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2019 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL – PDF DOWNLOAD
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2019 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
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2019 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
Language : English
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2019 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL – PDF DOWNLOAD:
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2019 HINO TRUCK COE 155 155H 195 195H J05E WORKSHOP MANUAL
FOREWORD.................................................................................................................. 2 CHAPTER REFERENCES........................................................................................................ 3 INDEX..................................................................................................................... 4 GENERAL INTRODUCTION...................................................................................................... 6 HOW TO IDENTIFY VEHICLE TYPE.......................................................................................... 7 HOW TO IDENTIFY VEHICLE TYPE...................................................................................... 7 VEHICLE MODEL................................................................................................. 7 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE................................................................. 8 APPEARANCE OF VEHICLE................................................................................................. 9 APPEARANCE........................................................................................................ 9 APPEARANCE OF VEHICLE......................................................................................... 9 SAFETY INSTRUCTIONS AND READINESS TO WORK............................................................................. 10 WARNING........................................................................................................... 10 GENERAL PRECAUTIONS........................................................................................... 10 IDENTIFICATION INFORMATION.................................................................................... 14 SAFETY INSTRUCTIONS FOR WORK...................................................................................... 17 PRECAUTIONS................................................................................................... 17 INTRODUCTION TO WORKSHOP MANUAL................................................................................... 21 GENERAL....................................................................................................... 21 INTRODUCTION TO DESCRIPTIONS.................................................................................. 22 DEFINITION OF TERM............................................................................................ 24 TIGHTENING OF BOLTS AND NUTS...................................................................................... 25 BOLTS AND NUTS................................................................................................ 25 PURPOSES OF TIGHTENING TORQUE................................................................................. 25 CAUTIONS TO PREVENT LOOSENESS................................................................................. 25 TYPES AND IDENTIFICATION...................................................................................... 26 COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)............................................................ 27 STRENGTH CLASSES AND SYMBOLS.................................................................................. 28 PART No....................................................................................................... 29 LIST OF TIGHTENING TORQUE..................................................................................... 30 TIGHTENING OF FLARE NUTS AND HOSES............................................................................ 32 HANDLING OF LIQUID GASKET......................................................................................... 33 LIQUID GASKET................................................................................................. 33 GLOSSARY.............................................................................................................. 34 DEFINITION OF ABBREVIATION IN THIS MANUAL......................................................................... 34 LIST OF ABBREVIATION.......................................................................................... 34 GLOSSARY OF SAE AND HINO TERMS................................................................................ 37 LUBRICANTS............................................................................................................ 40 LUBRICANTS........................................................................................................ 40 RECOMMENDED LUBRICANTS........................................................................................ 40 HYBRID.................................................................................................................... 42 STANDARD VALUE........................................................................................................ 43 HYBRID SYSTEM..................................................................................................... 43 SERVICE PLUG.................................................................................................. 43 PCU........................................................................................................... 43 HV BATTERY.................................................................................................... 44 HV BATTERY COOLING FAN........................................................................................ 44 HV BATTERY ECU................................................................................................ 44 SYSTEM MAIN RELAY JUNCTION BLOCK.............................................................................. 44 INVERTER...................................................................................................... 45 HV-ECU........................................................................................................ 45 HYBRID JUNCTION BLOCK......................................................................................... 45 WATER PUMP.................................................................................................... 46 INVERTER RADIATOR............................................................................................. 46 COOLANT....................................................................................................... 46 MOTOR CABLE................................................................................................... 46 REQUIRED ITEMS........................................................................................................ 47 HYBRID SYSTEM..................................................................................................... 47 HYBRID SYSTEM................................................................................................. 47 SERVICE PLUG.................................................................................................. 47 COOLANT....................................................................................................... 47 HYBRID SYSTEM......................................................................................................... 48 HYBRID SYSTEM..................................................................................................... 48 CAUTIONS...................................................................................................... 48 SERVICE PLUG...................................................................................................... 52 COMPONENT LOCATOR............................................................................................. 52 UNIT CHECK.................................................................................................... 52 REPLACEMENT................................................................................................... 53 PCU............................................................................................................... 55 COMPONENT LOCATOR............................................................................................. 55 REPLACEMENT................................................................................................... 59 HV BATTERY........................................................................................................ 64 COMPONENT LOCATOR............................................................................................. 64 REPLACEMENT................................................................................................... 66 HV BATTERY COOLING FAN............................................................................................ 71 COMPONENT LOCATOR............................................................................................. 71 REPLACEMENT................................................................................................... 73 HV BATTERY ECU.................................................................................................... 76 COMPONENT LOCATOR............................................................................................. 76 REPLACEMENT................................................................................................... 77 SYSTEM MAIN RELAY JUNCTION BLOCK.................................................................................. 80 COMPONENT LOCATOR............................................................................................. 80 REPLACEMENT................................................................................................... 81 INVERTER.......................................................................................................... 83 COMPONENT LOCATOR............................................................................................. 83 REPLACEMENT................................................................................................... 84 HV-ECU............................................................................................................ 88 COMPONENT LOCATOR............................................................................................. 88 REPLACEMENT................................................................................................... 89 HYBRID JUNCTION BLOCK............................................................................................. 91 COMPONENT LOCATOR............................................................................................. 91 REPLACEMENT................................................................................................... 92 WATER PUMP........................................................................................................ 95 COMPONENT LOCATOR............................................................................................. 95 REPLACEMENT................................................................................................... 96 INVERTER RADIATOR................................................................................................. 99 COMPONENT LOCATOR............................................................................................. 99 REPLACEMENT................................................................................................... 100 COOLANT........................................................................................................... 102 REPLACEMENT................................................................................................... 102 MOTOR CABLE....................................................................................................... 104 COMPONENT LOCATOR............................................................................................. 104 REPLACEMENT................................................................................................... 107 TRANSMISSION (A465)....................................................................................................... 113 STANDARD VALUE........................................................................................................ 114 MOUNTING AND DISMOUNTING 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 MOUNTING AND DISMOUNTING THE TRANSMISSION......................................................................... 118 AUTOMATIC TRANSMISSION ASSEMBLY............................................................................... 118 NEUTRAL SWITCH................................................................................................ 118 FRONT OIL SEAL................................................................................................ 118 MOUNTING AND DISMOUNTING 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............................................................................................... 194 OVERHAUL...................................................................................................... 194 FRONT OIL SEAL.................................................................................................... 203 OVERHAUL...................................................................................................... 203 PROPELLER SHAFT (LD)...................................................................................................... 205 STANDARD VALUE........................................................................................................ 206 PROPELLER SHAFT MECHANICAL........................................................................................ 206 PROPELLER SHAFT ASSEMBLY...................................................................................... 206 REQUIRED ITEMS........................................................................................................ 207 PROPELLER SHAFT MECHANICAL........................................................................................ 207 PROPELLER SHAFT ASSEMBLY...................................................................................... 207 PROPELLER SHAFT MECHANICAL............................................................................................ 209 PROPELLER SHAFT ASSEMBLY.......................................................................................... 209 COMPONENT LOCATOR............................................................................................. 209 OVERHAUL...................................................................................................... 211 AXLE...................................................................................................................... 226 STANDARD VALUE........................................................................................................ 227 FRONT AXLE........................................................................................................ 227 STEERING KNUCKLE.............................................................................................. 227 FRONT AXLE HUB................................................................................................ 228 REAR AXLE......................................................................................................... 229 REAR AXLE HUB................................................................................................. 229 REAR AXLE SHAFT............................................................................................... 230 REQUIRED ITEMS........................................................................................................ 231 FRONT AXLE........................................................................................................ 231 STEERING KNUCKLE.............................................................................................. 231 FRONT AXLE HUB................................................................................................ 232 REAR AXLE......................................................................................................... 235 REAR AXLE HUB................................................................................................. 235 REAR AXLE SHAFT............................................................................................... 236 WHEEL AND TIRE................................................................................................ 237 FRONT AXLE............................................................................................................ 238 STEERING KNUCKLE.................................................................................................. 238 COMPONENT LOCATOR............................................................................................. 238 OVERHAUL...................................................................................................... 242 FRONT AXLE HUB.................................................................................................... 257 COMPONENT LOCATOR............................................................................................. 257 OVERHAUL...................................................................................................... 259 FRONT AXLE HUB BOLT............................................................................................... 271 COMPONENT LOCATOR............................................................................................. 271 OVERHAUL...................................................................................................... 272 REAR AXLE............................................................................................................. 274 REAR AXLE HUB..................................................................................................... 274 COMPONENT LOCATOR............................................................................................. 274 OVERHAUL...................................................................................................... 276 REAR AXLE SHAFT................................................................................................... 286 COMPONENT LOCATOR............................................................................................. 286 OVERHAUL...................................................................................................... 287 WHEEL AND TIRE........................................................................................................ 289 WHEEL AND TIRE.................................................................................................... 289 COMPONENT LOCATOR............................................................................................. 289 INSPECTION.................................................................................................... 290 REPLACEMENT................................................................................................... 292 OVERHAUL (TUBELESS TIRE)...................................................................................... 295 DIFFERENTIAL (SH13)....................................................................................................... 302 STANDARD VALUE........................................................................................................ 303 DIFFERENTIAL...................................................................................................... 303 DIFFERENTIAL CARRIER.......................................................................................... 303 REQUIRED ITEMS........................................................................................................ 305 DIFFERENTIAL...................................................................................................... 305 DIFFERENTIAL CARRIER.......................................................................................... 305 DIFFERENTIAL.......................................................................................................... 308 DIFFERENTIAL CARRIER.............................................................................................. 308 COMPONENT LOCATOR............................................................................................. 308 OVERHAUL...................................................................................................... 316 BRAKE..................................................................................................................... 353 STANDARD VALUE........................................................................................................ 355 BRAKE CONTROL..................................................................................................... 355 SERVICE BRAKE................................................................................................. 355 BRAKE FLUID................................................................................................... 355 BRAKE ACTUATOR................................................................................................ 356 SPEED SENSOR.................................................................................................. 356 BRAKE PEDAL................................................................................................... 357 BRAKE MASTER CYLINDER......................................................................................... 357 BRAKE BOOSTER................................................................................................. 357 HYDRO BOOSTER................................................................................................. 358 ELECTRIC VACUUM PUMP.......................................................................................... 358 VACUUM PUMP................................................................................................... 358 HYDRO PUMP.................................................................................................... 359 VACUUM RESERVOIR.............................................................................................. 359 FRONT FLEXIBLE HOSE........................................................................................... 359 REAR FLEXIBLE HOSE............................................................................................ 359 VACUUM WARNING BUZZER......................................................................................... 359 VACUUM SENSOR (FOR SKID CONTROL).............................................................................. 360 DISC BRAKE ....................................................................................................... 360 FRONT DISC CALIPER............................................................................................ 360 REAR DISC CALIPER............................................................................................. 361 PARKING BRAKE..................................................................................................... 362 PARKING BRAKE................................................................................................. 362 PARKING BRAKE CABLE No.2...................................................................................... 362 PARKING BRAKE CABLE No.3...................................................................................... 362 PARKING BRAKE LEVER........................................................................................... 362 PARKING BRAKE DRUM............................................................................................ 363 PARKING BRAKE SWITCH.......................................................................................... 363 REQUIRED ITEMS........................................................................................................ 364 SERVICE BRAKE..................................................................................................... 364 SERVICE BRAKE................................................................................................. 364 BRAKE FLUID................................................................................................... 364 SPEED SENSOR.................................................................................................. 364 BRAKE PEDAL................................................................................................... 364 BRAKE BOOSTER................................................................................................. 364 HYDRO BOOSTER................................................................................................. 365 VACUUM RESERVOIR.............................................................................................. 365 DISC BRAKE........................................................................................................ 365 FRONT DISC CALIPER............................................................................................ 365 REAR DISC CALIPER............................................................................................. 365 PARKING BRAKE..................................................................................................... 366 PARKING BRAKE DRUM............................................................................................ 366 BRAKE CONTROL......................................................................................................... 367 SERVICE BRAKE..................................................................................................... 367 INSPECTION AND ADJUSTMENT..................................................................................... 367 BRAKE FLUID....................................................................................................... 372 REPLACEMENT................................................................................................... 372 ABS ACTUATOR...................................................................................................... 375 COMPONENT LOCATOR............................................................................................. 375 REPLACEMENT................................................................................................... 376 UNIT CHECK.................................................................................................... 378 SPEED SENSOR...................................................................................................... 379 COMPONENT LOCATOR............................................................................................. 379 UNIT CHECK.................................................................................................... 381 REPLACEMENT................................................................................................... 382 BRAKE PEDAL....................................................................................................... 385 COMPONENT LOCATOR............................................................................................. 385 REPLACEMENT................................................................................................... 386 BRAKE MASTER CYLINDER............................................................................................. 389 COMPONENT LOCATOR............................................................................................. 389 REPLACEMENT................................................................................................... 390 BRAKE BOOSTER..................................................................................................... 393 COMPONENT LOCATOR............................................................................................. 393 REPLACEMENT................................................................................................... 394 HYDRO BOOSTER..................................................................................................... 402 COMPONENT LOCATOR............................................................................................. 402 REPLACEMENT................................................................................................... 403 ELECTRIC VACUUM PUMP.............................................................................................. 408 COMPONENT LOCATOR............................................................................................. 408 OVERHAUL...................................................................................................... 409 VACUUM PUMP....................................................................................................... 413 COMPONENT LOCATOR............................................................................................. 413 OVERHAUL...................................................................................................... 414 HYDRO PUMP........................................................................................................ 416 COMPONENT LOCATOR............................................................................................. 416 OVERHAUL...................................................................................................... 417 VACUUM RESERVOIR.................................................................................................. 418 COMPONENT LOCATOR............................................................................................. 418 REPLACEMENT................................................................................................... 419 FRONT FLEXIBLE HOSE............................................................................................... 421 COMPONENT LOCATOR............................................................................................. 421 REPLACEMENT................................................................................................... 422 REAR FLEXIBLE HOSE................................................................................................ 424 COMPONENT LOCATOR............................................................................................. 424 REPLACEMENT................................................................................................... 425 VACUUM WARNING BUZZER............................................................................................. 427 BEHIND-THE-WHEEL INSPECTION................................................................................... 427 REPLACEMENT................................................................................................... 427 VACUUM SENSOR (FOR SKID CONTROL).................................................................................. 428 COMPONENT LOCATOR............................................................................................. 428 REPLACEMENT................................................................................................... 429 DISC BRAKE............................................................................................................ 432 FRONT BRAKE CALIPER............................................................................................... 432 COMPONENT LOCATOR............................................................................................. 432 OVERHAUL...................................................................................................... 433 REAR BRAKE CALIPER................................................................................................ 440 COMPONENT LOCATOR............................................................................................. 440 OVERHAUL...................................................................................................... 441 PARKING BRAKE......................................................................................................... 448 PARKING BRAKE..................................................................................................... 448 INSPECTION AND ADJUSTMENT..................................................................................... 448 PARKING BRAKE CABLE No.2.......................................................................................... 450 COMPONENT LOCATOR............................................................................................. 450 REPLACEMENT................................................................................................... 451 PARKING BRAKE CABLE No.3.......................................................................................... 457 COMPONENT LOCATOR............................................................................................. 457 REPLACEMENT................................................................................................... 458 PARKING BRAKE LEVER............................................................................................... 463 COMPONENT LOCATOR............................................................................................. 463 REPLACEMENT................................................................................................... 464 PARKING BRAKE DRUM................................................................................................ 468 COMPONENT LOCATOR............................................................................................. 468 OVERHAUL...................................................................................................... 470 PARKING BRAKE SWITCH.............................................................................................. 480 COMPONENT LOCATOR............................................................................................. 480 REPLACEMENT................................................................................................... 481 STEERING.................................................................................................................. 483 STANDARD VALUE........................................................................................................ 484 STEERING CONTROL.................................................................................................. 484 POWER STEERING SYSTEM......................................................................................... 484 STEERING WHEEL................................................................................................ 484 STEERING COLUMN............................................................................................... 484 STEERING LINKAGE.............................................................................................. 485 POWER STEERING GEAR........................................................................................... 485 POWER STEERING PUMP........................................................................................... 485 REQUIRED ITEMS........................................................................................................ 486 STEERING CONTROL.................................................................................................. 486 POWER STEERING SYSTEM......................................................................................... 486 STEERING WHEEL................................................................................................ 486 STEERING COLUMN............................................................................................... 487 STEERING LINKAGE.............................................................................................. 487 POWER STEERING GEAR........................................................................................... 488 POWER STEERING PUMP........................................................................................... 488 STEERING CONTROL...................................................................................................... 489 POWER STEERING SYSTEM............................................................................................. 489 PERFORMANCE INSPECTION........................................................................................ 489 STEERING WHEEL.................................................................................................... 492 COMPONENT LOCATOR............................................................................................. 492 REPLACEMENT................................................................................................... 493 STEERING COLUMN................................................................................................... 496 COMPONENT LOCATOR............................................................................................. 496 REPLACEMENT................................................................................................... 497 STEERING LINKAGE.................................................................................................. 504 COMPONENT LOCATOR............................................................................................. 504 REPLACEMENT................................................................................................... 505 POWER STEERING GEAR............................................................................................... 512 COMPONENT LOCATOR............................................................................................. 512 REPLACEMENT................................................................................................... 513 POWER STEERING PUMP............................................................................................... 524 COMPONENT LOCATOR............................................................................................. 524 REPLACEMENT .................................................................................................. 525 SUSPENSION................................................................................................................ 527 STANDARD VALUE........................................................................................................ 528 FRONT SUSPENSION.................................................................................................. 528 SHOCK ABSORBER................................................................................................ 528 LEAF SPRING................................................................................................... 528 STABILIZER.................................................................................................... 529 WHEEL ALIGNMENT............................................................................................... 529 REAR SUSPENSION................................................................................................... 530 SHOCK ABSORBER................................................................................................ 530 LEAF SPRING................................................................................................... 530 REQUIRED ITEMS........................................................................................................ 531 FRONT SUSPENSION.................................................................................................. 531 SHOCK ABSORBER................................................................................................ 531 LEAF SPRING................................................................................................... 531 WHEEL ALIGNMENT............................................................................................... 532 REAR SUSPENSION................................................................................................... 533 SHOCK ABSORBER................................................................................................ 533 LEAF SPRING................................................................................................... 533 FRONT SUSPENSION...................................................................................................... 534 SHOCK ABSORBER.................................................................................................... 534 COMPONENT LOCATOR............................................................................................. 534 REPLACEMENT................................................................................................... 535 LEAF SPRING....................................................................................................... 538 COMPONENT LOCATOR............................................................................................. 538 OVERHAUL...................................................................................................... 539 STABILIZER........................................................................................................ 547 COMPONENT LOCATOR............................................................................................. 547 REPLACEMENT................................................................................................... 548 WHEEL ALIGNMENT................................................................................................... 550 ADJUSTMENT.................................................................................................... 550 REAR SUSPENSION....................................................................................................... 554 SHOCK ABSORBER.................................................................................................... 554 COMPONENT LOCATOR............................................................................................. 554 REPLACEMENT................................................................................................... 555 LEAF SPRING....................................................................................................... 558 COMPONENT LOCATOR............................................................................................. 558 OVERHAUL...................................................................................................... 560 FRAME AND FRAME ACCESSORY................................................................................................. 569 STANDARD VALUE........................................................................................................ 570 FRAME............................................................................................................. 570 CHASSIS FRAME................................................................................................. 570 FRONT BUMPER.................................................................................................. 571 REQUIRED ITEMS........................................................................................................ 572 FRAME............................................................................................................. 572 CHASSIS FRAME & CHASSIS FRAME ACCESSORIES..................................................................... 572 FRAME................................................................................................................. 573 FRAME AND FRAME ACCESSORIES....................................................................................... 573 COMPONENT LOCATOR............................................................................................. 573 FRAME............................................................................................................. 574 INSPECTION.................................................................................................... 574 REPAIR........................................................................................................ 575 FRONT BUMPER...................................................................................................... 580 COMPONENT LOCATOR............................................................................................. 580 REPLACEMENT................................................................................................... 581 CAB MOUNTING AND CAB SUSPENSION........................................................................................... 586 STANDARD VALUE........................................................................................................ 587 CAB MOUNTING AND CAB SUSPENSION................................................................................... 587 ASSEMBLY...................................................................................................... 587 CAB MOUNTING.................................................................................................. 587 TILT CAB STAY................................................................................................. 588 MOUNTING AND DISMOUNTING CAB.......................................................................................... 589 CAB ASSEMBLY...................................................................................................... 589 REPLACEMENT................................................................................................... 589 CAB MOUNTING AND CAB SUSPENSION....................................................................................... 603 CAB MOUNTING...................................................................................................... 603 COMPONENT LOCATOR............................................................................................. 603 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................... 607 REPLACEMENT................................................................................................... 608 CAB TILT STAY..................................................................................................... 619 COMPONENT LOCATOR............................................................................................. 619 PRECAUTIONS IN TILTING AND LOWERING THE CAB................................................................... 622 REPLACEMENT................................................................................................... 623 CAB DIMENSIONAL DRAWING............................................................................................... 628 CAB ASSEMBLY...................................................................................................... 628 SINGLE CAB.................................................................................................... 628 CREW CAB...................................................................................................... 630 BODY INSIDE ACCESSORY..................................................................................................... 632 STANDARD VALUE........................................................................................................ 633 INSTRUMENT PANEL AND DRIVER INFORMATION........................................................................... 633 INSTRUMENT PANEL.............................................................................................. 633 INTERIOR ACCESSORY................................................................................................ 633 ROOF ACCESSORY................................................................................................ 633 SEAT.............................................................................................................. 633 DRIVER'S SEAT................................................................................................. 633 ASSISTANT'S SEAT.............................................................................................. 634 REAR SEAT..................................................................................................... 634 INSTRUMENT PANEL AND DRIVER INFORMATION............................................................................... 635 INSTRUMENT PANEL.................................................................................................. 635 COMPONENT LOCATOR............................................................................................. 635 REPLACEMENT................................................................................................... 637 COMBINATION METER................................................................................................. 647 REPLACEMENT................................................................................................... 647 INTERIOR ACCESSORY.................................................................................................... 648 INTERIOR ACCESSORY................................................................................................ 648 COMPONENT LOCATOR............................................................................................. 648 REPLACEMENT................................................................................................... 650 FLOOR ACCESSORY................................................................................................... 653 COMPONENT LOCATOR............................................................................................. 653 REPLACEMENT................................................................................................... 654 ROOF ACCESSORY.................................................................................................... 655 COMPONENT LOCATOR............................................................................................. 655 REPLACEMENT................................................................................................... 656 SEAT.................................................................................................................. 663 DRIVER'S SEAT..................................................................................................... 663 COMPONENT LOCATOR............................................................................................. 663 OVERHAUL...................................................................................................... 665 ASSISTANT'S SEAT.................................................................................................. 677 COMPONENT LOCATOR............................................................................................. 677 OVERHAUL (THREE-SEATER)....................................................................................... 680 OVERHAUL (CREW CAB)........................................................................................... 688 REAR SEAT......................................................................................................... 694 COMPONENT LOCATOR............................................................................................. 694 OVERHAUL...................................................................................................... 696 BODY OUTSIDE ACCESSORY.................................................................................................... 706 STANDARD VALUE........................................................................................................ 707 DOOR.............................................................................................................. 707 DOOR HINGE.................................................................................................... 707 DOOR ACCESSORIES.............................................................................................. 707 REQUIRED ITEMS........................................................................................................ 708 DOOR.............................................................................................................. 708 DOOR ACCESSORIES.............................................................................................. 708 POWER WINDOW.................................................................................................. 708 AUTO DOOR LOCK SYSTEM......................................................................................... 708 WINDOW GLASS...................................................................................................... 709 GLASS......................................................................................................... 709 MIRROR............................................................................................................ 710 POWER MIRROR.................................................................................................. 710 DOOR.................................................................................................................. 711 DOOR HINGE........................................................................................................ 711 INSPECTION AND ADJUSTMENT..................................................................................... 711 DOOR ACCESSORY.................................................................................................... 715 COMPONENT LOCATOR............................................................................................. 715 OVERHAUL...................................................................................................... 721 POWER WINDOW...................................................................................................... 743 SINGLE UNIT INSPECTION........................................................................................ 743 AUTO DOOR LOCK SYSTEM............................................................................................. 746 PERFORMANCE INSPECTION........................................................................................ 746 SINGLE UNIT INSPECTION........................................................................................ 746 KEYLESS ENTRY..................................................................................................... 748 PERFORMANCE INSPECTION........................................................................................ 748 WINDOW GLASS.......................................................................................................... 749 GLASS............................................................................................................. 749 COMPONENT LOCATOR............................................................................................. 749 REPLACEMENT................................................................................................... 751 MIRROR................................................................................................................ 762 REAR VIEW MIRROR.................................................................................................. 762 COMPONENT LOCATOR............................................................................................. 762 REPLACEMENT................................................................................................... 763 POWER MIRROR...................................................................................................... 764 SINGLE UNIT INSPECTION........................................................................................ 764 ACCESSORY............................................................................................................. 765 OUTSIDE ACCESSORY................................................................................................. 765 COMPONENT LOCATOR............................................................................................. 765 REPLACEMENT................................................................................................... 766 AIR BAG AND SEAT BELT..................................................................................................... 771 STANDARD VALUE........................................................................................................ 772 SEAT BELT......................................................................................................... 772 SEAT BELT..................................................................................................... 772 CENTER SEAT BELT.............................................................................................. 772 REAR SEAT BELT................................................................................................ 773 SEAT BELT............................................................................................................. 774 SEAT BELT......................................................................................................... 774 COMPONENT LOCATOR............................................................................................. 774 REPLACEMENT................................................................................................... 775 CENTER SEAT BELT.................................................................................................. 777 COMPONENT LOCATOR............................................................................................. 777 REPLACEMENT................................................................................................... 778 REAR SEAT BELT.................................................................................................... 779 COMPONENT LOCATOR............................................................................................. 779 REPLACEMENT................................................................................................... 780 HEATER AND AIR CONDITIONER................................................................................................ 783 STANDARD VALUE........................................................................................................ 784 AIR CONDITIONER................................................................................................... 784 AIR CONDITIONER............................................................................................... 784 V-BELT........................................................................................................ 785 COOLER COMPRESSOR............................................................................................. 785 CONDENSER..................................................................................................... 785 HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)......................................................... 786 HEATER CONTROL................................................................................................ 786 REAR HEATER (CREW CAB)........................................................................................ 786 REAR COOLER (CREW CAB)........................................................................................ 787 REQUIRED ITEMS........................................................................................................ 788 AIR CONDITIONER................................................................................................... 788 AIR CONDITIONER............................................................................................... 788 V-BELT........................................................................................................ 788 COOLER COMPRESSOR............................................................................................. 789 CONDENSER..................................................................................................... 789 AIR CONDITIONER....................................................................................................... 790 AIR CONDITIONER................................................................................................... 790 SAFETY INSTRUCTIONS FOR WORK.................................................................................. 790 COLLECTION/FILLING OF REFRIGERANT............................................................................. 794 MAINTENANCE................................................................................................... 802 V-BELT............................................................................................................ 805 COMPONENT LOCATOR............................................................................................. 805 REPLACEMENT................................................................................................... 806 COOLER COMPRESSOR................................................................................................. 811 COMPONENT LOCATOR............................................................................................. 811 REPLACEMENT................................................................................................... 812 CONDENSER......................................................................................................... 816 COMPONENT LOCATOR............................................................................................. 816 CONDENSER (WIDE CAB MODEL TYPE WITH FAN).......................................................................... 817 REPLACEMENT................................................................................................... 817 HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)............................................................. 822 COMPONENT LOCATOR............................................................................................. 822 HVAC (WIDE CAB MODEL)............................................................................................. 824 REPLACEMENT................................................................................................... 824 HEATER CONTROL.................................................................................................... 831 COMPONENT LOCATOR............................................................................................. 831 REPLACEMENT................................................................................................... 832 REAR HEATER (CREW CAB)............................................................................................ 835 COMPONENT LOCATOR............................................................................................. 835 REPLACEMENT................................................................................................... 836 REAR HEATER BLOWER SWITCH (CREW CAB).............................................................................. 842 COMPONENT LOCATOR............................................................................................. 842 REPLACEMENT................................................................................................... 843 REAR COOLER (CREW CAB)............................................................................................ 845 COMPONENT LOCATOR............................................................................................. 845 REPLACEMENT................................................................................................... 846 COOLER CONTROL SWITCH (CREW CAB).................................................................................. 853 COMPONENT LOCATOR............................................................................................. 853 REPLACEMENT................................................................................................... 854 ELECTRICAL................................................................................................................ 857 STANDARD VALUE........................................................................................................ 858 LIGHTING.......................................................................................................... 858 HEADLIGHT..................................................................................................... 858 WIPER AND WASHER.................................................................................................. 858 WIPER......................................................................................................... 858 WASHER........................................................................................................ 858 REQUIRED ITEMS........................................................................................................ 859 LIGHTING.......................................................................................................... 859 COMBINATION SWITCH............................................................................................ 859 LIGHTING.............................................................................................................. 860 HEADLIGHT......................................................................................................... 860 COMPONENT LOCATOR............................................................................................. 860 OPTICAL AXIS ADJUSTMENT....................................................................................... 861 REPLACEMENT................................................................................................... 862 FOG LIGHT......................................................................................................... 863 REPLACEMENT................................................................................................... 863 ID LIGHT.......................................................................................................... 864 COMPONENT LOCATOR............................................................................................. 864 REPLACEMENT................................................................................................... 865 ROOM LIGHT........................................................................................................ 866 COMPONENT LOCATOR............................................................................................. 866 REPLACEMENT................................................................................................... 867 COMBINATION SWITCH................................................................................................ 868 COMPONENT LOCATOR............................................................................................. 868 REPLACEMENT................................................................................................... 869 INSPECTION.................................................................................................... 869 WIPER AND WASHER...................................................................................................... 872 WIPER............................................................................................................. 872 COMPONENT LOCATOR............................................................................................. 872 REPLACEMENT................................................................................................... 873 WASHER............................................................................................................ 876 COMPONENT LOCATOR............................................................................................. 876 REPLACEMENT .................................................................................................. 877 COMPUTER.............................................................................................................. 879 COMPUTER.......................................................................................................... 879 MOUNTING POSITION............................................................................................. 879 SWITCH................................................................................................................ 881 SWITCH............................................................................................................ 881 MOUNTING POSITION............................................................................................. 881 FUSE AND RELAY........................................................................................................ 882 FUSE BLOCK........................................................................................................ 882 MOUNTING POSITION............................................................................................. 882 RELAY............................................................................................................. 884 MOUNTING POSITION............................................................................................. 884 CONTROL SYSTEM............................................................................................................ 885 REQUIRED ITEMS........................................................................................................ 886 HINO STOP&START SYSTEM............................................................................................ 886 SLOPE LEARNING................................................................................................ 886 HINO STOP&START SYSTEM................................................................................................ 887 HINO STOP&START SYSTEM............................................................................................ 887 SLOPE LEARNING................................................................................................ 887 CRUISE CONTROL........................................................................................................ 889 CRUISE MAIN SWITCH................................................................................................ 889 COMPONENT LOCATOR............................................................................................. 889 REPLACEMENT................................................................................................... 890 SINGLE UNIT INSPECTION........................................................................................ 891 FOREWORD.................................................................................................................. 893 CHAPTER REFERENCES........................................................................................................ 894 INDEX..................................................................................................................... 895 GENERAL INTRODUCTION...................................................................................................... 897 HOW TO IDENTIFY VEHICLE TYPE.......................................................................................... 898 VEHICLE MODEL..................................................................................................... 898 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE..................................................................... 899 APPEARANCE OF VEHICLE................................................................................................. 900 APPEARANCE OF VEHICLE............................................................................................. 900 SAFETY INSTRUCTIONS AND READINESS TO WORK............................................................................. 901 WARNING........................................................................................................... 901 IDENTIFICATION INFORMATION........................................................................................ 905 SAFETY INSTRUCTIONS FOR WORK...................................................................................... 908 INTRODUCTION TO WORKSHOP MANUAL................................................................................... 911 TIGHTENING OF BOLTS AND NUTS...................................................................................... 915 HANDLING OF LIQUID GASKET......................................................................................... 925 GLOSSARY.............................................................................................................. 926 DEFINITION OF ABBREVIATION IN THIS MANUAL......................................................................... 926 LUBRICANTS............................................................................................................ 932 RECOMMENDED LUBRICANTS............................................................................................ 932 STANDARD VALUE (J05E)..................................................................................................... 933 MOUNTING AND DISMOUNTING THE ENGINE................................................................................... 935 ENGINE ASSEMBLY................................................................................................... 935 ENGINE CONTROL........................................................................................................ 936 ENGINE ECU........................................................................................................ 936 ENGINE SPEED MAIN SENSOR.......................................................................................... 936 ENGINE SPEED SUB SENSOR........................................................................................... 936 ACCELERATOR PEDAL................................................................................................. 937 BLOCK HEATER...................................................................................................... 937 FUEL SYSTEM........................................................................................................... 938 FUEL TANK......................................................................................................... 938 FUEL SENDER GAUGE................................................................................................. 938 FUEL FILTER AND CASE (ENGINE SIDE)................................................................................ 939 SUPPLY PUMP....................................................................................................... 940 INJECTOR.......................................................................................................... 940 COMMON RAIL....................................................................................................... 941 FUEL FILTER AND CASE (VEHICLE SIDE)............................................................................... 941 FUEL COOLER....................................................................................................... 941 EMISSION CONTROL...................................................................................................... 942 EGR VALVE & COOLER................................................................................................ 942 CLOSED VENTILATOR................................................................................................. 942 INTAKE................................................................................................................ 943 INTAKE MANIFOLD................................................................................................... 943 DIESEL THROTTLE................................................................................................... 943 INTAKE PIPE (EXHAUST SIDE)........................................................................................ 943 STACK DUCT........................................................................................................ 943 AIR CLEANER....................................................................................................... 944 INTAKE TEMPERATURE SENSOR......................................................................................... 944 BOOST PRESSURE SENSOR............................................................................................. 944 AIR FLOW SENSOR................................................................................................... 944 ENGINE MECHANICAL..................................................................................................... 945 HEAD COVER........................................................................................................ 945 ROCKER ARM ASSEMBLY............................................................................................... 945 CAMSHAFT ASSEMBLY................................................................................................. 946 CYLINDER HEAD ASSEMBLY............................................................................................ 947 VALVE SYSTEM...................................................................................................... 948 CRANKSHAFT PULLEY................................................................................................. 949 FRONT OIL SEAL RETAINER........................................................................................... 949 FLYWHEEL ASSEMBLY................................................................................................. 949 FLYWHEEL HOUSING.................................................................................................. 949 TIMING GEAR AND CAM IDLE GEAR..................................................................................... 950 PISTON AND CONNECTING ROD......................................................................................... 952 CRANKSHAFT........................................................................................................ 953 CYLINDER LINER.................................................................................................... 954 CYLINDER BLOCK.................................................................................................... 954 ENGINE MOUNTING AND BRACKET....................................................................................... 955 GLOW PLUG......................................................................................................... 955 EXHAUST............................................................................................................... 956 EXHAUST MANIFOLD.................................................................................................. 956 EXHAUST PIPE...................................................................................................... 956 EXHAUST PIPE (ATC)................................................................................................ 956 DEF-SCR........................................................................................................... 957 DPR CLEANER....................................................................................................... 957 AFTERTREATMENT FUEL INJECTOR...................................................................................... 958 AFTERTREATMENT FUEL CUTOFF VALVE.................................................................................. 958 DEF PUMP.......................................................................................................... 958 DEF INJECTOR...................................................................................................... 959 DEF TANK.......................................................................................................... 959 COOLANT CUTOFF VALVE.............................................................................................. 959 DCU............................................................................................................... 960 DPR DIFFERENTIAL PRESSURE SENSOR.................................................................................. 960 SCR UPSTREAM NOx SENSOR........................................................................................... 960 SCR DOWNSTREAM NOx SENSOR......................................................................................... 960 PM SENSOR......................................................................................................... 961 EXHAUST TEMPERATURE SENSOR 1 (ATC INLET).......................................................................... 961 EXHAUST TEMPERATURE SENSOR 2 (ATC OUTLET)......................................................................... 961 EXHAUST TEMPERATURE SENSOR 3 (DOC INLET).......................................................................... 962 EXHAUST TEMPERATURE SENSOR 4 (DPR INLET).......................................................................... 962 EXHAUST TEMPERATURE SENSOR 5 (DPR OUTLET)......................................................................... 962 DEF SCR TEMPERATURE SENSOR (SCR INLET)............................................................................ 963 EXHAUST BRAKE..................................................................................................... 964 EXHAUST BRAKE MAGNETIC VALVE...................................................................................... 964 COOLING............................................................................................................... 965 RADIATOR.......................................................................................................... 965 RADIATOR CAP...................................................................................................... 965 RESERVE TANK...................................................................................................... 965 INTERCOOLER....................................................................................................... 966 THERMOSTAT CASE AND THERMOSTAT.................................................................................... 966 COOLANT PUMP...................................................................................................... 967 COOLING FAN AND FAN CLUTCH........................................................................................ 967 COOLANT TEMPERATURE SENSOR........................................................................................ 967 LUBRICATION........................................................................................................... 968 OIL FILTER........................................................................................................ 968 OIL COOLER........................................................................................................ 968 OIL PUMP.......................................................................................................... 969 OIL PAN........................................................................................................... 970 OIL STRAINER...................................................................................................... 970 OIL PRESSURE SWITCH............................................................................................... 970 OIL LEVEL GAUGE AND GUIDE......................................................................................... 970 STARTING/CHARGING..................................................................................................... 971 STARTER........................................................................................................... 971 V-BELT............................................................................................................ 971 ALTERNATOR (130 A)................................................................................................ 972 TURBOCHARGER.......................................................................................................... 973 TURBOCHARGER ASSEMBLY............................................................................................. 973 REQUIRED ITEMS (J05E)..................................................................................................... 974 MOUNTING AND DISMOUNTING THE ENGINE................................................................................... 975 ENGINE ASSEMBLY................................................................................................... 975 ENGINE CONTROL........................................................................................................ 976 ENGINE ECU........................................................................................................ 976 ENGINE MAIN REVOLUTION SENSOR..................................................................................... 976 ENGINE SUB REVOLUTION SENSOR...................................................................................... 977 ACCELERATOR PEDAL................................................................................................. 978 IDLE SET VOLUME................................................................................................... 978 FUEL SYSTEM........................................................................................................... 979 FUEL SENDER GAUGE................................................................................................. 979 WATER LEVEL WARNING SWITCH........................................................................................ 979 SUPPLY PUMP....................................................................................................... 980 INJECTOR.......................................................................................................... 981 COMMON RAIL....................................................................................................... 982 FUEL FILTER AND CASE (VEHICLE SIDE)............................................................................... 982 EMISSION CONTROL...................................................................................................... 983 EGR VALVE AND COOLER.............................................................................................. 983 INTAKE................................................................................................................ 984 DIESEL THROTTLE................................................................................................... 984 BOOST PRESSURE SENSOR............................................................................................. 985 AIR FLOW SENSOR................................................................................................... 986 ENGINE MECHANICAL..................................................................................................... 987 HEAD COVER........................................................................................................ 987 ROCKER ARM ASSEMBLY............................................................................................... 987 CAMSHAFT ASSEMBLY................................................................................................. 987 CYLINDER HEAD ASSEMBLY............................................................................................ 988 VALVE SYSTEM...................................................................................................... 989 CRANKSHAFT FRONT OIL SEAL......................................................................................... 990 FRONT OIL SEAL RETAINER........................................................................................... 990 FLYWHEEL ASSEMBLY................................................................................................. 990 CRANKSHAFT REAR OIL SEAL.......................................................................................... 991 FLYWHEEL HOUSING.................................................................................................. 991 TIMING GEAR AND CAM IDLE GEAR..................................................................................... 992 PISTON AND CONNECTING ROD......................................................................................... 994 CRANKSHAFT........................................................................................................ 996 CYLINDER LINER.................................................................................................... 997 CYLINDER BLOCK.................................................................................................... 998 GLOW PLUG......................................................................................................... 998 EXHAUST............................................................................................................... 999 EXHAUST MANIFOLD.................................................................................................. 999 DPR CLEANER....................................................................................................... 999 AFTERTREATMENT FUEL INJECTOR......................................................................................1000 DEF PUMP..........................................................................................................1000 DEF INJECTOR......................................................................................................1000 DEF TANK..........................................................................................................1001 DEF SENSOR........................................................................................................1001 DPR DIFFERENTIAL PRESSURE SENSOR..................................................................................1001 SCR UPSTREAM NOx SENSOR...........................................................................................1001 SCR DOWNSTREAM NOx SENSOR.........................................................................................1002 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)......................................................................1002 EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET).....................................................................1002 EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)......................................................................1003 EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)......................................................................1003 EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET).....................................................................1003 DEF SCR TEMPERATURE SENSOR (SCR INLET)............................................................................1004 EXHAUST BRAKE.....................................................................................................1004 EXHAUST BRAKE MAGNETIC VALVE......................................................................................1004 COOLING...............................................................................................................1005 RADIATOR CAP......................................................................................................1005 THERMOSTAT CASE AND THERMOSTAT....................................................................................1005 COOLANT PUMP......................................................................................................1006 COOLANT TEMPERATURE SENSOR........................................................................................1006 LUBRICATION...........................................................................................................1007 OIL FILTER........................................................................................................1007 OIL COOLER........................................................................................................1007 OIL PUMP..........................................................................................................1008 OIL PAN...........................................................................................................1008 OIL PRESSURE SWITCH...............................................................................................1008 STARTING/CHARGING.....................................................................................................1009 STARTER...........................................................................................................1009 V-BELT............................................................................................................1009 ALTERNATOR (130A).................................................................................................1009 TURBOCHARGER..........................................................................................................1010 TURBOCHARGER ASSEMBLY.............................................................................................1010 MOUNTING AND DISMOUNTING THE ENGINE (J05E)................................................................................1012 ENGINE ASSEMBLY.......................................................................................................1013 PRECAUTIONS IN TILTING AND LOWERING THE CAB.......................................................................1013 MEASUREMENT OF COMPRESSION PRESSURE...............................................................................1013 ADJUSTING THE VALVE CLEARANCE.....................................................................................1016 REPLACEMENT.......................................................................................................1018 ENGINE CONTROL (J05E).....................................................................................................1027 CONTROL PARTS.........................................................................................................1028 SYSTEM BLOCK DIAGRAM..............................................................................................1028 ENGINE ECU............................................................................................................1029 COMPONENT LOCATOR.................................................................................................1029 REPLACEMENT.......................................................................................................1030 VEHICLE CONTROL ECU...................................................................................................1036 REPLACEMENT.......................................................................................................1036 ENGINE SPEED MAIN SENSOR..............................................................................................1037 COMPONENT LOCATOR.................................................................................................1037 INSPECTION........................................................................................................1038 REPLACEMENT.......................................................................................................1038 ENGINE SPEED SUB SENSOR...............................................................................................1039 COMPONENT LOCATOR.................................................................................................1039 INSPECTION........................................................................................................1040 REPLACEMENT.......................................................................................................1040 ACCELERATOR PEDAL.....................................................................................................1041 COMPONENT LOCATOR.................................................................................................1041 REPLACEMENT.......................................................................................................1042 BLOCK HEATER..........................................................................................................1043 COMPONENT LOCATOR.................................................................................................1043 REPLACEMENT.......................................................................................................1044 FUEL SENDER GAUGE.....................................................................................................1045 REPLACEMENT.......................................................................................................1045 INTAKE TEMPERATURE SENSOR.............................................................................................1045 REPLACEMENT.......................................................................................................1045 DIESEL THROTTLE.......................................................................................................1045 REPLACEMENT.......................................................................................................1045 BOOST PRESSURE SENSOR.................................................................................................1046 REPLACEMENT.......................................................................................................1046 AIR FLOW SENSOR.......................................................................................................1046 REPLACEMENT.......................................................................................................1046 DPR DIFFERENTIAL PRESSURE SENSOR......................................................................................1047 REPLACEMENT.......................................................................................................1047 SCR UPSTREAM NOx SENSOR...............................................................................................1047 REPLACEMENT.......................................................................................................1047 SCR DOWNSTREAM NOx SENSOR.............................................................................................1047 REPLACEMENT.......................................................................................................1047 PM SENSOR.............................................................................................................1048 REPLACEMENT.......................................................................................................1048 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)..........................................................................1048 REPLACEMENT.......................................................................................................1048 EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET).........................................................................1049 REPLACEMENT.......................................................................................................1049 EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)..........................................................................1049 REPLACEMENT.......................................................................................................1049 EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)..........................................................................1050 REPLACEMENT.......................................................................................................1050 EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET).........................................................................1050 REPLACEMENT.......................................................................................................1050 DEF SCR TEMPERATURE SENSOR (SCR INLET)................................................................................1051 REPLACEMENT.......................................................................................................1051 AMBIENT AIR TEMPERATURE SENSOR........................................................................................1051 REPLACEMENT.......................................................................................................1051 COOLANT TEMPERATURE SENSOR............................................................................................1052 REPLACEMENT.......................................................................................................1052 OIL PRESSURE SWITCH...................................................................................................1052 REPLACEMENT.......................................................................................................1052 FUEL SYSTEM (J05E)........................................................................................................1053 FUEL SYSTEM...........................................................................................................1054 FUEL SYSTEM DIAGRAM...............................................................................................1054 FUEL TANK.............................................................................................................1055 COMPONENT LOCATOR.................................................................................................1055 REPLACEMENT (30 GALLON)...........................................................................................1056 REPLACEMENT (33 GALLON)...........................................................................................1059 FUEL SENDER GAUGE.....................................................................................................1063 COMPONENT LOCATOR.................................................................................................1063 REPLACEMENT.......................................................................................................1064 FUEL FILTER AND CASE (ENGINE SIDE)....................................................................................1066 COMPONENT LOCATOR.................................................................................................1066 REPLACEMENT.......................................................................................................1068 SUPPLY PUMP...........................................................................................................1077 COMPONENT LOCATOR.................................................................................................1077 REPLACEMENT.......................................................................................................1078 INJECTOR..............................................................................................................1088 COMPONENT LOCATOR.................................................................................................1088 REPLACEMENT.......................................................................................................1089 COMMON RAIL...........................................................................................................1098 COMPONENT LOCATOR.................................................................................................1098 INSPECTION........................................................................................................1099 REPLACEMENT.......................................................................................................1100 FUEL FILTER AND CASE (VEHICLE SIDE)...................................................................................1105 COMPONENT LOCATOR.................................................................................................1105 REPLACEMENT.......................................................................................................1106 FUEL COOLER...........................................................................................................1113 COMPONENT LOCATOR.................................................................................................1113 REPLACEMENT.......................................................................................................1114 EMISSION CONTROL (J05E)...................................................................................................1116 EGR VALVE & COOLER....................................................................................................1117 COMPONENT LOCATOR.................................................................................................1117 INSPECTION........................................................................................................1118 REPLACEMENT.......................................................................................................1118 CLOSED VENTILATOR.....................................................................................................1125 COMPONENT LOCATOR.................................................................................................1125 REPLACEMENT.......................................................................................................1127 INTAKE (J05E).............................................................................................................1131 INTAKE MANIFOLD.......................................................................................................1132 COMPONENT LOCATOR.................................................................................................1132 REPLACEMENT.......................................................................................................1133 DIESEL THROTTLE.......................................................................................................1138 COMPONENT LOCATOR.................................................................................................1138 INSPECTION........................................................................................................1139 REPLACEMENT.......................................................................................................1139 INTAKE PIPE (EXHAUST SIDE)............................................................................................1141 COMPONENT LOCATOR.................................................................................................1141 REPLACEMENT.......................................................................................................1142 INTERCOOLER...........................................................................................................1148 OVERHAUL..........................................................................................................1148 STACK DUCT............................................................................................................1149 COMPONENT LOCATOR.................................................................................................1149 CLEANING THE PRECLEANER HOUSING...................................................................................1150 REPLACEMENT.......................................................................................................1151 AIR CLEANER...........................................................................................................1153 COMPONENT LOCATOR.................................................................................................1153 REPLACEMENT.......................................................................................................1155 CLEANING THE AIR CLEANER ELEMENT..................................................................................1159 INTAKE TEMPERATURE SENSOR.............................................................................................1160 COMPONENT LOCATOR.................................................................................................1160 REPLACEMENT.......................................................................................................1162 BOOST PRESSURE SENSOR.................................................................................................1163 COMPONENT LOCATOR.................................................................................................1163 INSPECTION........................................................................................................1164 REPLACEMENT.......................................................................................................1164 AIR FLOW SENSOR.......................................................................................................1166 COMPONENT LOCATOR.................................................................................................1166 INSPECTION........................................................................................................1167 REPLACEMENT.......................................................................................................1169 ENGINE MECHANICAL (J05E)..................................................................................................1170 HEAD COVER............................................................................................................1171 COMPONENT LOCATOR.................................................................................................1171 REPLACEMENT.......................................................................................................1172 ROCKER ARM ASSEMBLY...................................................................................................1175 COMPONENT LOCATOR.................................................................................................1175 OVERHAUL..........................................................................................................1176 CAMSHAFT ASSEMBLY.....................................................................................................1183 COMPONENT LOCATOR.................................................................................................1183 OVERHAUL..........................................................................................................1185 CYLINDER HEAD ASSEMBLY................................................................................................1190 COMPONENT LOCATOR.................................................................................................1190 REPLACEMENT.......................................................................................................1191 OVERHAUL..........................................................................................................1199 VALVE SYSTEM..........................................................................................................1205 COMPONENT LOCATOR.................................................................................................1205 OVERHAUL..........................................................................................................1206 CRANKSHAFT PULLEY.....................................................................................................1215 COMPONENT LOCATOR.................................................................................................1215 REPLACEMENT.......................................................................................................1216 CRANKSHAFT FRONT OIL SEAL.............................................................................................1218 COMPONENT LOCATOR.................................................................................................1218 REPLACEMENT.......................................................................................................1219 FRONT OIL SEAL RETAINER...............................................................................................1222 COMPONENT LOCATOR.................................................................................................1222 REPLACEMENT.......................................................................................................1223 FLYWHEEL ASSEMBLY.....................................................................................................1225 COMPONENT LOCATOR.................................................................................................1225 OVERHAUL..........................................................................................................1226 CRANKSHAFT REAR OIL SEAL..............................................................................................1230 COMPONENT LOCATOR.................................................................................................1230 REPLACEMENT.......................................................................................................1231 FLYWHEEL HOUSING......................................................................................................1234 COMPONENT LOCATOR.................................................................................................1234 REPLACEMENT.......................................................................................................1235 TIMING GEAR & CAM IDLE GEAR...........................................................................................1239 COMPONENT LOCATOR.................................................................................................1239 CONFIGURATION DIAGRAM.............................................................................................1240 OVERHAUL..........................................................................................................1241 PISTON AND CONNECTING ROD.............................................................................................1258 COMPONENT LOCATOR.................................................................................................1258 OVERHAUL..........................................................................................................1259 CRANKSHAFT............................................................................................................1275 COMPONENT LOCATOR.................................................................................................1275 REPLACEMENT.......................................................................................................1277 CYLINDER LINER........................................................................................................1286 COMPONENT LOCATOR.................................................................................................1286 REPLACEMENT.......................................................................................................1287 CYLINDER BLOCK........................................................................................................1291 COMPONENT LOCATOR.................................................................................................1291 OVERHAUL..........................................................................................................1292 ENGINE MOUNTING AND BRACKET...........................................................................................1300 COMPONENT LOCATOR.................................................................................................1300 REPLACEMENT.......................................................................................................1301 GLOW PLUG.............................................................................................................1303 COMPONENT LOCATOR.................................................................................................1303 REPLACEMENT.......................................................................................................1304 GCU...................................................................................................................1306 COMPONENT LOCATOR.................................................................................................1306 REPLACEMENT.......................................................................................................1306 EXHAUST (J05E)............................................................................................................1307 EXHAUST MANIFOLD......................................................................................................1309 COMPONENT LOCATOR.................................................................................................1309 REPLACEMENT.......................................................................................................1310 EXHAUST PIPE..........................................................................................................1313 COMPONENT LOCATOR.................................................................................................1313 REPLACEMENT.......................................................................................................1314 EXHAUST PIPE (ATC)....................................................................................................1322 COMPONENT LOCATOR.................................................................................................1322 REPLACEMENT.......................................................................................................1323 DEF-SCR & DPR.........................................................................................................1325 CONFIGURATION DIAGRAM.............................................................................................1325 HANDLING OF DEF...................................................................................................1326 CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING ...........................................................1327 DEF-SCR...............................................................................................................1329 COMPONENT LOCATOR.................................................................................................1329 REPLACEMENT.......................................................................................................1330 DPR CLEANER...........................................................................................................1334 COMPONENT LOCATOR.................................................................................................1334 DPR INSPECTION....................................................................................................1335 INSPECTION PROCEDURE FOLLOWED WHEN “EXHAUST GAS AFTER TREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT” LIGHT UP....1336 INSPECTION BY WAY OF HINO DXⅡ.....................................................................................1337 INSPECTION PROCEDURE FOLLOWED WHEN MALFUNCTION INDICATOR LIGHT ILLUMINATES (ABNORMAL).............................1341 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX Ⅱ..............................................1344 CHECKING THE DPR STATE............................................................................................1344 REPLACEMENT.......................................................................................................1345 OVERALL OPERATION FLOW............................................................................................1350 AIR CLEANING FLOW.................................................................................................1357 AFTERTREATMENT FUEL INJECTOR..........................................................................................1358 COMPONENT LOCATOR.................................................................................................1358 REPLACEMENT.......................................................................................................1359 AFTERTREATMENT FUEL CUTOFF VALVE......................................................................................1367 COMPONENT LOCATOR.................................................................................................1367 REPLACEMENT.......................................................................................................1368 DEF PUMP..............................................................................................................1370 COMPONENT LOCATOR.................................................................................................1370 REPLACEMENT.......................................................................................................1371 DEF INJECTOR..........................................................................................................1381 COMPONENT LOCATOR.................................................................................................1381 REPLACEMENT.......................................................................................................1382 DEF TANK..............................................................................................................1387 COMPONENT LOCATOR.................................................................................................1387 INSPECTION........................................................................................................1388 REPLACEMENT.......................................................................................................1389 DEF SENSOR............................................................................................................1397 COMPONENT LOCATOR.................................................................................................1397 REPLACEMENT.......................................................................................................1398 COOLANT CUTOFF VALVE..................................................................................................1400 COMPONENT LOCATOR.................................................................................................1400 REPLACEMENT.......................................................................................................1401 DCU...................................................................................................................1403 COMPONENT LOCATOR.................................................................................................1403 REPLACEMENT.......................................................................................................1404 DPR DIFFERENTIAL PRESSURE SENSOR......................................................................................1410 COMPONENT LOCATOR.................................................................................................1410 REPLACEMENT.......................................................................................................1411 SCR UPSTREAM NOx SENSOR...............................................................................................1413 COMPONENT LOCATOR.................................................................................................1413 REPLACEMENT.......................................................................................................1414 SCR DOWNSTREAM NOx SENSOR.............................................................................................1416 COMPONENT LOCATOR.................................................................................................1416 REPLACEMENT.......................................................................................................1417 PM SENSOR.............................................................................................................1419 COMPONENT LOCATOR.................................................................................................1419 REPLACEMENT.......................................................................................................1420 EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)..........................................................................1422 COMPONENT LOCATOR.................................................................................................1422 REPLACEMENT.......................................................................................................1423 EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET).........................................................................1425 COMPONENT LOCATOR.................................................................................................1425 REPLACEMENT.......................................................................................................1426 EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)..........................................................................1428 COMPONENT LOCATOR.................................................................................................1428 REPLACEMENT.......................................................................................................1429 EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)..........................................................................1431 COMPONENT LOCATOR.................................................................................................1431 REPLACEMENT.......................................................................................................1432 EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET).........................................................................1434 COMPONENT LOCATOR.................................................................................................1434 REPLACEMENT.......................................................................................................1435 DEF SCR TEMPERATURE SENSOR (SCR INLET)................................................................................1437 COMPONENT LOCATOR.................................................................................................1437 REPLACEMENT.......................................................................................................1438 AMBIENT AIR TEMPERATURE SENSOR........................................................................................1441 COMPONENT LOCATOR.................................................................................................1441 REPLACEMENT.......................................................................................................1442 EXHAUST BRAKE.........................................................................................................1443 COMPONENT LOCATOR.................................................................................................1443 REPLACEMENT.......................................................................................................1444 EXHAUST BRAKE MAGNETIC VALVE..........................................................................................1447 COMPONENT LOCATOR.................................................................................................1447 REPLACEMENT.......................................................................................................1448 COOLING (J05E)............................................................................................................1450 COOLING SYSTEM........................................................................................................1451 COOLING SYSTEM DIAGRAM............................................................................................1451 RADIATOR..............................................................................................................1452 COMPONENT LOCATOR.................................................................................................1452 INSPECTION........................................................................................................1453 REPLACEMENT.......................................................................................................1454 RADIATOR CAP..........................................................................................................1464 COMPONENT LOCATOR.................................................................................................1464 REPLACEMENT.......................................................................................................1465 RESERVE TANK..........................................................................................................1467 COMPONENT LOCATOR.................................................................................................1467 REPLACEMENT.......................................................................................................1468 INTERCOOLER...........................................................................................................1469 COMPONENT LOCATOR.................................................................................................1469 OVERHAUL..........................................................................................................1470 THERMOSTAT CASE AND THERMOSTAT........................................................................................1472 COMPONENT LOCATOR.................................................................................................1472 OVERHAUL..........................................................................................................1473 COOLANT PUMP..........................................................................................................1479 COMPONENT LOCATOR.................................................................................................1479 REPLACEMENT.......................................................................................................1480 COOLING FAN AND FAN CLUTCH............................................................................................1482 COMPONENT LOCATOR.................................................................................................1482 OVERHAUL..........................................................................................................1483 COOLANT TEMPERATURE SENSOR............................................................................................1486 COMPONENT LOCATOR.................................................................................................1486 REPLACEMENT.......................................................................................................1487 LUBRICATION (J05E)........................................................................................................1489 LUBRICATION SYSTEM....................................................................................................1490 LUBRICATION SYSTEM DIAGRAM........................................................................................1490 OIL FILTER............................................................................................................1491 COMPONENT LOCATOR.................................................................................................1491 REPLACEMENT.......................................................................................................1492 OIL COOLER............................................................................................................1495 COMPONENT LOCATOR.................................................................................................1495 OVERHAUL..........................................................................................................1496 OIL PUMP..............................................................................................................1503 COMPONENT LOCATOR.................................................................................................1503 OVERHAUL..........................................................................................................1504 OIL PAN...............................................................................................................1510 COMPONENT LOCATOR.................................................................................................1510 REPLACEMENT.......................................................................................................1511 OIL STRAINER..........................................................................................................1515 COMPONENT LOCATOR.................................................................................................1515 REPLACEMENT.......................................................................................................1516 OIL PRESSURE SWITCH...................................................................................................1517 COMPONENT LOCATOR.................................................................................................1517 REPLACEMENT.......................................................................................................1518 OIL LEVEL GAUGE AND GUIDE.............................................................................................1520 COMPONENT LOCATOR.................................................................................................1520 REPLACEMENT.......................................................................................................1521 STARTING/CHARGING (J05E)..................................................................................................1523 STARTER...............................................................................................................1524 COMPONENT LOCATOR.................................................................................................1524 REPLACEMENT.......................................................................................................1525 V-BELT................................................................................................................1530 COMPONENT LOCATOR.................................................................................................1530 REPLACEMENT.......................................................................................................1531 ALTERNATOR (130A).....................................................................................................1534 COMPONENT LOCATOR.................................................................................................1534 OVERHAUL..........................................................................................................1535 TURBOCHARGER (J05E).......................................................................................................1549 TURBOCHARGER ASSEMBLY.................................................................................................1550 COMPONENT LOCATOR.................................................................................................1550 INSPECTION........................................................................................................1551 REPLACEMENT.......................................................................................................1553 FOREWORD..................................................................................................................1562 CHAPTER REFERENCES........................................................................................................1563 INDEX.....................................................................................................................1564 GENERAL INTRODUCTION......................................................................................................1565 HOW TO USE THIS MANUAL................................................................................................1566 GRAPHICAL SYMBOLS FOR WIRING DIAGRAMS, ABBREVIATIONS AND TERMS....................................................1566 WIRING DIAGRAM....................................................................................................1571 WIRE TO WIRE CONNECTOR............................................................................................1572 JUNCTION CONNECTOR................................................................................................1573 LOCATION..........................................................................................................1574 RELAY LOCATION / FUSE AND RELAY BLOCK.............................................................................1575 ABOUT CONNECTOR...................................................................................................1579 WIRING DIAGRAM ACCORDING TO SYSTEM........................................................................................1581 WIRING DIAGRAM........................................................................................................1582 WIRING HARNESS CODE...............................................................................................1582 AC. POWER SUPPLY CIRCUIT..........................................................................................1584 AF. GROUND CIRCUIT................................................................................................1588 AH. CHARGING CIRCUIT..............................................................................................1590 AK. ENGINE STARTING CIRCUIT.......................................................................................1592 AN. CAN COMMUNICATION CIRCUIT.....................................................................................1594 AO. CAN COMMUNICATION CIRCUIT [HV]................................................................................1596 BG. ENGINE ECU CIRCUIT [J05] 1/2..................................................................................1600 BH. ENGINE ECU CIRCUIT [J05] 2/2..................................................................................1604 BI. DEF SCR CIRCUIT...............................................................................................1612 BJ. HYDRO BOOST SYSTEM CIRCUIT....................................................................................1614 BN. GLOW PLUG CIRCUIT.............................................................................................1616 BP. FUEL HEATER CIRCUIT...........................................................................................1618 CC. AT CIRCUIT [A465].............................................................................................1620 CE. CLUTCH ECU CIRCUIT............................................................................................1626 CF. HV PCU CIRCUIT................................................................................................1630 DA. ABS/PAB+VSC CIRCUIT...........................................................................................1632 DD. VEHICLE CONTROL ECU CIRCUIT...................................................................................1634 EC. POWER DOOR LOCK CIRCUIT.......................................................................................1636 ED. KEYLESS ENTRY CIRCUIT.........................................................................................1638 EG. POWER WINDOW CIRCUIT [FRONT]..................................................................................1640 EH. POWER WINDOW CIRCUIT [REAR]...................................................................................1642 FA. COMBINATION METER CIRCUIT.....................................................................................1644 FB. PARKING BRAKE WARNING CIRCUIT.................................................................................1648 FC. WEAR INDICATOR CIRCUIT........................................................................................1650 FD. HORN RELAY CIRCUIT............................................................................................1652 FE. COOLANT LEVEL WARNING CIRCUIT.................................................................................1654 FF. DIAGNOSIS MONITOR CIRCUIT.....................................................................................1656 FJ. RHEOSTAT CIRCUIT..............................................................................................1658 FK. TELEMATICS CIRCUIT............................................................................................1660 GA. HEADLIGHT CIRCUIT.............................................................................................1662 GD. HEADLIGHT SUB CIRCUIT ........................................................................................1664 GG. TAIL LIGHT CIRCUIT............................................................................................1666 GH. STOP LIGHT CIRCUIT............................................................................................1668 GJ. TURN / HAZARD CIRCUIT.........................................................................................1670 GL. COMBINATION LIGHT CIRCUIT.....................................................................................1672 GM. FOG LIGHT CIRCUIT [FRONT].....................................................................................1674 HA. ROOM LIGHT CIRCUIT............................................................................................1676 JA. WIPER AND WASHER CIRCUIT......................................................................................1678 JD. MIRROR HEATER CIRCUIT.........................................................................................1680 JE. REMOTE CONTROL MIRROR CIRCUIT.................................................................................1682 KA. RADIO CIRCUIT.................................................................................................1684 KB. CIGAR LIGHTER CIRCUIT.........................................................................................1686 LB. HEATER AND AIR CONDITIONER CIRCUIT............................................................................1688 LF. REAR HEATER AND AIR CONDITIONER CIRCUIT.......................................................................1692 MA. OUTLET POWER SUPPLY CIRCUIT...................................................................................1694 MB. PASS THROUGH CIRCUIT..........................................................................................1696 MC. VAN LIGHT CIRCUIT.............................................................................................1698 MD. TRAILER BRAKE CIRCUIT.........................................................................................1700 WIRE TO WIRE CONNECTOR....................................................................................................1702 WIRE TO WIRE CONNECTOR................................................................................................1703 WIRE TO WIRE CONNECTOR LIST.......................................................................................1703 JUNCTION CONNECTOR........................................................................................................1720 JUNCTION CONNECTOR....................................................................................................1721 JUNCTION CONNECTOR LIST...........................................................................................1721 LOCATION..................................................................................................................1738 CONNECTOR LOCATION....................................................................................................1739 CONTENTS..........................................................................................................1739 QUICK REFERENCE...................................................................................................1740 IP-1 [INSTRUMENT PANEL (1 of 6)]..................................................................................1741 IP-2 [INSTRUMENT PANEL (2 of 6)]..................................................................................1743 IP-3 [INSTRUMENT PANEL (3 of 6)]..................................................................................1745 IP-4 [INSTRUMENT PANEL (4 of 6)]..................................................................................1747 IP-5 [INSTRUMENT PANEL (5 of 6)]..................................................................................1751 IP-6 [INSTRUMENT PANEL (6 of 6)]..................................................................................1753 CA-1 [CAB (1 of 2)] (Models: Single cab (Floor / Cowl))...........................................................1755 CA-2 [CAB (2 of 2)] (Models: Single cab (Roof / Door))............................................................1757 CA-3 [CAB (1 of 2)] (Models: Crew cab (Floor))....................................................................1759 CA-4 [CAB (2 of 2)] (Models: Crew cab (Roof / Door))..............................................................1761 EG-1 [ENGINE (1 of 4)] (Models: J05E Engine)......................................................................1763 EG-2 [ENGINE (2 of 4)] (Models: J05E Engine)......................................................................1765 EG-3 [ENGINE (3 of 4)] (Models: J05E Engine)......................................................................1767 EG-4 [ENGINE (4 of 4)] (Models: J05E Engine)......................................................................1769 EG-5 [ENGINE] (Models: J05E Engine (Right rear))..................................................................1771 EG-6 [ENGINE (1 of 4)] (Models: J05E Engine HV)...................................................................1773 EG-7 [ENGINE (2 of 4)] (Models: J05E Engine HV)...................................................................1775 EG-8 [ENGINE (3 of 4)] (Models: J05E Engine HV)...................................................................1777 EG-9 [ENGINE (4 of 4)] (Models: J05E Engine HV)...................................................................1779 EG-10 [ENGINE] (Models: J05E Engine HV (Right rear))..............................................................1781 RR-1 [REAR] (Models: Except HV)...................................................................................1783 RR-2 [REAR] (Models: HV)..........................................................................................1785 RELAY LOCATION/FUSE AND RELAY BLOCK.......................................................................................1787 RELAY LOCATION........................................................................................................1788 INSTRUMENT PANEL..................................................................................................1788 CHASSIS...........................................................................................................1789 FUSE AND RELAY BLOCK..................................................................................................1790 CHASSIS RELAY BLOCK...............................................................................................1790 CAB RELAY.........................................................................................................1793 RELAY BLOCK No.2..................................................................................................1794 RELAY BLOCK No.3..................................................................................................1795 JUNCTION BLOCK........................................................................................................1796 JUNCTION BLOCK....................................................................................................1796 WIRE TO WIRE BOX......................................................................................................1798 WIRE TO WIRE ALIGNMENT............................................................................................1798 INDEX.....................................................................................................................1799 CONNECTOR INDEX.......................................................................................................1800 ELECTRICAL EQUIPMENT CONNECTOR....................................................................................1800 WIRE TO WIRE CONNECTOR............................................................................................1817 JUNCTION CONNECTOR................................................................................................1821 FOREWORD..................................................................................................................1825 CHAPTER REFERENCES........................................................................................................1826 INDEX.....................................................................................................................1827 GENERAL INTRODUCTION......................................................................................................1829 HOW TO IDENTIFY VEHICLE TYPE..........................................................................................1830 HOW TO IDENTIFY VEHICLE TYPE......................................................................................1830 VEHICLE TYPE .................................................................................................1830 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE.................................................................1831 APPEARANCE OF VEHICLE.................................................................................................1832 APPEARANCE........................................................................................................1832 APPEARANCE OF VEHICLE.........................................................................................1832 SAFETY INSTRUCTIONS AND READINESS TO WORK.............................................................................1833 WARNING...........................................................................................................1833 GENERAL PRECAUTIONS...........................................................................................1833 IDENTIFICATION INFORMATION....................................................................................1838 SAFETY INSTRUCTIONS FOR WORK......................................................................................1841 PRECAUTIONS...................................................................................................1841 INTRODUCTION TO WORKSHOP MANUAL...................................................................................1845 GENERAL.......................................................................................................1845 INTRODUCTION TO DESCRIPTIONS..................................................................................1846 DEFINITION OF TERM............................................................................................1849 TROUBLE SHOOTING......................................................................................................1850 TROUBLESHOOTING WITH DIAGNOSIS MONITOR............................................................................1850 TROUBLESHOOTING PROCEDURE.....................................................................................1850 APPARATUS FOR TROUBLE SHOOTING................................................................................1852 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXII) .................................................................1853 STEP OF TROUBLE DIAGNOSIS.....................................................................................1853 APPARATUS FOR TROUBLE DIAGNOSIS...............................................................................1854 GLOSSARY..............................................................................................................1855 DEFINITION OF ABBREVIATION........................................................................................1855 LIST OF ABBREVIATION..........................................................................................1855 GLOSSARY OF SAE AND HINO TERMS................................................................................1858 ENGINE (J05E).............................................................................................................1861 TROUBLESHOOTING.......................................................................................................1864 ENGINE ECU (J05E).................................................................................................1864 PRECAUTIONS FOR DIAGNOSIS.....................................................................................1864 ELECTRICAL....................................................................................................1866 PRECAUTIONS...................................................................................................1867 COMPUTER (ECU) PIN ASSIGNMENT.................................................................................1871 ENGINE ECU CONNECTOR..........................................................................................1877 INSPECTION....................................................................................................1881 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...............................................................1882 DIAGNOSTIC TROUBLE CODE (DTC) TABLE...........................................................................1883 GROUP SHARING THE SENSOR SUPPLY TERMINAL......................................................................1911 GROUP SHARING THE SENSOR GND TERMINAL.........................................................................1912 MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION..................................................1913 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)......................................................1916 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL]...............................1921 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID]...............................1931 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL]............................................1942 PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID]............................................1947 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL]...............................1953 DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID]...............................1958 MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY.............................................................1974 ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....................................................1975 NO DTC........................................................................................................1979 DTC: P0005....................................................................................................1983 DTC: P0006 and P0007..........................................................................................1987 DTC: P0016....................................................................................................1993 DTC: P0027....................................................................................................1996 DTC: P003A....................................................................................................2001 DTC: P0045....................................................................................................2006 DTC: P0047....................................................................................................2010 DTC: P0048....................................................................................................2014 DTC: P006E....................................................................................................2018 DTC: P006F....................................................................................................2022 DTC: P007B....................................................................................................2026 DTC: P007C and P007D..........................................................................................2040 DTC: P0088....................................................................................................2048 DTC: P0096....................................................................................................2056 DTC: P0097 and P0098 .........................................................................................2067 DTC: P0101....................................................................................................2076 DTC: P0104....................................................................................................2085 DTC: P0106....................................................................................................2092 DTC: P0107....................................................................................................2098 DTC: P0108....................................................................................................2104 DTC: P0111....................................................................................................2110 DTC: P0112 and P0113..........................................................................................2116 DTC: P0115....................................................................................................2124 DTC: P0117 and P0118..........................................................................................2133 DTC: P011A....................................................................................................2141 DTC: P0122 and P0123..........................................................................................2150 DTC: P0126....................................................................................................2160 DTC: P0128....................................................................................................2164 DTC: P0148 ...................................................................................................2169 DTC: P016E and P016F .........................................................................................2180 DTC: P0182 and P0183 .........................................................................................2190 DTC: P0191....................................................................................................2198 DTC: P0192 and P0193 .........................................................................................2206 DTC: P01A5....................................................................................................2216 DTC: P01A6....................................................................................................2223 DTC: P0200....................................................................................................2230 DTC: P0201, P0202, P0203 and P0204............................................................................2233 DTC: P0217....................................................................................................2238 DTC: P0219....................................................................................................2243 DTC: P0222 and P0223..........................................................................................2251 DTC: P0234....................................................................................................2261 DTC: P0263, P0266, P0269 and P0272............................................................................2267 DTC: P026C and P026D..........................................................................................2278 DTC: P0299....................................................................................................2291 DTC: P0300....................................................................................................2297 DTC: P0301, P0302, P0303 and P0304............................................................................2305 DTC: P0335....................................................................................................2314 DTC: P0336....................................................................................................2321 DTC: P0340....................................................................................................2328 DTC: P0341....................................................................................................2332 DTC: P0381....................................................................................................2340 DTC: P0401....................................................................................................2346 DTC: P0402....................................................................................................2362 DTC: P0404....................................................................................................2372 DTC: P0405 and P0406..........................................................................................2377 DTC: P041B....................................................................................................2383 DTC: P041C and P041D..........................................................................................2396 DTC: P0420....................................................................................................2404 DTC: P0421....................................................................................................2406 DTC: P0422....................................................................................................2419 DTC: P0489 and P0490..........................................................................................2422 DTC: P049D....................................................................................................2428 DTC: P04D5 and P04D6..........................................................................................2433 DTC: P04DA....................................................................................................2441 DTC: P04DB....................................................................................................2450 DTC: P0500 and P0501..........................................................................................2458 DTC: P0504....................................................................................................2465 DTC: P0506....................................................................................................2470 DTC: P0507....................................................................................................2474 DTC: P0521....................................................................................................2478 DTC: P0524....................................................................................................2482 DTC: P0545 and P0546..........................................................................................2487 DTC: P054E....................................................................................................2495 DTC: P054F....................................................................................................2499 DTC: P0562 and P0563..........................................................................................2503 DTC: P0605....................................................................................................2508 DTC: P0606....................................................................................................2510 DTC: P0607....................................................................................................2512 DTC: P0610....................................................................................................2514 DTC: P0611....................................................................................................2517 DTC: P0617....................................................................................................2519 DTC: P0628 and P0629..........................................................................................2523 DTC: P062F....................................................................................................2531 DTC: P0630....................................................................................................2535 DTC: P0642....................................................................................................2539 DTC: P0643....................................................................................................2544 DTC: P064C....................................................................................................2550 DTC: P0652....................................................................................................2555 DTC: P0653....................................................................................................2561 DTC: P0671 and P0672 .........................................................................................2568 DTC: P0673 and P0674..........................................................................................2574 DTC: P0683....................................................................................................2580 DTC: P0686....................................................................................................2586 DTC: P0698....................................................................................................2591 DTC: P0699....................................................................................................2594 DTC: P06A4....................................................................................................2597 DTC: P06A5....................................................................................................2600 DTC: P06D3 and P06D4..........................................................................................2603 DTC: P0700....................................................................................................2611 DTC: P073D....................................................................................................2613 DTC: P081A....................................................................................................2617 DTC: P081B....................................................................................................2623 DTC: P0A7B....................................................................................................2627 DTC: P0AC4....................................................................................................2629 DTC: P0CA1....................................................................................................2631 DTC: P104E....................................................................................................2633 DTC: P104F....................................................................................................2637 DTC: P1133....................................................................................................2641 DTC: P119F....................................................................................................2648 DTC: P1426....................................................................................................2654 DTC: P1427....................................................................................................2661 DTC: P1428....................................................................................................2668 DTC: P1458....................................................................................................2676 DTC: P1459....................................................................................................2681 DTC: P146F (2 digit diagnosis code: 01).......................................................................2686 FOREWORD..................................................................................................................2691 CHAPTER REFERENCES........................................................................................................2692 INDEX.....................................................................................................................2693 ENGINE (J05E).............................................................................................................2695 TROUBLESHOOTING.......................................................................................................2698 ENGINE ECU (J05E).................................................................................................2698 DTC: P14B0....................................................................................................2698 DTC: P14B2....................................................................................................2702 DTC: P14B3 and P14B4..........................................................................................2706 DTC: P14B7 and P14B8..........................................................................................2712 DTC: P14BC and P14BD..........................................................................................2718 DTC: P14BF....................................................................................................2724 DTC: P1515....................................................................................................2729 DTC: P1530....................................................................................................2734 DTC: P2002....................................................................................................2738 DTC: P200C....................................................................................................2760 DTC: P2032 and P2033..........................................................................................2769 DTC: P203F....................................................................................................2777 DTC: P204F....................................................................................................2781 DTC: P206B....................................................................................................2784 DTC: P207F....................................................................................................2809 DTC: P2080....................................................................................................2817 DTC: P2084....................................................................................................2825 DTC: P20CD....................................................................................................2833 DTC: P20CE....................................................................................................2837 DTC: P20D8....................................................................................................2840 DTC: P20DE....................................................................................................2846 DTC: P20DF....................................................................................................2850 DTC: P20E0....................................................................................................2856 DTC: P20EE....................................................................................................2862 DTC: P20EF....................................................................................................2870 DTC: P2100....................................................................................................2872 DTC: P2101....................................................................................................2878 DTC: P2103....................................................................................................2885 DTC: P2120....................................................................................................2890 DTC: P2122 and P2123..........................................................................................2894 DTC: P2127 and P2128..........................................................................................2904 DTC: P2135....................................................................................................2913 DTC: P2138....................................................................................................2918 DTC: P2146....................................................................................................2923 DTC: P2147 and P2148..........................................................................................2930 DTC: P2149....................................................................................................2938 DTC: P2150 and P2151..........................................................................................2945 DTC: P2184 and P2185..........................................................................................2953 DTC: P2201....................................................................................................2961 DTC: P2227....................................................................................................3006 DTC: P2228 and P2229..........................................................................................3010 DTC: P2269....................................................................................................3015 DTC: P226C....................................................................................................3019 DTC: P229F....................................................................................................3025 DTC: P22D3....................................................................................................3073 DTC: P240F....................................................................................................3077 DTC: P2428....................................................................................................3087 DTC: P242B....................................................................................................3091 DTC: P242C and P242D..........................................................................................3099 DTC: P244A....................................................................................................3107 DTC: P244B....................................................................................................3128 DTC: P2457....................................................................................................3144 DTC: P2458....................................................................................................3159 DTC: P2459....................................................................................................3170 DTC: P2463....................................................................................................3173 DTC: P246F....................................................................................................3180 DTC: P2470 and P2471..........................................................................................3188 DTC: P2481 and P2482..........................................................................................3196 DTC: P2483....................................................................................................3204 DTC: P24A0....................................................................................................3212 DTC: P24A1....................................................................................................3215 DTC: P24A2....................................................................................................3217 DTC: P24AE (2 digit diagnosis code: 04, 05, 06, 14, 25, 26, 27, 28)...........................................3227 DTC: P24AF (2 digit diagnosis code: 23).......................................................................3229 DTC: P24B0 (2 digit diagnosis code: 19, 20, 21)...............................................................3232 DTC: P24B1 (2 digit diagnosis code: 18).......................................................................3234 DTC: P24B4 (2 digit diagnosis code: 10, 11, 15, 17)...........................................................3236 DTC: P24B7 (2 digit diagnosis code: 08).......................................................................3238 DTC: P24C7 (2 digit diagnosis code: 09).......................................................................3241 DTC: P24D0 (2 digit diagnosis code: 02).......................................................................3245 DTC: P24D1 (2 digit diagnosis code: 12).......................................................................3249 DTC: P24DA (2 digit diagnosis code: 07).......................................................................3251 DTC: P24FE....................................................................................................3255 DTC: P2562....................................................................................................3264 DTC: P259E....................................................................................................3268 DTC: P259F....................................................................................................3274 DTC: P2635....................................................................................................3279 DTC: P268A and P2696..........................................................................................3288 DTC: P26C8....................................................................................................3294 DTC: P2A00....................................................................................................3296 DTC: P2A01....................................................................................................3300 DTC: P2BA9....................................................................................................3304 DTC: U0073....................................................................................................3309 DTC: U010A....................................................................................................3312 DTC: U010C....................................................................................................3317 DTC: U010E....................................................................................................3322 DTC: U0293....................................................................................................3328 DTC: U029D (DIESEL)...........................................................................................3333 DTC: U029D (HYBRID)...........................................................................................3339 DTC: U029E (DIESEL)...........................................................................................3345 DTC: U029E (HYBRID)...........................................................................................3351 DTC: U02A2....................................................................................................3357 DTC: U02A3....................................................................................................3363 DTC: U0301....................................................................................................3366 DTC: U1001....................................................................................................3369 DTC: U110A....................................................................................................3376 ENGINE (COMMON ITEMS).....................................................................................................3383 TROUBLESHOOTING.......................................................................................................3385 DCU...............................................................................................................3385 PRECAUTIONS FOR DIAGNOSIS.....................................................................................3385 DIAGRAM.......................................................................................................3387 SIGNAL CHECK HARNESS..........................................................................................3388 INSPECTION....................................................................................................3388 TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)...............................................................3390 DTC: P0071....................................................................................................3397 DTC: P0072....................................................................................................3407 DTC: P0073....................................................................................................3413 DTC: P0562....................................................................................................3419 DTC: P0563....................................................................................................3423 DTC: P060B....................................................................................................3427 DTC: P060C....................................................................................................3430 DTC: P062F....................................................................................................3432 DTC: P0667....................................................................................................3434 DTC: P068A....................................................................................................3436 DTC: P06AD....................................................................................................3441 DTC: P06AE....................................................................................................3443 DTC: P142A....................................................................................................3445 DTC: P142B....................................................................................................3456 DTC: P14C1....................................................................................................3467 DTC: P14C2....................................................................................................3481 DTC: P14C3....................................................................................................3486 DTC: P202E....................................................................................................3491 DTC: P203C....................................................................................................3496 DTC: P203D....................................................................................................3499 DTC: P2044....................................................................................................3502 DTC: P2045....................................................................................................3505 DTC: P2047....................................................................................................3508 DTC: P2048....................................................................................................3512 DTC: P2049....................................................................................................3517 DTC: P204B....................................................................................................3522 DTC: P204C....................................................................................................3525 DTC: P204D....................................................................................................3530 FOREWORD..................................................................................................................3536 CHAPTER REFERENCES........................................................................................................3537 INDEX.....................................................................................................................3538 ENGINE (COMMON ITEMS).....................................................................................................3540 TROUBLESHOOTING.......................................................................................................3540 DCU...............................................................................................................3540 DTC: P205B....................................................................................................3542 DTC: P205C....................................................................................................3551 DTC: P205D....................................................................................................3554 DTC: P206A....................................................................................................3557 DTC: P206C....................................................................................................3560 DTC: P206D....................................................................................................3563 DTC: P208A....................................................................................................3566 DTC: P208B....................................................................................................3572 DTC: P208C....................................................................................................3575 DTC: P208D....................................................................................................3580 DTC: P20A0....................................................................................................3585 DTC: P20A1....................................................................................................3590 DTC: P20A2....................................................................................................3594 DTC: P20A3....................................................................................................3599 DTC: P20B1....................................................................................................3604 DTC: P20B2....................................................................................................3609 DTC: P20B3....................................................................................................3618 DTC: P20B4....................................................................................................3623 DTC: P20BD, P20B9 and P20C1...................................................................................3628 DTC: P20C0, P20BC and P20C4...................................................................................3636 DTC: P20E8....................................................................................................3642 DTC: P20E9....................................................................................................3653 DTC: P20F4....................................................................................................3659 DTC: P21C2....................................................................................................3664 DTC: P21C3....................................................................................................3668 DTC: P21C4....................................................................................................3673 DTC: P2202....................................................................................................3678 DTC: P2203....................................................................................................3681 DTC: P2204....................................................................................................3684 DTC: P2209....................................................................................................3691 DTC: P22A0....................................................................................................3699 DTC: P22A1....................................................................................................3702 DTC: P22A2....................................................................................................3705 DTC: P22A7....................................................................................................3712 DTC: P2510....................................................................................................3720 DTC: P2BAE....................................................................................................3725 DTC: U0029....................................................................................................3733 DTC: U0038....................................................................................................3739 DTC: U0100....................................................................................................3745 DTC: U029D (DIESEL)...........................................................................................3749 DTC: U029D (HYBRID)...........................................................................................3755 DTC: U029E (DIESEL)...........................................................................................3761 DTC: U029E (HYBRID)...........................................................................................3767 DTC: U02A2....................................................................................................3773 VEHICLE CONTROL ECU...............................................................................................3779 CAUTIONS ON TROUBLESHOOTING...................................................................................3779 SYSTEM BLOCK DIAGRAM..........................................................................................3780 COMPUTER PIN ASSIGNMENT.......................................................................................3781 TROUBLESHOOTING WITH COMPUTER (HINO DXII) ....................................................................3785 DIAGNOSIS CODE TABLE..........................................................................................3786 DTC: C1244....................................................................................................3788 DTC: C1245....................................................................................................3793 DTC: C1249....................................................................................................3795 DTC: C1418....................................................................................................3801 DTC: C1491....................................................................................................3805 DTC: P0335....................................................................................................3807 DTC: P0501....................................................................................................3810 DTC: P0503....................................................................................................3816 DTC: P0555....................................................................................................3821 DTC: P0562....................................................................................................3823 DTC: P0563....................................................................................................3827 DTC: P0572....................................................................................................3830 DTC: P0573....................................................................................................3836 DTC: P0577....................................................................................................3842 DTC: P05BF....................................................................................................3846 DTC: P0604....................................................................................................3849 DTC: P0605 ...................................................................................................3851 DTC: P0605 ...................................................................................................3853 DTC: P0606....................................................................................................3855 DTC: P0617....................................................................................................3857 DTC: P062F....................................................................................................3860 DTC: P0702....................................................................................................3862 DTC: P081D....................................................................................................3864 DTC: P161F....................................................................................................3869 DTC: P1649....................................................................................................3874 DTC: P165A....................................................................................................3878 DTC: P165B....................................................................................................3881 DTC: P2525....................................................................................................3884 DTC: P2526....................................................................................................3887 DTC: P258D....................................................................................................3890 DTC: U0101....................................................................................................3893 DTC: U0105....................................................................................................3896 DTC: U0121....................................................................................................3899 DTC: U0155....................................................................................................3902 DTC: U0293....................................................................................................3905 DTC: U0418....................................................................................................3908 DTC: U1136....................................................................................................3911 HYBRID....................................................................................................................3914 TROUBLE SHOOTING......................................................................................................3917 HYBRID CONTROL SYSTEM.............................................................................................3917 TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM......................................................................3917 SAFETY MEASURES FOR HIGH-VOLTAGE WORK.........................................................................3926 LIST OF CONNECTOR SYMBOLS.....................................................................................3929 HV SYSTEM WIRING DIAGRAM......................................................................................3933 HEARING SHEET.................................................................................................3935 HYBRID ECU........................................................................................................3936 DIAGNOSIS CODE TABLE..........................................................................................3936 FREEZE FRAME DATA LIST........................................................................................3946 LIST OF DATA MONITOR ITEMS....................................................................................3949 ACTIVE TEST...................................................................................................3952 COMMON INSPECTION CHART.......................................................................................3953 DTC: C0081 (TCA0).............................................................................................3958 DTC: P0500 (TC51).............................................................................................3960 DTC: P0501 (TC5B).............................................................................................3967 DTC: P0562 (TC71).............................................................................................3971 DTC: P060B (TCB2).............................................................................................3977 DTC: P0617 (TC59).............................................................................................3979 DTC: P062F (TCB3).............................................................................................3985 DTC: P0810 (TC9C).............................................................................................3987 DTC: P0810 (TC9D).............................................................................................3990 DTC: P0A01 (TC7B).............................................................................................3993 DTC: P0A02 (TC78).............................................................................................3999 DTC: P0A03 (TC79).............................................................................................4005 DTC: P0A06 (TC7F).............................................................................................4010 DTC: P0A07 (TC7E).............................................................................................4018 DTC: P0A0F (TC31) ............................................................................................4021 DTC: P0A1D (TC12).............................................................................................4024 DTC: P0A1D (TC17).............................................................................................4026 DTC: P0A78 (TC21).............................................................................................4028 DTC: P0A78 (TC22).............................................................................................4030 DTC: P0A7E (TC48).............................................................................................4032 DTC: P0A82 (TC67).............................................................................................4036 DTC: P0A84 (TC66).............................................................................................4046 DTC: P0A85 (TC65).............................................................................................4057 DTC: P0A90 (TC2A).............................................................................................4062 DTC: P0A92 (TC29).............................................................................................4071 DTC: P0A93 (TC7A).............................................................................................4080 DTC: P0AFD (TC6B).............................................................................................4085 DTC: P0BC9 (TC69).............................................................................................4088 DTC: P0BCA (TC68).............................................................................................4100 DTC: P0C73 (TC80).............................................................................................4106 DTC: P3000 (TC42).............................................................................................4111 DTC: P3001 (TC41).............................................................................................4117 DTC: P3001 (TC43).............................................................................................4119 DTC: P3001 (TC45).............................................................................................4121 DTC: P3001 (TC46).............................................................................................4123 DTC: P3001 (TC47).............................................................................................4126 DTC: P3001 (TC4A).............................................................................................4129 DTC: P3001 (TC4B).............................................................................................4132 DTC: P3001 (TC4C).............................................................................................4134 DTC: P3001 (TC4D).............................................................................................4136 DTC: P3009 (TC49).............................................................................................4139 DTC: P3010 (TC4E).............................................................................................4149 DTC: P3010 (TC4F).............................................................................................4151 DTC: P3128 (TC7D).............................................................................................4154 DTC: P3129 (TC7C).............................................................................................4162 DTC: P314C (TC82).............................................................................................4166 DTC: P314D (TC81).............................................................................................4170 DTC: P324B (TC62).............................................................................................4178 DTC: P324C (TC61).............................................................................................4182 DTC: P33B1 (TC64).............................................................................................4187 DTC: P33B2 (TC63).............................................................................................4191 DTC: U0073 (TC11).............................................................................................4195 DTC: U0074 (TC16).............................................................................................4199 DTC: U0100 (TC13).............................................................................................4202 DTC: U0101 (TC18).............................................................................................4205 DTC: U0110 (TC14).............................................................................................4210 DTC: U0111 (TC15).............................................................................................4216 DTC: U0121 (TC24).............................................................................................4222 DTC: U0155 (TC25).............................................................................................4227 DTC: U110A (TC26).............................................................................................4232 DTC: U1136 (TC27).............................................................................................4237 INVERTER..........................................................................................................4242 DIAGNOSIS CODE TABLE..........................................................................................4242 FREEZE FRAME DATA LIST........................................................................................4248 DATA MONITOR ITEM LIST........................................................................................4250 CONNECTION DIAGRAM............................................................................................4253 INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR..................................................4254 DTC: P0562 (TC96) ............................................................................................4256 DTC: P0562 (TCA0) ............................................................................................4263 DTC: P0604 (TC18) ............................................................................................4270 DTC: P0604 (TCD2).............................................................................................4272 DTC: P0605 (TC17) ............................................................................................4274 DTC: P0605 (TCD1) ............................................................................................4276 DTC: P060B (TC1A).............................................................................................4278 DTC: P060C (TC1C).............................................................................................4281 DTC: P062F (TC41).............................................................................................4283 DTC: P0A0D (TC20).............................................................................................4285 DTC: P0A1B (TC16).............................................................................................4290 DTC: P0A1B (TC92).............................................................................................4295 DTC: P0A1B (TC97).............................................................................................4297 DTC: P0A1B (TC3F).............................................................................................4299 DTC: P0A1B (TCA1).............................................................................................4301 DTC: P0A1B (TCA2).............................................................................................4303 DTC: P0A1B (TCA3).............................................................................................4305 DTC: P0A1B (TCA4).............................................................................................4307 DTC: P0A1B (TCA5).............................................................................................4309 DTC: P0A1B (TCA6).............................................................................................4311 DTC: P0A1B (TCA7).............................................................................................4313 DTC: P0A1B (TCA8) ............................................................................................4315 DTC: P0A1B (TCA9).............................................................................................4317 DTC: P0A1B (TCAA).............................................................................................4319 DTC: P0A1B (TCBB).............................................................................................4323 DTC: P0A1B (TCBC).............................................................................................4325 DTC: P0A1B (TCBD).............................................................................................4327 DTC: P0A1B (TCBE).............................................................................................4329 DTC: P0A1B (TCBF).............................................................................................4331 DTC: P0A1B (TCD3).............................................................................................4333 DTC: P0A1B (TCD4).............................................................................................4335 DTC: P0A1B (TCD5).............................................................................................4337 DTC: P0A1D (TC21).............................................................................................4339 DTC: P0A2B (TCE9).............................................................................................4342 DTC: P0A2B (TCED).............................................................................................4349 DTC: P0A2C (TCDA).............................................................................................4356 DTC: P0A2D (TCDB).............................................................................................4362 FOREWORD..................................................................................................................4370 CHAPTER REFERENCES........................................................................................................4371 INDEX.....................................................................................................................4372 HYBRID....................................................................................................................4374 TROUBLE SHOOTING......................................................................................................4377 INVERTER..........................................................................................................4377 DTC: P0A2F (TC33) ............................................................................................4377 DTC: P0A3C (TC34).............................................................................................4383 DTC: P0A3F (TCB7).............................................................................................4396 DTC: P0A41 (TCC0).............................................................................................4402 DTC: P0A42 (TCC1).............................................................................................4410 DTC: P0A51 (TCD6).............................................................................................4418 DTC: P0A51 (TCD7).............................................................................................4420 DTC: P0A78 (TC13).............................................................................................4422 DTC: P0A78 (TC14).............................................................................................4429 DTC: P0A78 (TC15).............................................................................................4440 DTC: P0AA1 (TCD8).............................................................................................4445 DTC: P0AA4 (TCD9).............................................................................................4449 DTC: P0ADB (TC1F).............................................................................................4453 DTC: P0ADC (TC93).............................................................................................4458 DTC: P0ADF (TC1E).............................................................................................4464 DTC: P0AE0 (TC95).............................................................................................4469 DTC: P0AE6 (TC1D).............................................................................................4475 DTC: P0AE7 (TC94).............................................................................................4480 DTC: P0AEE (TC22).............................................................................................4486 DTC: P0AEE (TC23).............................................................................................4488 DTC: P0AEF (TC24).............................................................................................4490 DTC: P0AF0 (TC25).............................................................................................4493 DTC: P0BEA (TCB3).............................................................................................4496 DTC: P0BEA (TCB4).............................................................................................4498 DTC: P0BEB (TC9A).............................................................................................4500 DTC: P0BEC (TC9B).............................................................................................4502 DTC: P0BEE (TCB5).............................................................................................4504 DTC: P0BEE (TCB6).............................................................................................4506 DTC: P0BEF (TC9C).............................................................................................4508 DTC: P0BF0 (TC9D).............................................................................................4510 DTC: P3126 (TC12).............................................................................................4512 DTC: U0073 (TC91).............................................................................................4519 DTC: U0074 (TC3E).............................................................................................4523 DTC: U0293 (TC31).............................................................................................4526 BATTERY ECU.......................................................................................................4533 DIAGNOSIS CODE TABLE..........................................................................................4533 LIST OF FREEZE FRAME DATA.....................................................................................4537 LIST OF DATA MONITOR ITEMS....................................................................................4539 CONNECTION DIAGRAM............................................................................................4542 DTC: P0562....................................................................................................4543 DTC: P0604....................................................................................................4547 DTC: P0605....................................................................................................4549 DTC: P060B....................................................................................................4551 DTC: P062F....................................................................................................4553 DTC: P0A1F....................................................................................................4555 DTC: P0A7D....................................................................................................4557 DTC: P0A7F....................................................................................................4560 DTC: P0A80....................................................................................................4565 DTC: P0A95....................................................................................................4570 DTC: P0A9C....................................................................................................4574 DTC: P0A9D....................................................................................................4579 DTC: P0A9E....................................................................................................4583 DTC: P0ABF....................................................................................................4587 DTC: P0AC0....................................................................................................4592 DTC: P0AC1....................................................................................................4597 DTC: P0AC2....................................................................................................4602 DTC: P0AC6....................................................................................................4607 DTC: P0AC7....................................................................................................4612 DTC: P0AC8....................................................................................................4616 DTC: P0ACB....................................................................................................4620 DTC: P0ACC....................................................................................................4625 DTC: P0ACD....................................................................................................4629 DTC: P0AE9....................................................................................................4633 DTC: P0AEA....................................................................................................4638 DTC: P0AEB....................................................................................................4642 DTC: P0AFC....................................................................................................4646 DTC: P0B25....................................................................................................4648 DTC: P0B3D....................................................................................................4651 DTC: P0B42....................................................................................................4655 DTC: P0B47....................................................................................................4659 DTC: P0B4C....................................................................................................4663 DTC: P0B51....................................................................................................4667 DTC: P0B56....................................................................................................4671 DTC: P0B5B....................................................................................................4675 DTC: P0B60....................................................................................................4679 DTC: P0B65....................................................................................................4683 DTC: P0B6A....................................................................................................4687 DTC: P0B6F....................................................................................................4691 DTC: P0B74....................................................................................................4695 DTC: P0B79....................................................................................................4699 DTC: P0B7E....................................................................................................4703 DTC: P0B83....................................................................................................4707 DTC: P0B88....................................................................................................4711 DTC: P0B8D....................................................................................................4715 DTC: P0B92....................................................................................................4719 DTC: P0B97....................................................................................................4723 DTC: P0B9C....................................................................................................4727 DTC: P0BA1....................................................................................................4731 DTC: P0C30....................................................................................................4735 DTC: P3004....................................................................................................4742 DTC: P3011....................................................................................................4744 DTC: P3012....................................................................................................4749 DTC: P3013....................................................................................................4754 DTC: P3014....................................................................................................4759 DTC: P3015....................................................................................................4764 DTC: P3016....................................................................................................4769 DTC: P3017....................................................................................................4774 DTC: P3018....................................................................................................4779 DTC: P3019....................................................................................................4784 DTC: P301B....................................................................................................4789 DTC: P3020....................................................................................................4791 DTC: P3021....................................................................................................4796 DTC: P3022....................................................................................................4801 DTC: P3023....................................................................................................4806 DTC: P3024....................................................................................................4811 DTC: P3025....................................................................................................4816 DTC: P3026....................................................................................................4821 DTC: P3027....................................................................................................4826 DTC: P3028....................................................................................................4831 DTC: P3029....................................................................................................4836 DTC: P302F....................................................................................................4841 DTC: P3065....................................................................................................4846 DTC: P308A....................................................................................................4851 DTC: U0074....................................................................................................4855 DTC: U0293....................................................................................................4858 TRANSMISSION..............................................................................................................4862 TROUBLESHOOTING.......................................................................................................4864 TROUBLE SHOOTING BY TRANSMISSION SYMPTOM..........................................................................4864 AUTOMATIC TRANSMISSION........................................................................................4864 TROUBLESHOOTING.......................................................................................................4866 AUTOMATIC TRANSMISSION............................................................................................4866 PRECAUTIONS FOR DIAGNOSIS.....................................................................................4866 AT LEARNED VALUE INITIALIZATION...............................................................................4867 INSPECTING/CLEARING DIAGNOSIS CODES...........................................................................4871 SYSTEM BLOCK DIAGRAM..........................................................................................4874 COMPUTER PIN ASSIGNMENT.......................................................................................4875 DIAGNOSIS CODE TABLE..........................................................................................4878 DTC: P0500/DIAGNOSIS MONITOR CODE: 42.........................................................................4880 DTC: P0562/DIAGNOSIS MONITOR CODE: 11.........................................................................4886 DTC: P0705/DIAGNOSIS MONITOR CODE: 43.........................................................................4889 DTC: P0706/DIAGNOSIS MONITOR CODE: 44.........................................................................4897 DTC: P0710/DIAGNOSIS MONITOR CODE: 38.........................................................................4902 DTC: P0715/DIAGNOSIS MONITOR CODE: 12.........................................................................4909 DTC: P0720/DIAGNOSIS MONITOR CODE: 61.........................................................................4915 DTC: P0725/DIAGNOSIS MONITOR CODE: 86.........................................................................4921 DTC: P0730/DIAGNOSIS MONITOR CODE: 37.........................................................................4927 DTC: P0746/DIAGNOSIS MONITOR CODE: 31.........................................................................4935 DTC: P0748/DIAGNOSIS MONITOR CODE: 25.........................................................................4941 DTC: P0751/DIAGNOSIS MONITOR CODE: 45.........................................................................4946 DTC: P0756/DIAGNOSIS MONITOR CODE: 46.........................................................................4952 DTC: P0761/DIAGNOSIS MONITOR CODE: 47.48......................................................................4958 DTC: P0776/DIAGNOSIS MONITOR CODE: 32.........................................................................4968 DTC: P0778/DIAGNOSIS MONITOR CODE: 26.........................................................................4974 DTC: P0810/DIAGNOSIS MONITOR CODE: 88.........................................................................4979 DTC: P0973/DIAGNOSIS MONITOR CODE: 62.........................................................................4983 DTC: P0974/DIAGNOSIS MONITOR CODE: 62.........................................................................4988 DTC: P0976/DIAGNOSIS MONITOR CODE: 63.........................................................................4993 DTC: P0977/DIAGNOSIS MONITOR CODE: 63.........................................................................4998 DTC: P0979/DIAGNOSIS MONITOR CODE: 64.........................................................................5003 DTC: P0980/DIAGNOSIS MONITOR CODE: 64.........................................................................5008 DTC: P0985/DIAGNOSIS MONITOR CODE: 65.........................................................................5013 DTC: P0986/DIAGNOSIS MONITOR CODE: 65.........................................................................5018 DTC: P0A40/DIAGNOSIS MONITOR CODE: 88.........................................................................5023 DTC: P1604/DIAGNOSIS MONITOR CODE: 24.........................................................................5027 DTC: P1604/DIAGNOSIS MONITOR CODE: 54.........................................................................5031 DTC: P2545/DIAGNOSIS MONITOR CODE: 88.........................................................................5035 DTC: P2716/DIAGNOSIS MONITOR CODE: 28.........................................................................5039 DTC: P2740/DIAGNOSIS MONITOR CODE: 17.........................................................................5045 DTC: P2757/DIAGNOSIS MONITOR CODE: 33.........................................................................5050 DTC: P2759/DIAGNOSIS MONITOR CODE: 27.........................................................................5056 DTC: P2764/DIAGNOSIS MONITOR CODE: 36.........................................................................5062 DTC: U0100/DIAGNOSIS MONITOR CODE: 88.........................................................................5066 DTC: U110A/DIAGNOSIS MONITOR CODE: 88.........................................................................5075 TROUBLESHOOTING.......................................................................................................5084 CLUTCH ECU........................................................................................................5084 SYSTEM BLOCK DIAGRAM..........................................................................................5084 COMPUTER PIN ASSIGNMENT.......................................................................................5085 DIAGNOSIS CODE TABLE..........................................................................................5087 CAUTIONS ON HV DAMPER REPLACEMENT.............................................................................5089 DTC: P0560....................................................................................................5090 DTC: P0563....................................................................................................5094 DTC: P0604....................................................................................................5096 DTC: P0605....................................................................................................5098 DTC: P062F....................................................................................................5100 DTC: P0775....................................................................................................5102 DTC: P0778....................................................................................................5107 DTC: P0811....................................................................................................5112 DTC: P081E....................................................................................................5114 DTC: P0883....................................................................................................5116 DTC: P0948....................................................................................................5120 DTC: P1538....................................................................................................5125 DTC: P1539....................................................................................................5135 DTC: P18F2....................................................................................................5142 DTC: P18F3....................................................................................................5152 DTC: P18F5....................................................................................................5162 DTC: P18F7....................................................................................................5172 DTC: P18F8....................................................................................................5182 DTC: P18F9....................................................................................................5192 DTC: P18FB....................................................................................................5202 DTC: P18FC....................................................................................................5207 DTC: P18FD....................................................................................................5212 DTC: P191A....................................................................................................5217 DTC: P2859....................................................................................................5219 DTC: P3156....................................................................................................5221 DTC: P3157....................................................................................................5231 DTC: U0073....................................................................................................5235 DTC: U0101....................................................................................................5238 DTC: U0110....................................................................................................5241 DTC: U0293....................................................................................................5244 DTC: U110A....................................................................................................5247 AXLE......................................................................................................................5250 TROUBLESHOOTING.......................................................................................................5251 TROUBLE SHOOTING BY AXLE SYMPTOM..................................................................................5251 FRONT AXLE....................................................................................................5251 REAR AXLE.....................................................................................................5252 WHEEL AND TIRE................................................................................................5252 DIFFERENTIAL..............................................................................................................5254 TROUBLESHOOTING.......................................................................................................5255 TROUBLE SHOOTING BY DIFFERENTIAL SYMPTOM..........................................................................5255 REAR DIFFERENTIAL.............................................................................................5255
Description:
2019 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]
