Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual

Description

Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual

This Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual is the definitive diagnostic resource for technicians working on Hino 155, 155h, 195, and 195h series trucks equipped with the J05E diesel engine. Published by Hino Motors Sales U.S.A., Inc., this volume delivers the complete troubleshooting methodology used to identify, diagnose, and resolve faults across the engine management system, emission control devices, and related electronic control networks. From preliminary symptom checks through DTC-specific inspection procedures, this Hino workshop manual gives you a structured, step-by-step approach to fault finding that mirrors the procedures used in professional service environments.

File Details

• Manual type: Troubleshooting Workshop Manual
• Brand: Hino
• Models covered: HINO 155, 155h, 195, 195h
• Engine: J05E
• Language: English
• Page count: Approximately 845 pages
• File format: PDF
• Publication number: S7-LXJE03C 1/7 (U.S.A.), S7-LXJE04C 1/7 (CANADA)
• Production codes: XFC710, XFC720, XFC740, XJC700, XJC710, XJC720, XJC740

Chapters Covered

• General Introduction
• Engine
• Hybrid
• Transmission
• Clutch
• Propeller Shaft
• Axle
• Differential
• Brake
• Steering
• Suspension
• Frame and Frame Accessory
• Cab Mounting and Cab Suspension
• Body Construction
• Body Inside Accessory
• Body Outside Accessory
• Air Bag and Seat Belt
• Heater and Air Conditioner
• Electrical
• Control System

Within the troubleshooting group, the Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual provides deep coverage of the Engine ECU (J05E), including precautions for diagnosis, electrical connector handling, computer pin assignments, and engine ECU connector procedures. The diagnostic trouble code table spans the full range of DTCs, from fuel cut valve and VNT actuator faults through to CAN communication disruptions and aftertreatment system codes. Dedicated sections address CAN communication line inspection for both 250 k and 500 k networks, split between diesel and hybrid variants, giving technicians the schematic-level detail needed to trace communication faults accurately. The manual also includes an engine basic inspection sheet, a no-DTC diagnostic path, and individual inspection procedures for every DTC supported by the J05E engine management system.

What This Troubleshooting Manual Covers

The Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual is built around the diagnostic process rather than general maintenance. It opens with the general introduction chapter that explains how to identify vehicle type, read the VIN structure, interpret production codes, and work safely around high-voltage injector circuits and electronic control units. From there, the manual moves into the Engine (J05E) troubleshooting section, which forms the largest and most technically detailed part of the document.

The engine ECU section covers the precautions that must be observed before any diagnostic work begins, including connector disconnection sequences, handling of electronic components, wire harness routing, and the correct use of the signal check harness. It provides complete computer (ECU) pin assignment tables, engine ECU connector removal and installation procedures, and detailed instructions for cleaning and attaching the engine ECU connector without damaging terminals or waterproof seals. This level of connector detail is essential when performing pin-level voltage and resistance checks on the J05E engine management system.

The diagnostic trouble code (DTC) table lists every code the engine ECU can set, along with the associated diagnosis item and the components that should be inspected. This table is the starting point for any diagnostic session and is supported by group-sharing tables for sensor supply terminals and sensor GND terminals, which help isolate whether a fault lies in a shared reference circuit or in an individual sensor branch. The manual also includes a dedicated table for malfunction codes that appear when CAN communication is disrupted, covering both the engine equipment/emission control device CAN line at 250 k and the engine control/diagnosis CAN line at 500 k.

For CAN communication faults, the Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual provides pre-inspection procedures, disconnection inspection procedures for the CAN_H and CAN_L communication lines, and a malfunction part determination table for the engine ECU and DCU. These procedures are split between diesel and hybrid variants, reflecting the different network topologies used across the Hino 155, 155h, 195, and 195h model range. The 250 k line connects the engine ECU, VNT controller, EGR controller, NOx sensors, DEF sensor, and DCU, while the 500 k line links the engine ECU, DLC, ATM ECU, VCS ECU, ABS ECU, and DCU. Understanding these network layouts is critical for diagnosing communication faults efficiently, and the manual lays out the terminal-to-terminal resistance checks needed to confirm continuity and identify breaks or shorts.

The DTC-specific inspection procedures form the core of the diagnostic content. Each procedure follows a consistent structure: check for related DTCs first, then inspect the specific component or circuit, and finally verify the repair by clearing codes and rechecking. The manual covers codes across the full engine management spectrum, including fuel system pressure control codes (P0088, P016E, P016F, P0191), intake air temperature sensor codes (P007B, P007C, P007D, P0096, P0097, P0098, P0112, P0113, P011C), boost pressure sensor codes (P0106, P0108, P0237), EGR system codes (P0401, P0402, P0404, P0405, P0406, P041B, P041C, P041D, P0489, P0490, P049D), VNT actuator codes (P003A, P0045, P0047, P0048, P006E, P006F, P00AF, P2562, P259E, P259F), injector codes (P0200, P0201, P0202, P0203, P0204, P0263, P0266, P0269, P0272, P026C, P026D), and aftertreatment codes (P200C, P2032, P2033, P203F, P204F, P207F, P2080, P2084, P20CD, P20CE, P20CF, P20D8, P20DE, P20DF, P20E0, P20EE, P2214, P2269, P226C, P22D3, P240F, P2428, P242B, P242C, P242D, P244A, P244B, P2457, P2458, P2459, P2463, P246F, P2470, P2471, P24A0, P24A1, P24A2).

Additional DTC coverage includes crankshaft and camshaft position sensor codes (P0016, P0335, P0336, P0340, P0341), glow system codes (P0381, P064C, P0671, P0672, P0673, P0674, P0683), exhaust brake codes (P0027, P04D5, P04D6), idle speed and oil pressure codes (P0519, P0521, P0524), battery voltage codes (P0562, P0563), and internal ECU codes (P0200, P0605, P0606, P0607, P0610, P0611, P062F, P0630). CAN communication codes (U0073, U010A, U010C, U010E, U0293, U029D, U029E, U02A2, U0301, U1001, U110A) are also covered with dedicated diagnostic procedures. This breadth of coverage makes the manual suitable for both routine diagnostics and intermittent fault investigation on any Hino 155, 155h, 195, or 195h truck powered by the J05E engine.

Beyond the engine management system, the manual addresses troubleshooting for the hybrid system, transmission, clutch, propeller shaft, axle, differential, brake, steering, suspension, frame, cab mounting, body construction, body accessories, air bag and seat belt systems, and heater/air conditioner. Each section follows the same symptom-based troubleshooting format, with possible causes and corrective actions listed in chart form. The front axle troubleshooting chart, for example, lists symptoms such as shimmy of the steering wheel, heavy steering, failure to turn, and uneven tire wear, along with the worn or damaged components that typically cause each condition and the action required to restore correct operation.

The electrical and control system chapters complete the manual’s coverage, providing the diagnostic framework for the electronic architecture that underpins the J05E engine and the vehicle as a whole. Glossary sections define the abbreviations and SAE/Hino terminology used throughout the manual, making it accessible to technicians who may be less familiar with Hino-specific nomenclature. The definition of terms section clarifies direction conventions, standard values, repair limits, and service limits, so measurements taken during diagnosis can be interpreted correctly against the manufacturer’s specifications.

This Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual is intended for technicians who need to diagnose faults methodically rather than replace parts by guesswork. The procedures assume access to a Hino diagnostic tool (HINO-DX) and the special service tools listed in the manual, including the signal check harness (09843-E4050), diagnosis check wire (09843-18040), and various computer interface options. The manual explains how to connect the diagnostic tool to the vehicle, read fault information, perform activation tests, and clear DTCs after repair. It also covers the use of a circuit tester with an internal resistance of 100 kΩ or greater in the voltage measuring range, which is essential for accurate measurements on the engine ECU circuits.

Whether you are tracing an intermittent CAN communication fault, diagnosing a fuel system pressure code, testing a VNT actuator, or investigating an aftertreatment system malfunction, this troubleshooting workshop manual provides the terminal assignments, resistance values, voltage ranges, and step-by-step inspection sequences needed to reach a correct diagnosis. The DTC-specific procedures are written to be followed in order, with clear YES/NO decision points that route you to the next relevant check. This structured approach reduces diagnostic time and helps avoid unnecessary component replacement.

Diagnostic Coverage at a Glance

• Engine management: Fuel system pressure control, injector circuits, common rail pressure sensors (main and sub), SCV, supply pump, fuel temperature sensor
• Air system: Air flow sensor, boost pressure sensor, intake air temperature sensors (intercooler outlet, intake manifold, air flow sensor built-in), intake throttle valve position sensors
• EGR system: EGR valve, EGR controller, EGR cooler, EGR gas temperature sensor
• Turbocharger: VNT actuator, VNT controller, nozzle position control, boost pressure control
• Exhaust brake: Exhaust brake magnetic valve, exhaust brake valve performance
• Aftertreatment: DPR system, DOC, ATC, DEF-SCR system, NOx sensors, DEF sensor, dosing control unit
• Communication: CAN bus diagnostics for 250 k and 500 k networks, DLC connector, terminating resistors
• Hybrid system: HV ECU, HV PCU, CAN communication from HV system
• Electrical: Battery voltage, glow system, oil pressure switch, vehicle speed sensor, brake switch, idle speed control
• ECU: Flash ROM, control module processor, VIN data, injector driver charge circuit

With approximately 845 pages of diagnostic content, this Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual delivers the depth required for professional fault finding on J05E-powered Hino trucks. The combination of DTC-specific procedures, CAN communication diagnostics, and system-level troubleshooting charts makes it a practical reference for any technician servicing these vehicles.

Put This Hino Troubleshooting Manual to Work

The Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual equips you to diagnose and repair faults across the entire engine management and vehicle control architecture. It supports jobs ranging from reading and interpreting diagnostic trouble codes to tracing CAN communication line faults, testing sensors and actuators, verifying ECU pin assignments, and confirming repairs through post-repair verification procedures. With the DTC table, sensor supply and ground sharing tables, and detailed inspection procedures for every supported code, you can approach a fault systematically instead of replacing parts speculatively.

Correct diagnostic procedures and accurate specifications matter because the J05E engine and its associated electronic systems are tightly integrated. A misdiagnosed sensor fault can lead to unnecessary component replacement, while an overlooked CAN communication issue can cause multiple unrelated DTCs to appear simultaneously. This manual helps you distinguish between primary faults and cascading codes, so your diagnosis targets the actual root cause. The terminal resistance values, voltage ranges, and component test procedures give you measurable pass/fail criteria at each step, making it easier to confirm a repair before returning the vehicle to service.

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Delivered as an instant PDF download, this Hino 155 155h 195 195h J05E Engine Troubleshooting Workshop Manual is available immediately after purchase, with no shipping delays. The file can be viewed on any device — laptop, tablet, or smartphone — and individual pages or sections can be printed for use in the workshop. Whether you are working on a single truck or maintaining a fleet of Hino 155, 155h, 195, or 195h models, this manual provides the diagnostic foundation needed to keep these J05E-powered vehicles running correctly.