT LOCATOR............................................................................................. 237 OVERHAUL...................................................................................................... 241 FRONT AXLE HUB.................................................................................................... 256 COMPONENT LOCATOR............................................................................................. 256 OVERHAUL...................................................................................................... 258 FRONT AXLE HUB BOLT............................................................................................... 269 COMPONENT LOCATOR............................................................................................. 269 OVERHAUL...................................................................................................... 270 REAR AXLE............................................................................................................. 272 REAR AXLE HUB..................................................................................................... 272 COMPONENT LOCATOR............................................................................................. 272 OVERHAUL...................................................................................................... 274 REAR AXLE SHAFT................................................................................................... 284 COMPONENT LOCATOR............................................................................................. 284 OVERHAUL...................................................................................................... 285 WHEEL AND TIRE........................................................................................................ 287 WHEEL AND TIRE.................................................................................................... 287 COMPONENT LOCATOR............................................................................................. 287 INSPECTION.................................................................................................... 288 REPLACEMENT................................................................................................... 290 OVERHAUL (TUBELESS TIRE)...................................................................................... 293 DIFFERENTIAL (SH13)....................................................................................................... 300 STANDARD VALUE........................................................................................................ 301 DIFFERENTIAL...................................................................................................... 301 DIFFERENTIAL CARRIER.......................................................................................... 301 REQUIRED ITEMS........................................................................................................ 303 DIFFERENTIAL...................................................................................................... 303 DIFFERENTIAL CARRIER.......................................................................................... 303 DIFFERENTIAL.......................................................................................................... 306 DIFFERENTIAL CARRIER.............................................................................................. 306 COMPONENT LOCATOR............................................................................................. 306 OVERHAUL...................................................................................................... 314 BRAKE..................................................................................................................... 351 STANDARD VALUE........................................................................................................ 353 BRAKE CONTROL..................................................................................................... 353 SERVICE BRAKE................................................................................................. 353 BRAKE FLUID................................................................................................... 353 BRAKE ACTUATOR................................................................................................ 354 SPEED SENSOR.................................................................................................. 354 BRAKE PEDAL................................................................................................... 355 BRAKE MASTER CYLINDER......................................................................................... 355 BRAKE BOOSTER................................................................................................. 355 HYDRO BOOSTER................................................................................................. 356 ELECTRIC VACUUM PUMP.......................................................................................... 356 VACUUM PUMP................................................................................................... 356 HYDRO PUMP.................................................................................................... 357 VACUUM RESERVOIR.............................................................................................. 357 FRONT FLEXIBLE HOSE........................................................................................... 357 REAR FLEXIBLE HOSE............................................................................................ 357 VACUUM WARNING BUZZER......................................................................................... 357 VACUUM SENSOR (FOR SKID CONTROL).............................................................................. 358 DISC BRAKE ....................................................................................................... 358 FRONT DISC CALIPER............................................................................................ 358 REAR DISC CALIPER............................................................................................. 359 PARKING BRAKE..................................................................................................... 360 PARKING BRAKE................................................................................................. 360 PARKING BRAKE CABLE No.2...................................................................................... 360 PARKING BRAKE CABLE No.3...................................................................................... 360 PARKING BRAKE LEVER........................................................................................... 360 PARKING BRAKE DRUM............................................................................................ 361 PARKING BRAKE SWITCH.......................................................................................... 361 REQUIRED ITEMS........................................................................................................ 362 SERVICE BRAKE..................................................................................................... 362 SERVICE BRAKE................................................................................................. 362 BRAKE FLUID................................................................................................... 362 SPEED SENSOR.................................................................................................. 362 BRAKE PEDAL................................................................................................... 362 BRAKE BOOSTER................................................................................................. 362 HYDRO BOOSTER................................................................................................. 363 VACUUM RESERVOIR.............................................................................................. 363 DISC BRAKE........................................................................................................ 363 FRONT DISC CALIPER............................................................................................ 363 REAR DISC CALIPER............................................................................................. 363 PARKING BRAKE..................................................................................................... 364 PARKING BRAKE DRUM............................................................................................ 364 BRAKE CONTROL......................................................................................................... 365 SERVICE BRAKE..................................................................................................... 365 INSPECTION AND ADJUSTMENT..................................................................................... 365 BRAKE FLUID....................................................................................................... 370 REPLACEMENT................................................................................................... 370 ABS ACTUATOR...................................................................................................... 373 COMPONENT LOCATOR............................................................................................. 373 REPLACEMENT................................................................................................... 374 UNIT CHECK.................................................................................................... 376 SPEED SENSOR...................................................................................................... 377 COMPONENT LOCATOR............................................................................................. 377 UNIT CHECK.................................................................................................... 379 REPLACEMENT................................................................................................... 380 BRAKE PEDAL....................................................................................................... 383 COMPONENT LOCATOR............................................................................................. 383 REPLACEMENT................................................................................................... 384 BRAKE MASTER CYLINDER............................................................................................. 387 COMPONENT LOCATOR............................................................................................. 387 REPLACEMENT................................................................................................... 388 BRAKE BOOSTER..................................................................................................... 391 COMPONENT LOCATOR............................................................................................. 391 REPLACEMENT................................................................................................... 392 HYDRO BOOSTER..................................................................................................... 400 COMPONENT LOCATOR............................................................................................. 400 REPLACEMENT................................................................................................... 401 ELECTRIC VACUUM PUMP.............................................................................................. 406 COMPONENT LOCATOR............................................................................................. 406 OVERHAUL...................................................................................................... 407 VACUUM PUMP....................................................................................................... 411 COMPONENT LOCATOR............................................................................................. 411 OVERHAUL...................................................................................................... 412 HYDRO PUMP........................................................................................................ 414 COMPONENT LOCATOR............................................................................................. 414 OVERHAUL...................................................................................................... 415 VACUUM RESERVOIR.................................................................................................. 416 COMPONENT LOCATOR............................................................................................. 416 REPLACEMENT................................................................................................... 417 FRONT FLEXIBLE HOSE............................................................................................... 419 COMPONENT LOCATOR............................................................................................. 419 REPLACEMENT................................................................................................... 420 REAR FLEXIBLE HOSE................................................................................................ 422 COMPONENT LOCATOR............................................................................................. 422 REPLACEMENT................................................................................................... 423 VACUUM WARNING BUZZER............................................................................................. 425 BEHIND-THE-WHEEL INSPECTION................................................................................... 425 REPLACEMENT................................................................................................... 425 VACUUM SENSOR (FOR SKID CONTROL).................................................................................. 426 COMPONENT LOCATOR............................................................................................. 426 REPLACEMENT................................................................................................... 427 DISC BRAKE............................................................................................................ 430 FRONT BRAKE CALIPER............................................................................................... 430 COMPONENT LOCATOR............................................................................................. 430 OVERHAUL...................................................................................................... 431 REAR BRAKE CALIPER................................................................................................ 438 COMPONENT LOCATOR............................................................................................. 438 OVERHAUL...................................................................................................... 439 PARKING BRAKE......................................................................................................... 446 PARKING BRAKE..................................................................................................... 446 INSPECTION AND ADJUSTMENT..................................................................................... 446 PARKING BRAKE CABLE No.2.......................................................................................... 448 COMPONENT LOCATOR............................................................................................. 448 REPLACEMENT................................................................................................... 449 PARKING BRAKE CABLE No.3.......................................................................................... 455 COMPONENT LOCATOR............................................................................................. 455 REPLACEMENT................................................................................................... 456 PARKING BRAKE LEVER............................................................................................... 461 COMPONENT LOCATOR............................................................................................. 461 REPLACEMENT................................................................................................... 462 PARKING BRAKE DRUM................................................................................................ 466 COMPONENT LOCATOR............................................................................................. 466 OVERHAUL...................................................................................................... 468 PARKING BRAKE SWITCH.............................................................................................. 478 COMPONENT LOCATOR............................................................................................. 478 REPLACEMENT................................................................................................... 479 STEERING.................................................................................................................. 481 STANDARD VALUE........................................................................................................ 482 STEERING CONTROL.................................................................................................. 482 POWER STEERING SYSTEM......................................................................................... 482 STEERING WHEEL................................................................................................ 482 STEERING COLUMN............................................................................................... 482 STEERING LINKAGE.............................................................................................. 483 POWER STEERING GEAR........................................................................................... 483 POWER STEERING PUMP........................................................................................... 483 REQUIRED ITEMS........................................................................................................ 484 STEERING CONTROL.................................................................................................. 484 POWER STEERING SYSTEM......................................................................................... 484 STEERING WHEEL................................................................................................ 484 STEERING COLUMN............................................................................................... 485 STEERING LINKAGE.............................................................................................. 485 POWER STEERING GEAR........................................................................................... 486 POWER STEERING PUMP........................................................................................... 486 STEERING CONTROL...................................................................................................... 487 POWER STEERING SYSTEM............................................................................................. 487 PERFORMANCE INSPECTION........................................................................................ 487 STEERING WHEEL.................................................................................................... 490 COMPONENT LOCATOR............................................................................................. 490 REPLACEMENT................................................................................................... 491 STEERING COLUMN................................................................................................... 494 COMPONENT LOCATOR............................................................................................. 494 REPLACEMENT................................................................................................... 495 STEERING LINKAGE.................................................................................................. 502 COMPONENT LOCATOR............................................................................................. 502 REPLACEMENT................................................................................................... 503 POWER STEERING GEAR............................................................................................... 510 COMPONENT LOCATOR............................................................................................. 510 REPLACEMENT................................................................................................... 511 POWER STEERING PUMP............................................................................................... 522 COMPONENT LOCATOR............................................................................................. 522 REPLACEMENT .................................................................................................. 523 SUSPENSION................................................................................................................ 525 STANDARD VALUE........................................................................................................ 526 FRONT SUSPENSION.................................................................................................. 526 SHOCK ABSORBER................................................................................................ 526 LEAF SPRING................................................................................................... 526 STABILIZER.................................................................................................... 527 WHEEL ALIGNMENT............................................................................................... 527 REAR SUSPENSION................................................................................................... 528 SHOCK ABSORBER................................................................................................ 528 LEAF SPRING................................................................................................... 528 REQUIRED ITEMS........................................................................................................ 529 FRONT SUSPENSION.................................................................................................. 529 SHOCK ABSORBER................................................................................................ 529 LEAF SPRING................................................................................................... 529 WHEEL ALIGNMENT............................................................................................... 530 REAR SUSPENSION................................................................................................... 531 SHOCK ABSORBER................................................................................................ 531 LEAF SPRING................................................................................................... 531 FRONT SUSPENSION...................................................................................................... 532 SHOCK ABSORBER.................................................................................................... 532 COMPONENT LOCATOR............................................................................................. 532 REPLACEMENT................................................................................................... 533 LEAF SPRING....................................................................................................... 536 COMPONENT LOCATOR............................................................................................. 536 OVERHAUL...................................................................................................... 537 STABILIZER........................................................................................................ 545 COMPONENT LOCATOR............................................................................................. 545 REPLACEMENT................................................................................................... 546 WHEEL ALIGNMENT................................................................................................... 548 ADJUSTMENT.................................................................................................... 548 REAR SUSPENSION....................................................................................................... 552 SHOCK ABSORBER.................................................................................................... 552 COMPONENT LOCATOR............................................................................................. 552 REPLACEMENT................................................................................................... 553 LEAF SPRING....................................................................................................... 556 COMPONENT LOCATOR............................................................................................. 556 OVERHAUL...................................................................................................... 558 FRAME AND FRAME ACCESSORY................................................................................................. 567 STANDARD VALUE........................................................................................................ 568 FRAME............................................................................................................. 568 CHASSIS FRAME................................................................................................. 568 FRONT BUMPER.................................................................................................. 569 REQUIRED ITEMS........................................................................................................ 570 FRAME............................................................................................................. 570 CHASSIS FRAME & CHASSIS FRAME ACCESSORIES..................................................................... 570 FRAME................................................................................................................. 571 FRAME AND FRAME ACCESSORIES....................................................................................... 571 COMPONENT LOCATOR............................................................................................. 571 FRAME............................................................................................................. 572 INSPECTION.................................................................................................... 572 REPAIR........................................................................................................ 573 FRONT BUMPER...................................................................................................... 578 COMPONENT LOCATOR............................................................................................. 578 REPLACEMENT................................................................................................... 579 CAB MOUNTING AND CAB SUSPENSION........................................................................................... 584 STANDARD VALUE........................................................................................................ 585 CAB MOUNTING AND CAB SUSPENSION................................................................................... 585 ASSEMBLY...................................................................................................... 585 CAB MOUNTING.................................................................................................. 585 TILT CAB STAY................................................................................................. 586 MOUNTING AND DISMOUNTING CAB.......................................................................................... 587 CAB ASSEMBLY...................................................................................................... 587 REPLACEMENT................................................................................................... 587 CAB MOUNTING AND CAB SUSPENSION....................................................................................... 601 CAB MOUNTING...................................................................................................... 601 COMPONENT LOCATOR............................................................................................. 601 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................... 605 REPLACEMENT................................................................................................... 606 CAB TILT STAY..................................................................................................... 617 COMPONENT LOCATOR............................................................................................. 617 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................... 620 REPLACEMENT................................................................................................... 621 CAB DIMENSIONAL DRAWING............................................................................................... 626 CAB ASSEMBLY...................................................................................................... 626 SINGLE CAB.................................................................................................... 626 CREW CAB...................................................................................................... 628 BODY INSIDE ACCESSORY..................................................................................................... 630 STANDARD VALUE........................................................................................................ 631 INSTRUMENT PANEL AND DRIVER INFORMATION........................................................................... 631 INSTRUMENT PANEL.............................................................................................. 631 INTERIOR ACCESSORY................................................................................................ 631 ROOF ACCESSORY................................................................................................ 631 SEAT.............................................................................................................. 631 DRIVER'S SEAT................................................................................................. 631 ASSISTANT'S SEAT.............................................................................................. 632 REAR SEAT..................................................................................................... 632 INSTRUMENT PANEL AND DRIVER INFORMATION............................................................................... 633 INSTRUMENT PANEL.................................................................................................. 633 COMPONENT LOCATOR............................................................................................. 633 REPLACEMENT................................................................................................... 635 COMBINATION METER................................................................................................. 645 REPLACEMENT................................................................................................... 645 INTERIOR ACCESSORY.................................................................................................... 646 INTERIOR ACCESSORY................................................................................................ 646 COMPONENT LOCATOR............................................................................................. 646 REPLACEMENT................................................................................................... 648 FLOOR ACCESSORY................................................................................................... 651 COMPONENT LOCATOR............................................................................................. 651 REPLACEMENT................................................................................................... 652 ROOF ACCESSORY.................................................................................................... 653 COMPONENT LOCATOR............................................................................................. 653 REPLACEMENT................................................................................................... 654 SEAT.................................................................................................................. 661 DRIVER'S SEAT..................................................................................................... 661 COMPONENT LOCATOR............................................................................................. 661 OVERHAUL...................................................................................................... 663 ASSISTANT'S SEAT.................................................................................................. 675 COMPONENT LOCATOR............................................................................................. 675 OVERHAUL (THREE-SEATER)....................................................................................... 678 OVERHAUL (CREW CAB)........................................................................................... 686 REAR SEAT......................................................................................................... 692 COMPONENT LOCATOR............................................................................................. 692 OVERHAUL...................................................................................................... 694 BODY OUTSIDE ACCESSORY.................................................................................................... 704 STANDARD VALUE........................................................................................................ 705 DOOR.............................................................................................................. 705 DOOR HINGE.................................................................................................... 705 DOOR ACCESSORIES.............................................................................................. 705 REQUIRED ITEMS........................................................................................................ 706 DOOR.............................................................................................................. 706 DOOR ACCESSORIES.............................................................................................. 706 POWER WINDOW.................................................................................................. 706 AUTO DOOR LOCK SYSTEM......................................................................................... 706 WINDOW GLASS...................................................................................................... 707 GLASS......................................................................................................... 707 MIRROR............................................................................................................ 708 POWER MIRROR.................................................................................................. 708 DOOR.................................................................................................................. 709 DOOR HINGE........................................................................................................ 709 INSPECTION AND ADJUSTMENT..................................................................................... 709 DOOR ACCESSORY.................................................................................................... 713 COMPONENT LOCATOR............................................................................................. 713 OVERHAUL...................................................................................................... 719 POWER WINDOW...................................................................................................... 741 SINGLE UNIT INSPECTION........................................................................................ 741 AUTO DOOR LOCK SYSTEM............................................................................................. 744 PERFORMANCE INSPECTION........................................................................................ 744 SINGLE UNIT INSPECTION........................................................................................ 744 KEYLESS ENTRY..................................................................................................... 746 PERFORMANCE INSPECTION........................................................................................ 746 WINDOW GLASS.......................................................................................................... 747 GLASS............................................................................................................. 747 COMPONENT LOCATOR............................................................................................. 747 REPLACEMENT................................................................................................... 749 MIRROR................................................................................................................ 760 REAR VIEW MIRROR.................................................................................................. 760 COMPONENT LOCATOR............................................................................................. 760 REPLACEMENT................................................................................................... 761 POWER MIRROR...................................................................................................... 762 SINGLE UNIT INSPECTION........................................................................................ 762 ACCESSORY............................................................................................................. 763 OUTSIDE ACCESSORY................................................................................................. 763 COMPONENT LOCATOR............................................................................................. 763 REPLACEMENT................................................................................................... 764 AIR BAG AND SEAT BELT..................................................................................................... 769 STANDARD VALUE........................................................................................................ 770 SEAT BELT......................................................................................................... 770 SEAT BELT..................................................................................................... 770 CENTER SEAT BELT.............................................................................................. 770 REAR SEAT BELT................................................................................................ 771 SEAT BELT............................................................................................................. 772 SEAT BELT......................................................................................................... 772 COMPONENT LOCATOR............................................................................................. 772 REPLACEMENT................................................................................................... 773 CENTER SEAT BELT.................................................................................................. 775 COMPONENT LOCATOR............................................................................................. 775 REPLACEMENT................................................................................................... 776 REAR SEAT BELT.................................................................................................... 777 COMPONENT LOCATOR............................................................................................. 777 REPLACEMENT................................................................................................... 778 HEATER AND AIR CONDITIONER................................................................................................ 781 STANDARD VALUE........................................................................................................ 782 AIR CONDITIONER................................................................................................... 782 AIR CONDITIONER............................................................................................... 782 V-BELT........................................................................................................ 783 COOLER COMPRESSOR............................................................................................. 783 CONDENSER..................................................................................................... 783 HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)......................................................... 784 HEATER CONTROL................................................................................................ 784 REAR HEATER (CREW CAB)........................................................................................ 784 REAR COOLER (CREW CAB)........................................................................................ 785 REQUIRED ITEMS........................................................................................................ 786 AIR CONDITIONER................................................................................................... 786 AIR CONDITIONER............................................................................................... 786 V-BELT........................................................................................................ 786 COOLER COMPRESSOR............................................................................................. 787 CONDENSER..................................................................................................... 787 AIR CONDITIONER....................................................................................................... 788 AIR CONDITIONER................................................................................................... 788 SAFETY INSTRUCTIONS FOR WORK.................................................................................. 788 COLLECTION/FILLING OF REFRIGERANT............................................................................. 792 MAINTENANCE................................................................................................... 800 V-BELT............................................................................................................ 803 COMPONENT LOCATOR............................................................................................. 803 REPLACEMENT................................................................................................... 804 COOLER COMPRESSOR................................................................................................. 809 COMPONENT LOCATOR............................................................................................. 809 REPLACEMENT................................................................................................... 810 CONDENSER......................................................................................................... 814 COMPONENT LOCATOR............................................................................................. 814 REPLACEMENT................................................................................................... 815 HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)............................................................. 819 COMPONENT LOCATOR............................................................................................. 819 REPLACEMENT................................................................................................... 821 HEATER CONTROL.................................................................................................... 828 COMPONENT LOCATOR............................................................................................. 828 REPLACEMENT................................................................................................... 829 REAR HEATER (CREW CAB)............................................................................................ 832 COMPONENT LOCATOR............................................................................................. 832 REPLACEMENT................................................................................................... 833 REAR HEATER BLOWER SWITCH (CREW CAB).............................................................................. 839 COMPONENT LOCATOR............................................................................................. 839 REPLACEMENT................................................................................................... 840 REAR COOLER (CREW CAB)............................................................................................ 842 COMPONENT LOCATOR............................................................................................. 842 REPLACEMENT................................................................................................... 843 COOLER CONTROL SWITCH (CREW CAB).................................................................................. 850 COMPONENT LOCATOR............................................................................................. 850 REPLACEMENT................................................................................................... 851 ELECTRICAL................................................................................................................ 855 STANDARD VALUE........................................................................................................ 856 LIGHTING.......................................................................................................... 856 HEADLIGHT..................................................................................................... 856 WIPER AND WASHER.................................................................................................. 856 WIPER......................................................................................................... 856 WASHER........................................................................................................ 856 REQUIRED ITEMS........................................................................................................ 857 LIGHTING.......................................................................................................... 857 COMBINATION SWITCH............................................................................................ 857 LIGHTING.............................................................................................................. 858 HEADLIGHT......................................................................................................... 858 COMPONENT LOCATOR............................................................................................. 858 OPTICAL AXIS ADJUSTMENT....................................................................................... 859 REPLACEMENT................................................................................................... 860 FOG LIGHT......................................................................................................... 861 REPLACEMENT................................................................................................... 861 ID LIGHT.......................................................................................................... 862 COMPONENT LOCATOR............................................................................................. 862 REPLACEMENT................................................................................................... 863 ROOM LIGHT........................................................................................................ 864 COMPONENT LOCATOR............................................................................................. 864 REPLACEMENT................................................................................................... 865 COMBINATION SWITCH................................................................................................ 866 COMPONENT LOCATOR............................................................................................. 866 REPLACEMENT................................................................................................... 867 INSPECTION.................................................................................................... 867 WIPER AND WASHER...................................................................................................... 870 WIPER............................................................................................................. 870 COMPONENT LOCATOR............................................................................................. 870 REPLACEMENT................................................................................................... 871 WASHER............................................................................................................ 874 COMPONENT LOCATOR............................................................................................. 874 REPLACEMENT .................................................................................................. 875 COMPUTER.............................................................................................................. 877 COMPUTER.......................................................................................................... 877 MOUNTING POSITION............................................................................................. 877 SWITCH................................................................................................................ 879 SWITCH............................................................................................................ 879 MOUNTING POSITION............................................................................................. 879 FUSE AND RELAY........................................................................................................ 880 FUSE BLOCK........................................................................................................ 880 MOUNTING POSITION............................................................................................. 880 RELAY............................................................................................................. 882 MOUNTING POSITION............................................................................................. 882 CONTROL SYSTEM............................................................................................................ 883 REQUIRED ITEMS........................................................................................................ 884 HINO STOP&START SYSTEM............................................................................................ 884 SLOPE LEARNING................................................................................................ 884 HINO STOP&START SYSTEM................................................................................................ 885 HINO STOP&START SYSTEM............................................................................................ 885 SLOPE LEARNING................................................................................................ 885 CRUISE CONTROL........................................................................................................ 887 CRUISE MAIN SWITCH................................................................................................ 887 COMPONENT LOCATOR............................................................................................. 887 REPLACEMENT................................................................................................... 888 SINGLE UNIT INSPECTION........................................................................................ 889 FOREWORD.................................................................................................................. 891 CHAPTER REFERENCES........................................................................................................ 892 INDEX..................................................................................................................... 893 GENERAL INTRODUCTION...................................................................................................... 895 HOW TO IDENTIFY VEHICLE TYPE.......................................................................................... 896 VEHICLE MODEL..................................................................................................... 896 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE..................................................................... 897 APPEARANCE OF VEHICLE................................................................................................. 898 APPEARANCE OF VEHICLE............................................................................................. 898 SAFETY INSTRUCTIONS AND READINESS TO WORK............................................................................. 899 WARNING........................................................................................................... 899 IDENTIFICATION INFORMATION........................................................................................ 903 SAFETY INSTRUCTIONS FOR WORK...................................................................................... 906 INTRODUCTION TO WORKSHOP MANUAL................................................................................... 909 TIGHTENING OF BOLTS AND NUTS...................................................................................... 913 HANDLING OF LIQUID GASKET......................................................................................... 923 GLOSSARY.............................................................................................................. 924 DEFINITION OF ABBREVIATION IN THIS MANUAL......................................................................... 924 LUBRICANTS............................................................................................................ 930 RECOMMENDED LUBRICANTS............................................................................................ 930 STANDARD VALUE (J05E) .................................................................................................... 931 MOUNTING AND DISMOUNTING THE ENGINE................................................................................... 933 ENGINE ASSEMBLY................................................................................................... 933 ENGINE CONTROL........................................................................................................ 934 ENGINE ECU........................................................................................................ 934 ENGINE SPEED MAIN SENSOR.......................................................................................... 934 ENGINE SPEED SUB SENSOR........................................................................................... 934 ACCELERATOR PEDAL................................................................................................. 935 BLOCK HEATER...................................................................................................... 935 FUEL SYSTEM........................................................................................................... 936 FUEL TANK......................................................................................................... 936 FUEL SENDER GAUGE................................................................................................. 936 ENGINE-SIDE FUEL FILTER & CASE.................................................................................... 937 SUPPLY PUMP....................................................................................................... 938 INJECTOR.......................................................................................................... 938 COMMON RAIL....................................................................................................... 939 VEHICLE-SIDE FUEL FILTER.......................................................................................... 939 WATER LEVEL WARNING SWITCH........................................................................................ 939 FUEL COOLER....................................................................................................... 940 EMISSION CONTROL...................................................................................................... 941 EGR VALVE & COOLER................................................................................................ 941 CLOSED VENTILATOR................................................................................................. 941 INTAKE................................................................................................................ 942 INTAKE MANIFOLD................................................................................................... 942 DIESEL THROTTLE................................................................................................... 942 INTAKE PIPE (EXHAUST SIDE)........................................................................................ 942 STACK DUCT........................................................................................................ 942 AIR CLEANER....................................................................................................... 943 INTAKE TEMPERATURE SENSOR......................................................................................... 943 BOOST PRESSURE SENSOR............................................................................................. 943 AIR FLOW SENSOR................................................................................................... 943 ENGINE MECHANICAL..................................................................................................... 944 HEAD COVER........................................................................................................ 944 ROCKER ARM ASSEMBLY............................................................................................... 944 CAMSHAFT ASSEMBLY................................................................................................. 945 CYLINDER HEAD ASSEMBLY............................................................................................ 946 VALVE SYSTEM...................................................................................................... 947 CRANKSHAFT PULLEY................................................................................................. 948 FRONT OIL SEAL RETAINER........................................................................................... 948 FLYWHEEL ASSEMBLY................................................................................................. 948 FLYWHEEL HOUSING.................................................................................................. 948 TIMING GEAR & CAM IDLE GEAR....................................................................................... 949 PISTON & CONNECTING ROD........................................................................................... 950 CRANKSHAFT........................................................................................................ 951 CYLINDER LINER.................................................................................................... 952 CYLINDER BLOCK.................................................................................................... 952 ENGINE MOUNTING AND BRACKET....................................................................................... 953 GLOW PLUG......................................................................................................... 953 EXHAUST............................................................................................................... 954 EXHAUST MANIFOLD.................................................................................................. 954 EXHAUST PIPE...................................................................................................... 954 EXHAUST PIPE (ATC)................................................................................................ 954 DEF-SCR........................................................................................................... 955 DPR CLEANER....................................................................................................... 955 FUEL ADDITION VALVE............................................................................................... 956 FUEL CUTOFF VALVE................................................................................................. 956 DEF PUMP.......................................................................................................... 956 DEF INJECTOR...................................................................................................... 957 DEF TANK.......................................................................................................... 957 COOLANT CUTOFF VALVE.............................................................................................. 957 DCU............................................................................................................... 958 DPR DIFFERENTIAL PRESSURE SENSOR.................................................................................. 958 SCR UPSTREAM NOx SENSOR........................................................................................... 958 SCR DOWNSTREAM NOx SENSOR......................................................................................... 958 PM SENSOR......................................................................................................... 959 EXHAUST TEMPERATURE SENSOR No.1 (ATC INLET)....................................................................... 959 EXHAUST TEMPERATURE SENSOR No.0 (ATC OUTLET)...................................................................... 959 EXHAUST TEMPERATURE SENSOR No.2 (DOC INLET)....................................................................... 960 EXHAUST TEMPERATURE SENSOR No.3 (DPR INLET)....................................................................... 960 EXHAUST TEMPERATURE SENSOR No.4 (DPR OUTLET)...................................................................... 960 SCR UPSTREAM TEMPERATURE SENSOR................................................................................... 961 EXHAUST BRAKE..................................................................................................... 962 EXHAUST BRAKE MAGNETIC VALVE...................................................................................... 962 COOLING............................................................................................................... 963 RADIATOR.......................................................................................................... 963 RADIATOR CAP...................................................................................................... 963 RESERVE TANK...................................................................................................... 963 INTERCOOLER....................................................................................................... 964 THERMOSTAT CASE & THERMOSTAT...................................................................................... 964 COOLANT PUMP...................................................................................................... 964 COOLING FAN & FAN CLUTCH.......................................................................................... 965 COOLANT TEMPERATURE SENSOR........................................................................................ 965 LUBRICATION........................................................................................................... 966 OIL COOLER........................................................................................................ 966 OIL PUMP.......................................................................................................... 966 OIL PAN........................................................................................................... 967 OIL STRAINER...................................................................................................... 967 OIL PRESSURE SWITCH............................................................................................... 967 OIL LEVEL GAUGE AND GUIDE......................................................................................... 967 STARTING/CHARGING..................................................................................................... 968 STARTER........................................................................................................... 968 V-BELT............................................................................................................ 968 ALTERNATOR (130 A)................................................................................................ 969 TURBOCHARGER.......................................................................................................... 970 TURBOCHARGER ASSEMBLY............................................................................................. 970 REQUIRED ITEMS (J05E) .................................................................................................... 971 MOUNTING AND DISMOUNTING THE ENGINE................................................................................... 972 ENGINE ASSEMBLY................................................................................................... 972 ENGINE CONTROL........................................................................................................ 973 ENGINE ECU........................................................................................................ 973 ENGINE MAIN REVOLUTION SENSOR..................................................................................... 973 ENGINE SUB REVOLUTION SENSOR...................................................................................... 974 ACCELERATOR PEDAL................................................................................................. 975 IDLE SET VOLUME................................................................................................... 975 FUEL SYSTEM........................................................................................................... 976 FUEL SENDER GAUGE................................................................................................. 976 WATER LEVEL WARNING SWITCH........................................................................................ 976 SUPPLY PUMP....................................................................................................... 977 INJECTOR.......................................................................................................... 978 COMMON RAIL....................................................................................................... 979 FUEL FILTER AND CASE (VEHICLE SIDE)............................................................................... 979 EMISSION CONTROL...................................................................................................... 980 EGR VALVE AND COOLER.............................................................................................. 980 INTAKE................................................................................................................ 981 DIESEL THROTTLE................................................................................................... 981 BOOST PRESSURE SENSOR............................................................................................. 982 AIR FLOW SENSOR................................................................................................... 983 ENGINE MECHANICAL..................................................................................................... 984 HEAD COVER........................................................................................................ 984 ROCKER ARM ASSEMBLY............................................................................................... 984 CAMSHAFT ASSEMBLY................................................................................................. 984 CYLINDER HEAD ASSEMBLY............................................................................................ 985 VALVE SYSTEM...................................................................................................... 986 CRANKSHAFT FRONT OIL SEAL......................................................................................... 987 FRONT OIL SEAL RETAINER........................................................................................... 987 FLYWHEEL ASSEMBLY................................................................................................. 987 CRANKSHAFT REAR OIL SEAL.......................................................................................... 988 FLYWHEEL HOUSING.................................................................................................. 988 TIMING GEAR AND CAM IDLE GEAR..................................................................................... 989 PISTON AND CONNECTING ROD......................................................................................... 991 CRANKSHAFT........................................................................................................ 993 CYLINDER LINER.................................................................................................... 994 CYLINDER BLOCK.................................................................................................... 995 GLOW PLUG......................................................................................................... 995 EXHAUST............................................................................................................... 996 EXHAUST MANIFOLD.................................................................................................. 996 DPR............................................................................................................... 996 FUEL ADDITION VALVE............................................................................................... 997 DEF PUMP.......................................................................................................... 997 DEF INJECTOR...................................................................................................... 997 DEF TANK.......................................................................................................... 998 DEF SENSOR........................................................................................................ 998 DPR DIFFERENTIAL PRESSURE SENSOR.................................................................................. 998 SCR UPSTREAM NOx SENSOR........................................................................................... 998 SCR DOWNSTREAM NOx SENSOR......................................................................................... 999 EXHAUST TEMPERATURE SENSOR No.1 (ATC INLET)....................................................................... 999 EXHAUST TEMPERATURE SENSOR No.0 (ATC OUTLET)...................................................................... 999 EXHAUST TEMPERATURE SENSOR No.2 (DOC INLET).......................................................................1000 EXHAUST TEMPERATURE SENSOR No.3 (DPR INLET).......................................................................1000 EXHAUST TEMPERATURE SENSOR No.4 (DPR OUTLET)......................................................................1000 SCR UPSTREAM TEMPERATURE SENSOR...................................................................................1001 EXHAUST BRAKE.....................................................................................................1001 EXHAUST BRAKE MAGNETIC VALVE......................................................................................1001 COOLING...............................................................................................................1002 RADIATOR CAP......................................................................................................1002 THERMOSTAT CASE AND THERMOSTAT....................................................................................1002 COOLANT PUMP......................................................................................................1003 COOLANT TEMPERATURE SENSOR........................................................................................1003 LUBRICATION...........................................................................................................1004 OIL FILTER........................................................................................................1004 OIL COOLER........................................................................................................1004 OIL PUMP..........................................................................................................1005 OIL PAN...........................................................................................................1005 OIL PRESSURE SWITCH...............................................................................................1005 STARTING/CHARGING.....................................................................................................1006 STARTER...........................................................................................................1006 V-BELT............................................................................................................1006 ALTERNATOR (130A).................................................................................................1006 TURBOCHARGER..........................................................................................................1007 TURBOCHARGER ASSEMBLY.............................................................................................1007 MOUNTING AND DISMOUNTING THE ENGINE (J05E)................................................................................1009 ENGINE ASSEMBLY.......................................................................................................1010 PRECAUTIONS IN TILTING AND LOWERING THE CAB.......................................................................1010 MEASUREMENT OF COMPRESSION PRESSURE...............................................................................1010 ADJUSTING THE VALVE CLEARANCE.....................................................................................1013 REPLACEMENT.......................................................................................................1015 ENGINE CONTROL (J05E) ....................................................................................................1024 CONTROL PARTS.........................................................................................................1025 SYSTEM BLOCK DIAGRAM..............................................................................................1025 ENGINE ECU............................................................................................................1026 COMPONENT LOCATOR.................................................................................................1026 REPLACEMENT.......................................................................................................1027 VEHICLE CONTROL ECU...................................................................................................1033 REPLACEMENT.......................................................................................................1033 ENGINE SPEED MAIN SENSOR..............................................................................................1034 COMPONENT LOCATOR.................................................................................................1034 INSPECTION........................................................................................................1035 REPLACEMENT.......................................................................................................1035 ENGINE SPEED SUB SENSOR...............................................................................................1036 COMPONENT LOCATOR.................................................................................................1036 INSPECTION........................................................................................................1037 REPLACEMENT.......................................................................................................1037 ACCELERATOR PEDAL.....................................................................................................1038 COMPONENT LOCATOR.................................................................................................1038 REPLACEMENT.......................................................................................................1039 BLOCK HEATER..........................................................................................................1040 COMPONENT LOCATOR.................................................................................................1040 REPLACEMENT.......................................................................................................1041 FUEL SENDER GAUGE.....................................................................................................1042 REPLACEMENT.......................................................................................................1042 INTAKE TEMPERATURE SENSOR.............................................................................................1042 REPLACEMENT.......................................................................................................1042 DIESEL THROTTLE.......................................................................................................1042 REPLACEMENT.......................................................................................................1042 BOOST PRESSURE SENSOR.................................................................................................1043 REPLACEMENT.......................................................................................................1043 AIR FLOW SENSOR.......................................................................................................1043 REPLACEMENT.......................................................................................................1043 DPR DIFFERENTIAL PRESSURE SENSOR......................................................................................1044 REPLACEMENT.......................................................................................................1044 SCR UPSTREAM NOx SENSOR...............................................................................................1044 REPLACEMENT.......................................................................................................1044 SCR DOWNSTREAM NOx SENSOR.............................................................................................1044 REPLACEMENT.......................................................................................................1044 PM SENSOR.............................................................................................................1045 REPLACEMENT.......................................................................................................1045 EXHAUST TEMPERATURE SENSOR No.1 (ATC INLET)...........................................................................1045 REPLACEMENT.......................................................................................................1045 EXHAUST TEMPERATURE SENSOR No.0 (ATC OUTLET)..........................................................................1046 REPLACEMENT.......................................................................................................1046 EXHAUST TEMPERATURE SENSOR No.2 (DOC INLET)...........................................................................1046 REPLACEMENT.......................................................................................................1046 EXHAUST TEMPERATURE SENSOR No.3 (DPR INLET)...........................................................................1047 REPLACEMENT.......................................................................................................1047 EXHAUST TEMPERATURE SENSOR No.4 (DPR OUTLET)..........................................................................1047 REPLACEMENT.......................................................................................................1047 SCR UPSTREAM TEMPERATURE SENSOR.......................................................................................1048 REPLACEMENT.......................................................................................................1048 OUTSIDE TEMPERATURE SENSOR............................................................................................1048 REPLACEMENT.......................................................................................................1048 COOLANT TEMPERATURE SENSOR............................................................................................1049 REPLACEMENT.......................................................................................................1049 OIL PRESSURE SWITCH...................................................................................................1049 REPLACEMENT.......................................................................................................1049 FUEL SYSTEM (J05E) .......................................................................................................1050 FUEL SYSTEM...........................................................................................................1051 FUEL SYSTEM DIAGRAM...............................................................................................1051 FUEL TANK.............................................................................................................1052 COMPONENT LOCATOR.................................................................................................1052 REPLACEMENT (30 GALLON)...........................................................................................1053 REPLACEMENT (33 GALLON)...........................................................................................1056 FUEL SENDER GAUGE.....................................................................................................1060 COMPONENT LOCATOR.................................................................................................1060 REPLACEMENT.......................................................................................................1061 FUEL FILTER AND CASE (ENGINE SIDE)....................................................................................1063 COMPONENT LOCATOR.................................................................................................1063 REPLACEMENT.......................................................................................................1065 SUPPLY PUMP...........................................................................................................1074 COMPONENT LOCATOR.................................................................................................1074 REPLACEMENT.......................................................................................................1075 INJECTOR..............................................................................................................1085 COMPONENT LOCATOR.................................................................................................1085 REPLACEMENT.......................................................................................................1086 COMMON RAIL...........................................................................................................1095 COMPONENT LOCATOR.................................................................................................1095 INSPECTION........................................................................................................1096 REPLACEMENT.......................................................................................................1097 FUEL FILTER AND CASE (VEHICLE SIDE)...................................................................................1102 COMPONENT LOCATOR.................................................................................................1102 REPLACEMENT.......................................................................................................1103 FUEL COOLER...........................................................................................................1110 COMPONENT LOCATOR.................................................................................................1110 REPLACEMENT.......................................................................................................1111 EMISSION CONTROL (J05E) ..................................................................................................1113 EGR VALVE & COOLER....................................................................................................1114 COMPONENT LOCATOR.................................................................................................1114 INSPECTION........................................................................................................1115 REPLACEMENT.......................................................................................................1115 CLOSED VENTILATOR.....................................................................................................1122 COMPONENT LOCATOR.................................................................................................1122 REPLACEMENT.......................................................................................................1124 INTAKE (J05E) ............................................................................................................1128 INTAKE MANIFOLD.......................................................................................................1129 COMPONENT LOCATOR.................................................................................................1129 REPLACEMENT.......................................................................................................1130 DIESEL THROTTLE.......................................................................................................1135 COMPONENT LOCATOR.................................................................................................1135 INSPECTION........................................................................................................1136 REPLACEMENT.......................................................................................................1136 INTAKE PIPE (EXHAUST SIDE)............................................................................................1138 COMPONENT LOCATOR.................................................................................................1138 REPLACEMENT.......................................................................................................1139 INTERCOOLER...........................................................................................................1145 OVERHAUL..........................................................................................................1145 STACK DUCT............................................................................................................1146 COMPONENT LOCATOR.................................................................................................1146 CLEANING THE PRECLEANER HOUSING...................................................................................1147 REPLACEMENT.......................................................................................................1148 AIR CLEANER...........................................................................................................1150 COMPONENT LOCATOR.................................................................................................1150 REPLACEMENT.......................................................................................................1152 CLEANING THE AIR CLEANER ELEMENT..................................................................................1156 INTAKE TEMPERATURE SENSOR.............................................................................................1157 COMPONENT LOCATOR.................................................................................................1157 REPLACEMENT.......................................................................................................1159 BOOST PRESSURE SENSOR.................................................................................................1160 COMPONENT LOCATOR.................................................................................................1160 INSPECTION........................................................................................................1161 REPLACEMENT.......................................................................................................1161 AIR FLOW SENSOR.......................................................................................................1163 COMPONENT LOCATOR.................................................................................................1163 INSPECTION........................................................................................................1164 REPLACEMENT.......................................................................................................1166 ENGINE MECHANICAL (J05E) .................................................................................................1167 HEAD COVER............................................................................................................1168 COMPONENT LOCATOR.................................................................................................1168 REPLACEMENT.......................................................................................................1169 ROCKER ARM ASSEMBLY...................................................................................................1172 COMPONENT LOCATOR.................................................................................................1172 OVERHAUL..........................................................................................................1173 CAMSHAFT ASSEMBLY.....................................................................................................1180 COMPONENT LOCATOR.................................................................................................1180 OVERHAUL..........................................................................................................1182 CYLINDER HEAD ASSEMBLY................................................................................................1187 COMPONENT LOCATOR.................................................................................................1187 REPLACEMENT.......................................................................................................1188 OVERHAUL..........................................................................................................1197 VALVE SYSTEM..........................................................................................................1203 COMPONENT LOCATOR.................................................................................................1203 OVERHAUL..........................................................................................................1204 CRANKSHAFT PULLEY.....................................................................................................1213 COMPONENT LOCATOR.................................................................................................1213 REPLACEMENT.......................................................................................................1214 CRANKSHAFT FRONT OIL SEAL.............................................................................................1216 COMPONENT LOCATOR.................................................................................................1216 REPLACEMENT.......................................................................................................1217 FRONT OIL SEAL RETAINER...............................................................................................1220 COMPONENT LOCATOR.................................................................................................1220 REPLACEMENT.......................................................................................................1221 FLYWHEEL ASSEMBLY.....................................................................................................1223 COMPONENT LOCATOR.................................................................................................1223 OVERHAUL..........................................................................................................1224 CRANKSHAFT REAR OIL SEAL..............................................................................................1228 COMPONENT LOCATOR.................................................................................................1228 REPLACEMENT.......................................................................................................1229 FLYWHEEL HOUSING......................................................................................................1232 COMPONENT LOCATOR.................................................................................................1232 REPLACEMENT.......................................................................................................1233 TIMING GEAR & CAM IDLE GEAR...........................................................................................1237 COMPONENT LOCATOR.................................................................................................1237 CONFIGURATION DIAGRAM.............................................................................................1238 OVERHAUL..........................................................................................................1239 PISTON AND CONNECTING ROD.............................................................................................1256 COMPONENT LOCATOR.................................................................................................1256 OVERHAUL..........................................................................................................1257 CRANKSHAFT............................................................................................................1273 COMPONENT LOCATOR.................................................................................................1273 REPLACEMENT.......................................................................................................1275 CYLINDER LINER........................................................................................................1284 COMPONENT LOCATOR.................................................................................................1284 REPLACEMENT.......................................................................................................1285 CYLINDER BLOCK........................................................................................................1289 COMPONENT LOCATOR.................................................................................................1289 OVERHAUL..........................................................................................................1290 ENGINE MOUNTING AND BRACKET...........................................................................................1298 COMPONENT LOCATOR.................................................................................................1298 REPLACEMENT.......................................................................................................1299 GLOW PLUG.............................................................................................................1301 COMPONENT LOCATOR.................................................................................................1301 REPLACEMENT.......................................................................................................1302 GCU...................................................................................................................1304 COMPONENT LOCATOR.................................................................................................1304 REPLACEMENT.......................................................................................................1304 EXHAUST (J05E) ...........................................................................................................1305 EXHAUST MANIFOLD......................................................................................................1307 COMPONENT LOCATOR.................................................................................................1307 REPLACEMENT.......................................................................................................1308 EXHAUST PIPE..........................................................................................................1312 COMPONENT LOCATOR.................................................................................................1312 REPLACEMENT.......................................................................................................1313 EXHAUST PIPE (ATC)....................................................................................................1321 COMPONENT LOCATOR.................................................................................................1321 REPLACEMENT.......................................................................................................1322 DEF-SCR & DPR.........................................................................................................1324 CONFIGURATION DIAGRAM.............................................................................................1324 HANDLING OF DEF...................................................................................................1325 CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING ...........................................................1326 DEF-SCR...............................................................................................................1328 COMPONENT LOCATOR.................................................................................................1328 REPLACEMENT.......................................................................................................1329 DPR CLEANER...........................................................................................................1333 COMPONENT LOCATOR.................................................................................................1333 DPR INSPECTION....................................................................................................1334 INSPECTION PROCEDURE FOLLOWED WHEN “EXHAUST GAS AFTER TREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT” LIGHT UP....1335 INSPECTION BY WAY OF HINO DXⅡ.....................................................................................1336 INSPECTION PROCEDURE FOLLOWED WHEN MALFUNCTION INDICATOR LIGHT ILLUMINATES (ABNORMAL).............................1340 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX Ⅱ..............................................1343 CHECKING THE DPR STATE............................................................................................1343 REPLACEMENT.......................................................................................................1344 OVERALL OPERATION FLOW............................................................................................1349 AIR CLEANING FLOW.................................................................................................1356 FUEL ADDITION VALVE...................................................................................................1357 COMPONENT LOCATOR.................................................................................................1357 REPLACEMENT.......................................................................................................1358 FUEL CUTOFF VALVE.....................................................................................................1366 COMPONENT LOCATOR.................................................................................................1366 REPLACEMENT.......................................................................................................1367 DEF PUMP..............................................................................................................1369 COMPONENT LOCATOR.................................................................................................1369 REPLACEMENT.......................................................................................................1370 DEF INJECTOR..........................................................................................................1378 COMPONENT LOCATOR.................................................................................................1378 REPLACEMENT.......................................................................................................1379 DEF TANK..............................................................................................................1384 COMPONENT LOCATOR.................................................................................................1384 INSPECTION........................................................................................................1385 REPLACEMENT.......................................................................................................1386 DEF SENSOR............................................................................................................1395 COMPONENT LOCATOR.................................................................................................1395 REPLACEMENT.......................................................................................................1396 COOLANT CUTOFF VALVE..................................................................................................1398 COMPONENT LOCATOR.................................................................................................1398 REPLACEMENT.......................................................................................................1399 DCU...................................................................................................................1401 COMPONENT LOCATOR.................................................................................................1401 REPLACEMENT.......................................................................................................1402 DPR DIFFERENTIAL PRESSURE SENSOR......................................................................................1408 COMPONENT LOCATOR.................................................................................................1408 REPLACEMENT.......................................................................................................1409 SCR UPSTREAM NOx SENSOR...............................................................................................1411 COMPONENT LOCATOR.................................................................................................1411 REPLACEMENT.......................................................................................................1412 SCR DOWNSTREAM NOx SENSOR.............................................................................................1414 COMPONENT LOCATOR.................................................................................................1414 REPLACEMENT.......................................................................................................1415 PM SENSOR.............................................................................................................1417 COMPONENT LOCATOR.................................................................................................1417 REPLACEMENT.......................................................................................................1418 EXHAUST TEMPERATURE SENSOR No.1 (ATC INLET)...........................................................................1420 COMPONENT LOCATOR.................................................................................................1420 REPLACEMENT.......................................................................................................1421 EXHAUST TEMPERATURE SENSOR No.0 (ATC OUTLET)..........................................................................1423 COMPONENT LOCATOR.................................................................................................1423 REPLACEMENT.......................................................................................................1424 EXHAUST TEMPERATURE SENSOR No.2 (DOC INLET)...........................................................................1426 COMPONENT LOCATOR.................................................................................................1426 REPLACEMENT.......................................................................................................1427 EXHAUST TEMPERATURE SENSOR No.3 (DPR INLET)...........................................................................1429 COMPONENT LOCATOR.................................................................................................1429 REPLACEMENT.......................................................................................................1430 EXHAUST TEMPERATURE SENSOR No.4 (DPR OUTLET)..........................................................................1432 COMPONENT LOCATOR.................................................................................................1432 REPLACEMENT.......................................................................................................1433 SCR UPSTREAM TEMPERATURE SENSOR.......................................................................................1435 COMPONENT LOCATOR.................................................................................................1435 REPLACEMENT.......................................................................................................1436 OUTSIDE TEMPERATURE SENSOR............................................................................................1439 COMPONENT LOCATOR.................................................................................................1439 REPLACEMENT.......................................................................................................1440 EXHAUST BRAKE.........................................................................................................1441 COMPONENT LOCATOR.................................................................................................1441 REPLACEMENT.......................................................................................................1442 EXHAUST BRAKE MAGNETIC VALVE..........................................................................................1445 COMPONENT LOCATOR.................................................................................................1445 REPLACEMENT.......................................................................................................1446 COOLING (J05E) ...........................................................................................................1448 COOLING SYSTEM........................................................................................................1449 COOLING SYSTEM DIAGRAM............................................................................................1449 RADIATOR..............................................................................................................1450 COMPONENT LOCATOR.................................................................................................1450 INSPECTION........................................................................................................1451 REPLACEMENT.......................................................................................................1452 RADIATOR CAP..........................................................................................................1462 COMPONENT LOCATOR.................................................................................................1462 REPLACEMENT.......................................................................................................1463 RESERVE TANK..........................................................................................................1465 COMPONENT LOCATOR.................................................................................................1465 REPLACEMENT.......................................................................................................1466 INTERCOOLER...........................................................................................................1467 COMPONENT LOCATOR.................................................................................................1467 OVERHAUL..........................................................................................................1468 THERMOSTAT CASE AND THERMOSTAT........................................................................................1470 COMPONENT LOCATOR.................................................................................................1470 OVERHAUL..........................................................................................................1471 COOLANT PUMP..........................................................................................................1477 COMPONENT LOCATOR.................................................................................................1477 REPLACEMENT.......................................................................................................1478 COOLING FAN AND FAN CLUTCH............................................................................................1480 COMPONENT LOCATOR.................................................................................................1480 OVERHAUL..........................................................................................................1481 COOLANT TEMPERATURE SENSOR............................................................................................1484 COMPONENT LOCATOR.................................................................................................1484 REPLACEMENT.......................................................................................................1485 LUBRICATION (J05E) .......................................................................................................1487 LUBRICATION SYSTEM....................................................................................................1488 LUBRICATION SYSTEM DIAGRAM........................................................................................1488 OIL FILTER............................................................................................................1489 COMPONENT LOCATOR.................................................................................................1489 REPLACEMENT.......................................................................................................1490 OIL COOLER............................................................................................................1492 COMPONENT LOCATOR.................................................................................................1492 OVERHAUL..........................................................................................................1493 OIL PUMP..............................................................................................................1500 COMPONENT LOCATOR.................................................................................................1500 OVERHAUL..........................................................................................................1501 OIL PAN...............................................................................................................1508 COMPONENT LOCATOR.................................................................................................1508 REPLACEMENT.......................................................................................................1509 OIL STRAINER..........................................................................................................1513 COMPONENT LOCATOR.................................................................................................1513 REPLACEMENT.......................................................................................................1514 OIL PRESSURE SWITCH...................................................................................................1515 COMPONENT LOCATOR.................................................................................................1515 REPLACEMENT.......................................................................................................1516 OIL LEVEL GAUGE AND GUIDE.............................................................................................1518 COMPONENT LOCATOR.................................................................................................1518 REPLACEMENT.......................................................................................................1519 STARTING/CHARGING (J05E) .................................................................................................1521 STARTER...............................................................................................................1522 COMPONENT LOCATOR.................................................................................................1522 REPLACEMENT.......................................................................................................1523 V-BELT................................................................................................................1528 COMPONENT LOCATOR.................................................................................................1528 REPLACEMENT.......................................................................................................1529 ALTERNATOR (130A).....................................................................................................1532 COMPONENT LOCATOR.................................................................................................1532 OVERHAUL..........................................................................................................1533 TURBOCHARGER (J05E) ......................................................................................................1546 TURBOCHARGER ASSEMBLY.................................................................................................1547 COMPONENT LOCATOR.................................................................................................1547 INSPECTION........................................................................................................1548 REPLACEMENT.......................................................................................................1550 FOREWORD..................................................................................................................1559 CHAPTER REFERENCES........................................................................................................1560 INDEX.....................................................................................................................1561 GENERAL INTRODUCTION......................................................................................................1562 HOW TO USE THIS MANUAL................................................................................................1563 GRAPHICAL SYMBOLS FOR WIRING DIAGRAMS, ABBREVIATIONS AND TERMS....................................................1563 WIRING DIAGRAM....................................................................................................1568 WIRE TO WIRE CONNECTOR............................................................................................1569 JUNCTION CONNECTOR................................................................................................1570 LOCATION..........................................................................................................1571 RELAY LOCATION / FUSE AND RELAY BLOCK.............................................................................1572 ABOUT CONNECTOR...................................................................................................1576 WIRING DIAGRAM ACCORDING TO SYSTEM........................................................................................1578 WIRING DIAGRAM........................................................................................................1579 WIRING HARNESS CODE...............................................................................................1579 AC. POWER SUPPLY CIRCUIT..........................................................................................1581 AF. GROUND CIRCUIT................................................................................................1585 AH. CHARGING CIRCUIT..............................................................................................1587 AK. ENGINE STARTING CIRCUIT.......................................................................................1589 AN. CAN COMMUNICATION CIRCUIT.....................................................................................1591 AO. CAN COMMUNICATION CIRCUIT [HV]................................................................................1593 BG. ENGINE ECU CIRCUIT [J05] 1/2..................................................................................1597 BH. ENGINE ECU CIRCUIT [J05] 2/2..................................................................................1601 BI. DEF SCR CIRCUIT...............................................................................................1609 BJ. HYDRO BOOST SYSTEM CIRCUIT....................................................................................1611 BN. GLOW PLUG CIRCUIT.............................................................................................1613 BP. FUEL HEATER CIRCUIT...........................................................................................1615 CC. AT CIRCUIT [A465].............................................................................................1617 CE. CLUTCH ECU CIRCUIT............................................................................................1623 CF. HV PCU CIRCUIT................................................................................................1627 DA. ABS/PAB+VSC CIRCUIT...........................................................................................1629 DD. VEHICLE CONTROL ECU CIRCUIT...................................................................................1631 EC. POWER DOOR LOCK CIRCUIT.......................................................................................1633 ED. KEYLESS ENTRY CIRCUIT.........................................................................................1635 EG. POWER WINDOW CIRCUIT [FRONT]..................................................................................1637 EH. POWER WINDOW CIRCUIT [REAR]...................................................................................1639 FA. COMBINATION METER CIRCUIT.....................................................................................1641 FB. PARKING BRAKE WARNING CIRCUIT.................................................................................1645 FC. WEAR INDICATOR CIRCUIT........................................................................................1647 FD. HORN RELAY CIRCUIT............................................................................................1649 FE. COOLANT LEVEL WARNING CIRCUIT.................................................................................1651 FF. DIAGNOSIS MONITOR CIRCUIT.....................................................................................1653 FJ. RHEOSTAT CIRCUIT..............................................................................................1655 FK. TELEMATICS CIRCUIT............................................................................................1657 GA. HEADLIGHT CIRCUIT.............................................................................................1659 GD. HEADLIGHT SUB CIRCUIT ........................................................................................1661 GG. TAIL LIGHT CIRCUIT............................................................................................1663 GH. STOP LIGHT CIRCUIT............................................................................................1665 GJ. TURN / HAZARD CIRCUIT.........................................................................................1667 GL. COMBINATION LIGHT CIRCUIT.....................................................................................1669 GM. FOG LIGHT CIRCUIT [FRONT].....................................................................................1671 HA. ROOM LIGHT CIRCUIT............................................................................................1673 JA. WIPER AND WASHER CIRCUIT......................................................................................1675 JD. MIRROR HEATER CIRCUIT.........................................................................................1677 JE. REMOTE CONTROL MIRROR CIRCUIT.................................................................................1679 KA. RADIO CIRCUIT.................................................................................................1681 KB. CIGAR LIGHTER CIRCUIT.........................................................................................1683 LB. HEATER AND AIR CONDITIONER CIRCUIT............................................................................1685 LF. REAR HEATER AND AIR CONDITIONER CIRCUIT.......................................................................1689 MA. OUTLET POWER SUPPLY CIRCUIT...................................................................................1691 WIRE TO WIRE CONNECTOR....................................................................................................1693 WIRE TO WIRE CONNECTOR................................................................................................1694 WIRE TO WIRE CONNECTOR LIST.......................................................................................1694 JUNCTION CONNECTOR........................................................................................................1711 JUNCTION CONNECTOR....................................................................................................1712 JUNCTION CONNECTOR LIST...........................................................................................1712 LOCATION..................................................................................................................1729 CONNECTOR LOCATION....................................................................................................1730 CONTENTS..........................................................................................................1730 QUICK REFERENCE...................................................................................................1731 IP-1 [INSTRUMENT PANEL (1 of 6)]..................................................................................1732 IP-2 [INSTRUMENT PANEL (2 of 6)]..................................................................................1734 IP-3 [INSTRUMENT PANEL (3 of 6)]..................................................................................1736 IP-4 [INSTRUMENT PANEL (4 of 6)]..................................................................................1738 IP-5 [INSTRUMENT PANEL (5 of 6)]..................................................................................1742 IP-6 [INSTRUMENT PANEL (6 of 6)]..................................................................................1744 CA-1 [CAB (1 of 2)] (Models: Single cab (Floor / Cowl))...........................................................1746 CA-2 [CAB (2 of 2)] (Models: Single cab (Roof / Door))............................................................1748 CA-3 [CAB (1 of 2)] (Models: Crew cab (Floor))....................................................................1750 CA-4 [CAB (2 of 2)] (Models: Crew cab (Roof / Door))..............................................................1752 EG-1 [ENGINE (1 of 4)] (Models: J05E Engine)......................................................................1754 EG-2 [ENGINE (2 of 4)] (Models: J05E Engine)......................................................................1756 EG-3 [ENGINE (3 of 4)] (Models: J05E Engine)......................................................................1758 EG-4 [ENGINE (4 of 4)] (Models: J05E Engine)......................................................................1760 EG-5 [ENGINE] (Models: J05E Engine (Right rear))..................................................................1762 EG-6 [ENGINE (1 of 4)] (Models: J05E Engine HV)...................................................................1764 EG-7 [ENGINE (2 of 4)] (Models: J05E Engine HV)...................................................................1766 EG-8 [ENGINE (3 of 4)] (Models: J05E Engine HV)...................................................................1768 EG-9 [ENGINE (4 of 4)] (Models: J05E Engine HV)...................................................................1770 EG-10 [ENGINE] (Models: J05E Engine HV (Right rear))..............................................................1772 RR-1 [REAR] (Models: Except HV)...................................................................................1774 RR-2 [REAR] (Models: HV)..........................................................................................1776 RELAY LOCATION/FUSE AND RELAY BLOCK.......................................................................................1778 RELAY LOCATION........................................................................................................1779 INSTRUMENT PANEL..................................................................................................1779 CHASSIS...........................................................................................................1780 FUSE AND RELAY BLOCK..................................................................................................1781 CHASSIS RELAY BLOCK...............................................................................................1781 CAB RELAY.........................................................................................................1784 RELAY BLOCK No.2..................................................................................................1785 JUNCTION BLOCK........................................................................................................1786 JUNCTION BLOCK....................................................................................................1786 WIRE TO WIRE BOX......................................................................................................1788 WIRE TO WIRE ALIGNMENT............................................................................................1788 INDEX.....................................................................................................................1789 CONNECTOR INDEX.......................................................................................................1790 ELECTRICAL EQUIPMENT CONNECTOR....................................................................................1790 WIRE TO WIRE CONNECTOR............................................................................................1806 JUNCTION CONNECTOR................................................................................................1809 FOREWORD..................................................................................................................1813 CHAPTER REFERENCES........................................................................................................1814 INDEX.....................................................................................................................1815 GENERAL INTRODUCTION......................................................................................................1817 HOW TO IDENTIFY VEHICLE TYPE..........................................................................................1818 HOW TO IDENTIFY VEHICLE TYPE......................................................................................1818 VEHICLE TYPE .................................................................................................1818 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE.................................................................1819 APPEARANCE OF VEHICLE.................................................................................................1820 APPEARANCE........................................................................................................1820 APPEARANCE OF VEHICLE.........................................................................................1820 SAFETY INSTRUCTIONS AND READINESS TO WORK.............................................................................1821 WARNING...........................................................................................................1821 GENERAL PRECAUTIONS...........................................................................................1821 IDENTIFICATION INFORMATION....................................................................................1826 SAFETY INSTRUCTIONS FOR WORK......................................................................................1829 PRECAUTIONS...................................................................................................1829 INTRODUCTION TO WORKSHOP MANUAL...................................................................................1833 GENERAL.......................................................................................................1833 INTRODUCTION TO DESCRIPTIONS..................................................................................1834 DEFINITION OF TERM............................................................................................1837 TROUBLE SHOOTING......................................................................................................1838 TROUBLESHOOTING WITH DIAGNOSIS MONITOR............................................................................1838 TROUBLESHOOTING PROCEDURE.....................................................................................1838 APPARATUS FOR TROUBLE SHOOTING................................................................................1840 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXII) .................................................................1841 STEP OF TROUBLE DIAGNOSIS.....................................................................................1841 APPARATUS FOR TROUBLE DIAGNOSIS...............................................................................1842 GLOSSARY..............................................................................................................1843 DEFINITION OF ABBREVIATION........................................................................................1843 LIST OF ABBREVIATION..........................................................................................1843 GLOSSARY OF SAE AND HINO TERMS................................................................................1846 ENGINE (J05E).............................................................................................................1849 TROUBLESHOOTING.......................................................................................................1852 ENGINE ECU (J05E).................................................................................................1852 PRECAUTIONS FOR DIAGNOSIS.....................................................................................1852 ELECTRICAL....................................................................................................1854 PRECAUTIONS...................................................................................................1855 COMPUTER (ECU) PIN ASSIGNMENT.................................................................................1859 ENGINE ECU CONNECTOR..........................................................................................1865 INSPECTION....................................................................................................1869 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...............................................................1870 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...........................................................................1871 GROUP SHARING THE SENSOR SUPPLY TERMINAL......................................................................1898 GROUP SHARING THE SENSOR GND TERMINAL.........................................................................1899 MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION..................................................1900 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)......................................................1903 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL]...............................1908 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID]...............................1918 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL]............................................1929 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID]............................................1934 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL]...............................1940 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID]...............................1945 MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY.............................................................1950 ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....................................................1951 NO DTC........................................................................................................1955 DTC: P0005....................................................................................................1959 DTC: P0006 and P0007..........................................................................................1963 DTC: P0016....................................................................................................1968 DTC: P0027....................................................................................................1971 DTC: P003A....................................................................................................1976 DTC: P0045....................................................................................................1981 DTC: P0047....................................................................................................1985 DTC: P0048....................................................................................................1989 DTC: P006E....................................................................................................1993 DTC: P006F....................................................................................................1997 DTC: P007B....................................................................................................2001 DTC: P007C and P007D..........................................................................................2015 DTC: P0088....................................................................................................2023 DTC: P0096....................................................................................................2031 DTC: P0097 and P0098 .........................................................................................2042 DTC: P00AF....................................................................................................2051 DTC: P0101....................................................................................................2055 DTC: P0104....................................................................................................2064 DTC: P0106....................................................................................................2071 DTC: P0107....................................................................................................2077 DTC: P0108....................................................................................................2083 DTC: P0111....................................................................................................2089 DTC: P0112 and P0113..........................................................................................2095 DTC: P0115....................................................................................................2103 DTC: P0117 and P0118..........................................................................................2112 DTC: P011A....................................................................................................2120 DTC: P0122 and P0123..........................................................................................2129 DTC: P0126....................................................................................................2139 DTC: P0128....................................................................................................2143 DTC: P0148 ...................................................................................................2149 DTC: P016E and P016F .........................................................................................2161 DTC: P0182 and P0183 .........................................................................................2171 DTC: P0191....................................................................................................2179 DTC: P0192 and P0193 .........................................................................................2188 DTC: P01A5....................................................................................................2198 DTC: P01A6....................................................................................................2205 DTC: P0200....................................................................................................2212 DTC: P0201, P0202, P0203 and P0204............................................................................2215 DTC: P0217....................................................................................................2220 DTC: P0219....................................................................................................2225 DTC: P0222 and P0223..........................................................................................2233 DTC: P0234....................................................................................................2243 DTC: P0263, P0266, P0269 and P0272............................................................................2249 DTC: P026C and P026D..........................................................................................2260 DTC: P0299....................................................................................................2273 DTC: P0300....................................................................................................2279 DTC: P0301, P0302, P0303 and P0304............................................................................2287 DTC: P0335....................................................................................................2296 DTC: P0336....................................................................................................2303 DTC: P0340....................................................................................................2310 DTC: P0341....................................................................................................2314 DTC: P0381....................................................................................................2322 DTC: P0401....................................................................................................2328 DTC: P0402....................................................................................................2344 DTC: P0404....................................................................................................2355 DTC: P0405 and P0406..........................................................................................2360 DTC: P041B....................................................................................................2366 DTC: P041C and P041D..........................................................................................2379 DTC: P0420....................................................................................................2387 DTC: P0421....................................................................................................2389 DTC: P0422....................................................................................................2402 DTC: P0489 and P0490..........................................................................................2405 DTC: P049D....................................................................................................2411 DTC: P04D5 and P04D6..........................................................................................2416 DTC: P04DA....................................................................................................2424 DTC: P04DB....................................................................................................2434 DTC: P0500 and P0501..........................................................................................2442 DTC: P0504....................................................................................................2449 DTC: P0506....................................................................................................2454 DTC: P0507....................................................................................................2458 DTC: P0521....................................................................................................2462 DTC: P0524....................................................................................................2466 DTC: P0545 and P0546..........................................................................................2471 DTC: P054E....................................................................................................2479 DTC: P054F....................................................................................................2483 DTC: P0562 and P0563..........................................................................................2487 DTC: P0603....................................................................................................2492 DTC: P0605....................................................................................................2496 DTC: P0606....................................................................................................2498 DTC: P0607....................................................................................................2500 DTC: P0610....................................................................................................2502 DTC: P0611....................................................................................................2505 DTC: P0617....................................................................................................2507 DTC: P0628 and P0629..........................................................................................2511 DTC: P062F....................................................................................................2519 DTC: P0630....................................................................................................2523 DTC: P0642....................................................................................................2527 DTC: P0643....................................................................................................2532 DTC: P064C....................................................................................................2538 DTC: P0652....................................................................................................2543 DTC: P0653....................................................................................................2549 DTC: P0671 and P0672 .........................................................................................2556 DTC: P0673 and P0674..........................................................................................2562 DTC: P0683....................................................................................................2568 DTC: P0686....................................................................................................2574 DTC: P0698....................................................................................................2579 DTC: P0699....................................................................................................2582 DTC: P06A4....................................................................................................2585 DTC: P06A5....................................................................................................2588 DTC: P06D3 and P06D4..........................................................................................2591 DTC: P0700....................................................................................................2600 DTC: P073D....................................................................................................2602 DTC: P081A....................................................................................................2606 DTC: P081B....................................................................................................2612 DTC: P0A7B....................................................................................................2616 DTC: P0AC4....................................................................................................2618 DTC: P0CA1....................................................................................................2620 DTC: P1133....................................................................................................2622 DTC: P119F....................................................................................................2629 DTC: P1426....................................................................................................2635 DTC: P1427....................................................................................................2642 DTC: P1428....................................................................................................2649 DTC: P1458....................................................................................................2657 DTC: P1459....................................................................................................2662 DTC: P14B0....................................................................................................2667 DTC: P14B2....................................................................................................2671 DTC: P14B3 and P14B4..........................................................................................2675 DTC: P14B7 and P14B8..........................................................................................2681 DTC: P14BC and P14BD..........................................................................................2687 DTC: P14BF....................................................................................................2693 FOREWORD..................................................................................................................2699 CHAPTER REFERENCES........................................................................................................2700 INDEX.....................................................................................................................2701 ENGINE (J05E).............................................................................................................2703 TROUBLESHOOTING.......................................................................................................2706 ENGINE ECU (J05E).................................................................................................2706 DTC: P1515....................................................................................................2706 DTC: P1530....................................................................................................2711 DTC: P2002....................................................................................................2715 DTC: P200C....................................................................................................2736 DTC: P2032 and P2033..........................................................................................2745 DTC: P203F....................................................................................................2753 DTC: P204F....................................................................................................2757 DTC: P206B....................................................................................................2760 DTC: P207F....................................................................................................2785 DTC: P2080....................................................................................................2793 DTC: P2084....................................................................................................2801 DTC: P20CD....................................................................................................2809 DTC: P20CE....................................................................................................2813 DTC: P20CF....................................................................................................2816 DTC: P20D8....................................................................................................2822 DTC: P20DE....................................................................................................2828 DTC: P20DF....................................................................................................2832 DTC: P20E0....................................................................................................2838 DTC: P20EE....................................................................................................2844 DTC: P20EF....................................................................................................2852 DTC: P2100....................................................................................................2854 DTC: P2101....................................................................................................2860 DTC: P2103....................................................................................................2867 DTC: P2120....................................................................................................2872 DTC: P2122 and P2123..........................................................................................2876 DTC: P2127 and P2128..........................................................................................2886 DTC: P2135....................................................................................................2895 DTC: P2138....................................................................................................2900 DTC: P2146....................................................................................................2905 DTC: P2147 and P2148..........................................................................................2912 DTC: P2149....................................................................................................2920 DTC: P2150 and P2151..........................................................................................2927 DTC: P2184 and P2185..........................................................................................2935 DTC: P2201....................................................................................................2943 DTC: P2227....................................................................................................2989 DTC: P2228 and P2229..........................................................................................2993 DTC: P2269....................................................................................................2998 DTC: P226C....................................................................................................3002 DTC: P229F....................................................................................................3008 DTC: P22D3....................................................................................................3055 DTC: P240F....................................................................................................3059 DTC: P2428....................................................................................................3069 DTC: P242B....................................................................................................3073 DTC: P242C and P242D..........................................................................................3081 DTC: P244A....................................................................................................3089 DTC: P244B....................................................................................................3109 DTC: P2457....................................................................................................3126 DTC: P2458....................................................................................................3141 DTC: P2459....................................................................................................3152 DTC: P2463....................................................................................................3155 DTC: P246F....................................................................................................3163 DTC: P2470 and P2471..........................................................................................3171 DTC: P2481 and P2482..........................................................................................3179 DTC: P2483....................................................................................................3187 DTC: P24A0....................................................................................................3195 DTC: P24A1....................................................................................................3198 DTC: P24A2....................................................................................................3200 DTC: P24A3 (2 digit diagnosis code: 01).......................................................................3210 DTC: P24AE (2 digit diagnosis code: 04, 05, 06, 14, 25, 26, 27, 28)...........................................3214 DTC: P24AF (2 digit diagnosis code: 23).......................................................................3216 DTC: P24B0 (2 digit diagnosis code: 19, 20, 21)...............................................................3219 DTC: P24B1 (2 digit diagnosis code: 18).......................................................................3221 DTC: P24B4 (2 digit diagnosis code: 10, 11, 15, 17)...........................................................3223 DTC: P24B7 (2 digit diagnosis code: 08).......................................................................3225 DTC: P24C7 (2 digit diagnosis code: 09).......................................................................3228 DTC: P24D0 (2 digit diagnosis code: 02).......................................................................3232 DTC: P24D1 (2 digit diagnosis code: 12).......................................................................3236 DTC: P24DA (2 digit diagnosis code: 07).......................................................................3238 DTC: P2562....................................................................................................3242 DTC: P259E....................................................................................................3246 DTC: P259F....................................................................................................3252 DTC: P2635....................................................................................................3257 DTC: P268A and P2696..........................................................................................3266 DTC: P26C8....................................................................................................3272 DTC: P2A00....................................................................................................3274 DTC: P2A01....................................................................................................3278 DTC: P2BA9....................................................................................................3282 DTC: U0073....................................................................................................3287 DTC: U010A....................................................................................................3290 DTC: U010C....................................................................................................3296 DTC: U010E....................................................................................................3302 DTC: U0293....................................................................................................3308 DTC: U029D (DIESEL)...........................................................................................3313 DTC: U029D (HYBRID)...........................................................................................3319 DTC: U029E (DIESEL)...........................................................................................3325 DTC: U029E (HYBRID)...........................................................................................3331 DTC: U02A2....................................................................................................3337 DTC: U02A3....................................................................................................3343 DTC: U0301....................................................................................................3346 DTC: U1001....................................................................................................3349 DTC: U110A....................................................................................................3356 ENGINE (COMMON ITEMS).....................................................................................................3363 TROUBLESHOOTING.......................................................................................................3365 DCU...............................................................................................................3365 PRECAUTIONS FOR DIAGNOSIS.....................................................................................3365 DIAGRAM.......................................................................................................3367 SIGNAL CHECK HARNESS..........................................................................................3368 INSPECTION....................................................................................................3368 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...............................................................3370 DTC: P0071....................................................................................................3377 DTC: P0072....................................................................................................3387 DTC: P0073....................................................................................................3393 DTC: P0562....................................................................................................3399 DTC: P0563....................................................................................................3403 DTC: P060B....................................................................................................3407 DTC: P060C....................................................................................................3410 DTC: P062F....................................................................................................3412 DTC: P0667....................................................................................................3414 DTC: P068A....................................................................................................3416 DTC: P06AD....................................................................................................3421 DTC: P06AE....................................................................................................3423 DTC: P142A....................................................................................................3425 DTC: P142B....................................................................................................3436 DTC: P14C1....................................................................................................3447 DTC: P14C2....................................................................................................3460 DTC: P14C3....................................................................................................3465 DTC: P202E....................................................................................................3470 DTC: P203C....................................................................................................3474 DTC: P203D....................................................................................................3477 DTC: P2044....................................................................................................3480 DTC: P2045....................................................................................................3483 DTC: P2047....................................................................................................3486 DTC: P2048....................................................................................................3489 DTC: P2049....................................................................................................3494 DTC: P204B....................................................................................................3499 DTC: P204C....................................................................................................3502 DTC: P204D....................................................................................................3507 DTC: P205B....................................................................................................3512 DTC: P205C....................................................................................................3521 DTC: P205D....................................................................................................3524 DTC: P206A....................................................................................................3527 DTC: P206C....................................................................................................3530 DTC: P206D....................................................................................................3533 DTC: P208A....................................................................................................3536 DTC: P208B....................................................................................................3542 DTC: P208C....................................................................................................3545 DTC: P208D....................................................................................................3550 DTC: P20A0....................................................................................................3555 DTC: P20A1....................................................................................................3560 DTC: P20A2....................................................................................................3564 FOREWORD..................................................................................................................3570 CHAPTER REFERENCES........................................................................................................3571 INDEX.....................................................................................................................3572 ENGINE (COMMON ITEMS).....................................................................................................3574 TROUBLESHOOTING.......................................................................................................3576 DCU...............................................................................................................3576 DTC: P20A3....................................................................................................3576 DTC: P20B1....................................................................................................3581 DTC: P20B2....................................................................................................3586 DTC: P20B3....................................................................................................3596 DTC: P20B4....................................................................................................3601 DTC: P20BD, P20B9 and P20C1...................................................................................3606 DTC: P20C0, P20BC and P20C4...................................................................................3614 DTC: P20E8....................................................................................................3620 DTC: P20E9....................................................................................................3631 DTC: P20F4....................................................................................................3637 DTC: P21C2....................................................................................................3641 DTC: P21C3....................................................................................................3645 DTC: P21C4....................................................................................................3650 DTC: P2201....................................................................................................3655 DTC: P2202....................................................................................................3698 DTC: P2203....................................................................................................3701 DTC: P2204....................................................................................................3704 DTC: P2209....................................................................................................3711 DTC: P229F....................................................................................................3719 DTC: P22A0....................................................................................................3761 DTC: P22A1....................................................................................................3764 DTC: P22A2....................................................................................................3767 DTC: P22A7....................................................................................................3774 DTC: P2510....................................................................................................3782 DTC: P2BAE....................................................................................................3787 DTC: U0029....................................................................................................3794 DTC: U0038....................................................................................................3800 DTC: U0100....................................................................................................3806 DTC: U029D (DIESEL)...........................................................................................3810 DTC: U029D (HYBRID)...........................................................................................3816 DTC: U029E (DIESEL)...........................................................................................3822 DTC: U029E (HYBRID)...........................................................................................3828 DTC: U02A2....................................................................................................3834 VEHICLE CONTROL ECU...............................................................................................3841 CAUTIONS ON TROUBLESHOOTING...................................................................................3841 SYSTEM BLOCK DIAGRAM..........................................................................................3842 COMPUTER PIN ASSIGNMENT.......................................................................................3843 TROUBLESHOOTING WITH COMPUTER (HINO DXII) ....................................................................3847 DIAGNOSIS CODE TABLE..........................................................................................3848 DTC: C1244....................................................................................................3850 DTC: C1245....................................................................................................3855 DTC: C1249....................................................................................................3857 DTC: C1418....................................................................................................3863 DTC: C1491....................................................................................................3867 DTC: P0335....................................................................................................3869 DTC: P0501....................................................................................................3872 DTC: P0503....................................................................................................3878 DTC: P0555....................................................................................................3883 DTC: P0562....................................................................................................3885 DTC: P0563....................................................................................................3889 DTC: P0572....................................................................................................3892 DTC: P0573....................................................................................................3899 DTC: P0577....................................................................................................3905 DTC: P05BF....................................................................................................3909 DTC: P0604....................................................................................................3912 DTC: P0605 ...................................................................................................3914 DTC: P0605 ...................................................................................................3916 DTC: P0606....................................................................................................3918 DTC: P0617....................................................................................................3920 DTC: P062F....................................................................................................3923 DTC: P0702....................................................................................................3925 DTC: P081D....................................................................................................3927 DTC: P161F....................................................................................................3932 DTC: P1649....................................................................................................3937 DTC: P165A....................................................................................................3941 DTC: P165B....................................................................................................3944 DTC: P2525....................................................................................................3947 DTC: P2526....................................................................................................3950 DTC: P258D....................................................................................................3953 DTC: U0101....................................................................................................3956 DTC: U0105....................................................................................................3959 DTC: U0121....................................................................................................3962 DTC: U0155....................................................................................................3965 DTC: U0293....................................................................................................3968 DTC: U0418....................................................................................................3971 DTC: U1136....................................................................................................3974 HYBRID....................................................................................................................3977 TROUBLE SHOOTING......................................................................................................3980 HYBRID CONTROL SYSTEM.............................................................................................3980 TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM......................................................................3980 SAFETY MEASURES FOR HIGH-VOLTAGE WORK.........................................................................3989 LIST OF CONNECTOR SYMBOLS.....................................................................................3992 HV SYSTEM WIRING DIAGRAM......................................................................................3996 HEARING SHEET.................................................................................................3998 HYBRID ECU........................................................................................................3999 DIAGNOSIS CODE TABLE..........................................................................................3999 FREEZE FRAME DATA LIST........................................................................................4009 LIST OF DATA MONITOR ITEMS....................................................................................4012 ACTIVE TEST...................................................................................................4015 COMMON INSPECTION CHART.......................................................................................4016 DTC: C0081 (TCA0).............................................................................................4021 DTC: P0500 (TC51).............................................................................................4023 DTC: P0501 (TC5B).............................................................................................4030 DTC: P0562 (TC71).............................................................................................4034 DTC: P060B (TCB2).............................................................................................4040 DTC: P0617 (TC59).............................................................................................4042 DTC: P062F (TCB3).............................................................................................4048 DTC: P0810 (TC9C).............................................................................................4050 DTC: P0810 (TC9D).............................................................................................4053 DTC: P0A01 (TC7B).............................................................................................4056 DTC: P0A02 (TC78).............................................................................................4062 DTC: P0A03 (TC79).............................................................................................4068 DTC: P0A06 (TC7F).............................................................................................4073 DTC: P0A07 (TC7E).............................................................................................4081 DTC: P0A0F (TC31) ............................................................................................4084 DTC: P0A1D (TC12).............................................................................................4087 DTC: P0A1D (TC17).............................................................................................4089 DTC: P0A78 (TC21).............................................................................................4091 DTC: P0A78 (TC22).............................................................................................4093 DTC: P0A7E (TC48).............................................................................................4095 DTC: P0A82 (TC67).............................................................................................4099 DTC: P0A84 (TC66).............................................................................................4109 DTC: P0A85 (TC65).............................................................................................4120 DTC: P0A90 (TC2A).............................................................................................4125 DTC: P0A92 (TC29).............................................................................................4134 DTC: P0A93 (TC7A).............................................................................................4143 DTC: P0AFD (TC6B).............................................................................................4148 DTC: P0BC9 (TC69).............................................................................................4151 DTC: P0BCA (TC68).............................................................................................4163 DTC: P0C73 (TC80).............................................................................................4169 DTC: P3000 (TC42).............................................................................................4174 DTC: P3001 (TC41).............................................................................................4180 DTC: P3001 (TC43).............................................................................................4182 DTC: P3001 (TC44).............................................................................................4184 DTC: P3001 (TC45).............................................................................................4186 DTC: P3001 (TC46).............................................................................................4188 DTC: P3001 (TC47).............................................................................................4191 DTC: P3001 (TC4A).............................................................................................4194 DTC: P3001 (TC4B).............................................................................................4197 DTC: P3001 (TC4C).............................................................................................4199 DTC: P3001 (TC4D).............................................................................................4201 DTC: P3009 (TC49).............................................................................................4204 DTC: P3010 (TC4E).............................................................................................4214 DTC: P3010 (TC4F).............................................................................................4216 DTC: P3128 (TC7D).............................................................................................4219 DTC: P3129 (TC7C).............................................................................................4227 DTC: P314C (TC82).............................................................................................4231 DTC: P314D (TC81).............................................................................................4235 DTC: P324B (TC62).............................................................................................4243 DTC: P324C (TC61).............................................................................................4247 DTC: P33B1 (TC64).............................................................................................4252 DTC: P33B2 (TC63).............................................................................................4256 DTC: U0073 (TC11).............................................................................................4260 DTC: U0074 (TC16).............................................................................................4264 DTC: U0100 (TC13).............................................................................................4267 DTC: U0101 (TC18).............................................................................................4270 DTC: U0110 (TC14).............................................................................................4275 DTC: U0111 (TC15).............................................................................................4281 DTC: U0121 (TC24).............................................................................................4287 DTC: U0155 (TC25).............................................................................................4292 DTC: U110A (TC26).............................................................................................4297 DTC: U1136 (TC27).............................................................................................4302 INVERTER..........................................................................................................4307 DIAGNOSIS CODE TABLE..........................................................................................4307 FREEZE FRAME DATA LIST........................................................................................4313 DATA MONITOR ITEM LIST........................................................................................4315 CONNECTION DIAGRAM............................................................................................4318 INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR [ROTATION MACHINE]...............................4319 DTC: P0562 (TC96) ............................................................................................4321 DTC: P0562 (TCA0) ............................................................................................4328 DTC: P0604 (TC18) ............................................................................................4335 DTC: P0604 (TCD2).............................................................................................4337 DTC: P0605 (TC17) ............................................................................................4339 DTC: P0605 (TCD1) ............................................................................................4341 DTC: P060B (TC1A).............................................................................................4343 DTC: P060C (TC1C).............................................................................................4346 DTC: P062F (TC41).............................................................................................4348 DTC: P0A0D (TC20).............................................................................................4350 DTC: P0A1B (TC16).............................................................................................4355 DTC: P0A1B (TC92).............................................................................................4360 DTC: P0A1B (TC97).............................................................................................4362 DTC: P0A1B (TC3F).............................................................................................4364 DTC: P0A1B (TCA1).............................................................................................4366 DTC: P0A1B (TCA2).............................................................................................4368 DTC: P0A1B (TCA3).............................................................................................4370 DTC: P0A1B (TCA4).............................................................................................4372 DTC: P0A1B (TCA5).............................................................................................4374 DTC: P0A1B (TCA6).............................................................................................4376 DTC: P0A1B (TCA7).............................................................................................4378 DTC: P0A1B (TCA8) ............................................................................................4380 DTC: P0A1B (TCA9).............................................................................................4382 DTC: P0A1B (TCAA).............................................................................................4384 DTC: P0A1B (TCBB).............................................................................................4388 DTC: P0A1B (TCBC).............................................................................................4390 DTC: P0A1B (TCBD).............................................................................................4392 DTC: P0A1B (TCBE).............................................................................................4394 DTC: P0A1B (TCBF).............................................................................................4396 DTC: P0A1B (TCD3).............................................................................................4398 DTC: P0A1B (TCD4).............................................................................................4400 DTC: P0A1B (TCD5).............................................................................................4402 DTC: P0A1D (TC21).............................................................................................4404 DTC: P0A2B (TCE9).............................................................................................4407 DTC: P0A2B (TCED).............................................................................................4414 DTC: P0A2C (TCDA).............................................................................................4421 DTC: P0A2D (TCDB).............................................................................................4427 FOREWORD..................................................................................................................4435 CHAPTER REFERENCES........................................................................................................4436 INDEX.....................................................................................................................4437 HYBRID....................................................................................................................4439 TROUBLE SHOOTING......................................................................................................4442 INVERTER..........................................................................................................4442 DTC: P0A2F (TC33) ............................................................................................4442 DTC: P0A3C (TC34).............................................................................................4447 DTC: P0A3F (TCB7).............................................................................................4460 DTC: P0A41 (TCC0).............................................................................................4466 DTC: P0A42 (TCC1).............................................................................................4474 DTC: P0A51 (TCD6).............................................................................................4482 DTC: P0A51 (TCD7).............................................................................................4484 DTC: P0A78 (TC13).............................................................................................4486 DTC: P0A78 (TC14).............................................................................................4493 DTC: P0A78 (TC15).............................................................................................4504 DTC: P0AA1 (TCD8).............................................................................................4509 DTC: P0AA4 (TCD9).............................................................................................4513 DTC: P0ADB (TC1F).............................................................................................4517 DTC: P0ADC (TC93).............................................................................................4522 DTC: P0ADF (TC1E).............................................................................................4528 DTC: P0AE0 (TC95).............................................................................................4533 DTC: P0AE6 (TC1D).............................................................................................4539 DTC: P0AE7 (TC94).............................................................................................4544 DTC: P0AEE (TC22).............................................................................................4550 DTC: P0AEE (TC23).............................................................................................4552 DTC: P0AEF (TC24).............................................................................................4554 DTC: P0AF0 (TC25).............................................................................................4557 DTC: P0BEA (TCB3).............................................................................................4560 DTC: P0BEA (TCB4).............................................................................................4562 DTC: P0BEB (TC9A).............................................................................................4564 DTC: P0BEC (TC9B).............................................................................................4566 DTC: P0BEE (TCB5).............................................................................................4568 DTC: P0BEE (TCB6).............................................................................................4570 DTC: P0BEF (TC9C).............................................................................................4572 DTC: P0BF0 (TC9D).............................................................................................4574 DTC: P3126 (TC12).............................................................................................4576 DTC: U0073 (TC91).............................................................................................4583 DTC: U0074 (TC3E).............................................................................................4587 DTC: U0293 (TC31).............................................................................................4590 BATTERY ECU.......................................................................................................4597 DIAGNOSIS CODE TABLE..........................................................................................4597 LIST OF FREEZE FRAME DATA.....................................................................................4601 LIST OF DATA MONITOR ITEMS....................................................................................4603 CONNECTION DIAGRAM............................................................................................4606 DTC: P0562....................................................................................................4607 DTC: P0604....................................................................................................4611 DTC: P0605....................................................................................................4613 DTC: P060B....................................................................................................4615 DTC: P062F....................................................................................................4617 DTC: P0A1F....................................................................................................4619 DTC: P0A7D....................................................................................................4621 DTC: P0A7F....................................................................................................4624 DTC: P0A80....................................................................................................4629 DTC: P0A95....................................................................................................4634 DTC: P0A9C....................................................................................................4638 DTC: P0A9D....................................................................................................4643 DTC: P0A9E....................................................................................................4647 DTC: P0ABF....................................................................................................4651 DTC: P0AC0....................................................................................................4656 DTC: P0AC1....................................................................................................4661 DTC: P0AC2....................................................................................................4666 DTC: P0AC6....................................................................................................4671 DTC: P0AC7....................................................................................................4676 DTC: P0AC8....................................................................................................4680 DTC: P0ACB....................................................................................................4684 DTC: P0ACC....................................................................................................4689 DTC: P0ACD....................................................................................................4693 DTC: P0AE9....................................................................................................4697 DTC: P0AEA....................................................................................................4702 DTC: P0AEB....................................................................................................4706 DTC: P0AFC....................................................................................................4710 DTC: P0B25....................................................................................................4712 DTC: P0B3D....................................................................................................4715 DTC: P0B42....................................................................................................4719 DTC: P0B47....................................................................................................4723 DTC: P0B4C....................................................................................................4727 DTC: P0B51....................................................................................................4731 DTC: P0B56....................................................................................................4735 DTC: P0B5B....................................................................................................4739 DTC: P0B60....................................................................................................4743 DTC: P0B65....................................................................................................4747 DTC: P0B6A....................................................................................................4751 DTC: P0B6F....................................................................................................4755 DTC: P0B74....................................................................................................4759 DTC: P0B79....................................................................................................4763 DTC: P0B7E....................................................................................................4767 DTC: P0B83....................................................................................................4771 DTC: P0B88....................................................................................................4775 DTC: P0B8D....................................................................................................4779 DTC: P0B92....................................................................................................4783 DTC: P0B97....................................................................................................4787 DTC: P0B9C....................................................................................................4791 DTC: P0BA1....................................................................................................4795 DTC: P0C30....................................................................................................4799 DTC: P3004....................................................................................................4806 DTC: P3011....................................................................................................4808 DTC: P3012....................................................................................................4813 DTC: P3013....................................................................................................4818 DTC: P3014....................................................................................................4823 DTC: P3015....................................................................................................4828 DTC: P3016....................................................................................................4833 DTC: P3017....................................................................................................4838 DTC: P3018....................................................................................................4843 DTC: P3019....................................................................................................4848 DTC: P301B....................................................................................................4853 DTC: P3020....................................................................................................4855 DTC: P3021....................................................................................................4860 DTC: P3022....................................................................................................4865 DTC: P3023....................................................................................................4870 DTC: P3024....................................................................................................4875 DTC: P3025....................................................................................................4880 DTC: P3026....................................................................................................4885 DTC: P3027....................................................................................................4890 DTC: P3028....................................................................................................4895 DTC: P3029....................................................................................................4900 DTC: P302F....................................................................................................4905 DTC: P3065....................................................................................................4910 DTC: P308A....................................................................................................4915 DTC: U0074....................................................................................................4919 DTC: U0293....................................................................................................4922 TRANSMISSION..............................................................................................................4926 TROUBLESHOOTING.......................................................................................................4928 TROUBLE SHOOTING BY TRANSMISSION SYMPTOM..........................................................................4928 AUTOMATIC TRANSMISSION........................................................................................4928 TROUBLESHOOTING.......................................................................................................4930 AUTOMATIC TRANSMISSION............................................................................................4930 PRECAUTIONS FOR DIAGNOSIS.....................................................................................4930 AT LEARNED VALUE INITIALIZATION...............................................................................4931 INSPECTING/CLEARING DIAGNOSIS CODES...........................................................................4935 SYSTEM BLOCK DIAGRAM..........................................................................................4938 COMPUTER PIN ASSIGNMENT.......................................................................................4939 DIAGNOSIS CODE TABLE..........................................................................................4942 DTC: P0500/DIAGNOSIS MONITOR CODE: 42.........................................................................4944 DTC: P0562/DIAGNOSIS MONITOR CODE: 11.........................................................................4950 DTC: P0705/DIAGNOSIS MONITOR CODE: 43.........................................................................4953 DTC: P0706/DIAGNOSIS MONITOR CODE: 44.........................................................................4961 DTC: P0710/DIAGNOSIS MONITOR CODE: 38.........................................................................4966 DTC: P0715/DIAGNOSIS MONITOR CODE: 12.........................................................................4973 DTC: P0720/DIAGNOSIS MONITOR CODE: 61.........................................................................4979 DTC: P0725/DIAGNOSIS MONITOR CODE: 86.........................................................................4985 DTC: P0730/DIAGNOSIS MONITOR CODE: 37.........................................................................4991 DTC: P0746/DIAGNOSIS MONITOR CODE: 31.........................................................................4999 DTC: P0748/DIAGNOSIS MONITOR CODE: 25.........................................................................5005 DTC: P0751/DIAGNOSIS MONITOR CODE: 45.........................................................................5010 DTC: P0756/DIAGNOSIS MONITOR CODE: 46.........................................................................5016 DTC: P0761/DIAGNOSIS MONITOR CODE: 47.48......................................................................5022 DTC: P0776/DIAGNOSIS MONITOR CODE: 32.........................................................................5032 DTC: P0778/DIAGNOSIS MONITOR CODE: 26.........................................................................5038 DTC: P0810/DIAGNOSIS MONITOR CODE: 88.........................................................................5043 DTC: P0973/DIAGNOSIS MONITOR CODE: 62.........................................................................5047 DTC: P0974/DIAGNOSIS MONITOR CODE: 62.........................................................................5052 DTC: P0976/DIAGNOSIS MONITOR CODE: 63.........................................................................5057 DTC: P0977/DIAGNOSIS MONITOR CODE: 63.........................................................................5062 DTC: P0979/DIAGNOSIS MONITOR CODE: 64.........................................................................5067 DTC: P0980/DIAGNOSIS MONITOR CODE: 64.........................................................................5072 DTC: P0985/DIAGNOSIS MONITOR CODE: 65.........................................................................5077 DTC: P0986/DIAGNOSIS MONITOR CODE: 65.........................................................................5082 DTC: P0A40/DIAGNOSIS MONITOR CODE: 88.........................................................................5087 DTC: P1604/DIAGNOSIS MONITOR CODE: 24.........................................................................5091 DTC: P1604/DIAGNOSIS MONITOR CODE: 54.........................................................................5095 DTC: P2545/DIAGNOSIS MONITOR CODE: 88.........................................................................5099 DTC: P2716/DIAGNOSIS MONITOR CODE: 28.........................................................................5103 DTC: P2740/DIAGNOSIS MONITOR CODE: 17.........................................................................5109 DTC: P2757/DIAGNOSIS MONITOR CODE: 33.........................................................................5114 DTC: P2759/DIAGNOSIS MONITOR CODE: 27.........................................................................5120 DTC: P2764/DIAGNOSIS MONITOR CODE: 36.........................................................................5126 DTC: U0100/DIAGNOSIS MONITOR CODE: 88.........................................................................5130 DTC: U110A/DIAGNOSIS MONITOR CODE: 88.........................................................................5139 TROUBLESHOOTING.......................................................................................................5148 CLUTCH ECU........................................................................................................5148 SYSTEM BLOCK DIAGRAM..........................................................................................5148 COMPUTER PIN ASSIGNMENT.......................................................................................5149 DIAGNOSIS CODE TABLE..........................................................................................5151 CAUTIONS ON HV DAMPER REPLACEMENT.............................................................................5153 DTC: P0560....................................................................................................5154 DTC: P0563....................................................................................................5158 DTC: P0604....................................................................................................5160 DTC: P0605....................................................................................................5162 DTC: P062F....................................................................................................5164 DTC: P0775....................................................................................................5166 DTC: P0778....................................................................................................5171 DTC: P0811....................................................................................................5176 DTC: P081E....................................................................................................5178 DTC: P0883....................................................................................................5180 DTC: P0948....................................................................................................5184 DTC: P1538....................................................................................................5189 DTC: P1539....................................................................................................5199 DTC: P18F2....................................................................................................5206 DTC: P18F3....................................................................................................5216 DTC: P18F5....................................................................................................5226 DTC: P18F7....................................................................................................5236 DTC: P18F8....................................................................................................5246 DTC: P18F9....................................................................................................5256 DTC: P18FB....................................................................................................5266 DTC: P18FC....................................................................................................5271 DTC: P18FD....................................................................................................5276 DTC: P191A....................................................................................................5281 DTC: P2859....................................................................................................5283 DTC: P3156....................................................................................................5285 DTC: P3157....................................................................................................5295 DTC: U0073....................................................................................................5299 DTC: U0101....................................................................................................5302 DTC: U0110....................................................................................................5305 DTC: U0293....................................................................................................5308 DTC: U110A....................................................................................................5311 AXLE......................................................................................................................5314 TROUBLESHOOTING.......................................................................................................5315 TROUBLE SHOOTING BY AXLE SYMPTOM..................................................................................5315 FRONT AXLE....................................................................................................5315 REAR AXLE.....................................................................................................5316 WHEEL AND TIRE................................................................................................5316 DIFFERENTIAL..............................................................................................................5318 TROUBLESHOOTING.......................................................................................................5319 TROUBLE SHOOTING BY DIFFERENTIAL SYMPTOM..........................................................................5319 REAR DIFFERENTIAL.............................................................................................5319
Description:
2018 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
- This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
- Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E 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 workshop manuals for the components and systems in these vehicles.
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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