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FOREWORD

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 sys- tems in these vehicles.

Manual Name

Pub. No.

Chassis Workshop Manual

S1-LXJE03A

S1-LXJE03A EWD

J05E Engine Workshop Manual

S5-LJ05E04A

Trouble shooting Workshop Manual

S7-LXJE03C 2/7

S7-LXJE03C 3/7

S7-LXJE03C 4/7

S7-LXJE03C 5/7

S7-LXJE03C 6/7

S7-LXJE03C 7/7

Trouble shooting Workshop Manual S7-LXJE03C 2/7 S7-LXJE03C 3/7 S7-LXJE03C 4/7 S7-LXJE03C 5/7 S7-LXJE03C 6/7 S7-LXJE03C 7/7

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.

 

MANUAL No.

S7-LXJE03C 1/7 (U.S.A.), S7-LXJE04C 1/7 (CANADA)

CHAPTER

MODELS

HINO 155, 155h, 195, 195h

Production Code

XFC710, XFC720, XFC740, XJC700, XJC710, XJC720, XJC740

GENERAL INTRODUCTION

1-001

ENGINE

2-001 (J05E)

WORKSHOP MANUAL INDEX: TROUBLE SHOOTING GROUP 1/2 GENERAL INTRODUCTION ENGINE HYBRID TRANSMISSION CLUTCH PROPELLER SHAFT

WORKSHOP

MANUAL

INDEX: TROUBLE SHOOTING GROUP 1/2

GENERAL INTRODUCTION

ENGINE

HYBRID

TRANSMISSION

CLUTCH

PROPELLER SHAFT

AXLE

DIFFERENTIAL

HYBRID TRANSMISSION CLUTCH PROPELLER SHAFT AXLE DIFFERENTIAL All rights reserved. This manual may not be reproduced

All rights reserved. This manual may not be reproduced or copied in whole in part, with- out the written consent of Hino Motors, Ltd.

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

INDEX: TROUBLE SHOOTING GROUP 2/2

ELECTRICAL

CONTROL SYSTEM

GENERAL INTRODUCTION

1–1

GENERAL INTRODUCTION

1

HOW TO IDENTIFY VEHICLE TYPE

1-2

HOW TO IDENTIFY VEHICLE TYPE

1-2

VEHICLE

TYPE

1-2

VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE

1-3

APPEARANCE OF VEHICLE

1-4

APPEARANCE

1-4

APPEARANCE OF VEHICLE

1-4

SAFETY INSTRUCTIONS AND READINESS TO WORK

1-5

WARNING

1-5

GENERAL PRECAUTIONS

1-5

IDENTIFICATION INFORMATION

1-10

SAFETY INSTRUCTIONS FOR WORK

1-12

PRECAUTIONS

1-12

INTRODUCTION TO WORKSHOP MANUAL 1-16 GENERAL 1-16 INTRODUCTION TO DESCRIPTIONS 1-17 DEFINITION OF TERM 1-20

TROUBLE SHOOTING

1-21

TROUBLESHOOTING WITH DIAGNOSIS MONITOR

1-21

TROUBLESHOOTING PROCEDURE

1-21

APPARATUS FOR TROUBLE SHOOTING

1-23

TROUBLESHOOTING WITH COMPUTER (HINO-DX)

1-24

STEP OF TROUBLE SHOOTING

1-24

APPARATUS FOR TROUBLE SHOOTING

1-25

GLOSSARY

1-26

DEFINITION OF ABBREVIATION

1-26

LIST OF ABBREVIATION

1-26

GLOSSARY OF SAE AND HINO TERMS

1-29

1-001

1–2

GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE

HOW TO IDENTIFY VEHICLE TYPE

HOW TO IDENTIFY VEHICLE TYPE

VEHICLE TYPE

EN01H01ZZZ010102001001

X J C 7 0 0 L H K T Q L A 3 REPORTED
X
J C
7 0
0 L
H
K
T Q
L
A 3
REPORTED MODEL
CLASSIFICATION
ENGINE MODEL
VEHICLE MODEL
DECK HEIGHT
X
F
J05E-TP (HV)
C
HEAVY DUTY TRACK
K
HIGH FLOOR CAB
X
J
J05E-TP (Diesel)
CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE
TRANSMISSION
CAB WIDTH
DRIVE
FRAME
WHEEL BASE
T 6AT
FORM
FRAME ASSEMBLY WIDTH
840 mm {33 in.}
7
0
WIDE
2WD
OPEN
MEDIUM
2,900 mm {114 in.}
7
1
WIDE
2WD
OPEN
LONG
3,500 mm {138 in.}
LOADING CAPACITY, GVW, REAR TIRES
6.58
t {14,500 lbs}
REAR DOUBLE
7
2
WIDE
2WD
OPEN
SUPER LONG
3,800 mm {150 in.}
Q
7
4
WIDE
2WD
OPEN
SUPER LONG
4,400 mm {173 in.}
8.14
t {17,950 lbs},
T
REAR DOUBLE
8.85
t {19,500 lbs}
TYPE OF SUSPENSION
ENGINE HORSEPOWER, FUEL
0 FRONT RIGID, REAR RIGID
FUEL
HORSEPOWER
EXHAUST
L DIESELOIL
VERY HIGH
US10
STEERING WHEEL POSITION
DESTINATION
L LEFT HAND DRIVE
DESTINATION
A
U.S., CANADA
CAB FORM, BRAKE TYPE
CAB FORM
BRAKE TYPE
H
SINGLE CAB
VACUUM
DECK FORM
Q
CREW CAB
VACUUM
3 CHASSIS WITH CAB
C
SINGLE CAB
HYDRAULIC
D
CREW CAB
HYDRAULIC

SHTS01ZZZ0100001

GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE

1–3

VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE

EN01H01ZZZ010102001002

WMI VDS CD VIS (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
WMI
VDS
CD
VIS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
J
H
H
K
D
L
2
H
X
C
K
00
1
0
0
1
MANUFACTURER ,TYPE
ASSEMBLY PLANTSERIES
CHECK DIGIT
SEQUENTIAL NUMBER
MODEL, CAB TYPE,
WHEEL BASE,
BRAKE SYSTEM
MODEL YEARENGINE
MODEL
MAKE
CODE
YEARYEAR
CODE
CODE
TYPEMANUFACTURER
C
2012
H
2017
JHN
HINO MOTORS, LTD.
INCOMPLETE VEHICLE
D
2013
J
2018
HINO MOTORS
2AY
INCOMPLETE VEHICLE
CANADA, LTD.
E
2014
K
2019
F
2015
L
2020
PRODUCTION
BRAKE
CODE
CLASS
MODEL
CAB TYPE
WHEEL BASE
CODE
SYSTEM
G
2016
M
2021
HINO 195h
XFC710
COE
H
5
3500mm{138 in.}
HYDRAULIC
For USA
SINGLE CAB
HINO 195
XJC710
CODE
ASSEMBLY PLANT
COE
CODE
MAKE
K
5
HINO 195
XJC700
2900mm{114 in.}
HYDRAULIC
HINO MOTORS,
LTD.
SINGLE CAB
K
Hamura
Plant in Japan
H
HINO
HINO 155h
XFC720
COE
L
4
3800mm{150 in.}
VACUUM
CREW CAB
HINO 155
XJC720
For Canada
HINO 155h
XFC740
COE
CODE
ASSEMBLY PLANT
P
4
4400mm{173 in.}
VACUUM
CREW CAB
HINO 155
XJC740
CODE
SERIES GVWR
1
Canada Plant (COE)
HINO 195h
XFC720
COE
R
5
3800mm{150 in.}
HYDRAULIC
6,580 kg
SINGLE CAB
1
HINO 195
XJC720
{14,500 lbs.}
HINO MOTORS,
LTD.
K
HINO 195h
XFC740
COE
Hamura
Plant in Japan
S
5
4400mm{173 in.}
HYDRAULIC
8,140 - 8,850 kg
SINGLE CAB
2
HINO 195
XJC740
{17,950 - 19,500 lbs.}
COE
T
4
HINO 155
XJC700
2900mm{114 in.}
VACUUM
SINGLE CAB
HINO 155h
XFC710
COE
U
4
3500mm{138 in.}
VACUUM
SINGLE CAB
HINO 155
XJC710
HINO 195h
XFC720
COE
V
5
3800mm{150 in.}
HYDRAULIC
CREW CAB
HINO 195
XJC720
CODE
APPLICATIONENGINE
MODEL
HINO 195h
XFC740
COE
W
5
4400mm{173 in.}
HYDRAULIC
PL
J05E
Hybrid
CREW CAB
HINO 195
XJC740
HINO 155h
XFC740
COE
DL
DieselJ05E
X
4
4400mm{173 in.}
VACUUM
SINGLE CAB
HINO 155
XJC740
HINO 155h
XFC720
COE
Y
4
3800mm{150 in.}
VACUUM
SINGLE CAB
HINO 155
XJC720

SHTS01ZZZ0100002

1–4

GENERAL INTRODUCTION/APPEARANCE OF VEHICLE

APPEARANCE OF VEHICLE

APPEARANCE

APPEARANCE OF VEHICLE

EN01H01ZZZ020101003001

OF VEHICLE APPEARANCE OF VEHICLE APPEARANCE APPEARANCE OF VEHICLE EN01H01ZZZ0 201010 03001 SHTS01ZZZ0200001

SHTS01ZZZ0200001

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–5

SAFETY INSTRUCTIONS AND READINESS TO WORK

WARNING

GENERAL PRECAUTIONS

EN01H01ZZZ030101001001

Some recommended and standard maintenance services for your vehicle are included in this section. When performing maintenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a mal- function of the vehicle which may result in personal injury and/or property damage. If you have any question about per- forming maintenance, please consult your Hino dealer.

WARNING

When working on your vehicle, observe the following general precautions to prevent death, personal injury and/ or property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chap- ter.

Always wear safety glasses or goggles to protect your eyes.

Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.

Bind long hair securely behind the head.

When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and block the wheels.

Always turn off the starter switch to stop the engine, unless the operation requires the engine running. Removing the key from the switch is recommended.

To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radia- tor, muffler, exhaust pipe and tail pipe.

Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.

Take utmost care when working on the battery. It contains corrosive sulfuric acid.

Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which can result in personal injury and/or property damage.

Read carefully and observe the instructions specified on the jack before using it.

Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a vehicle supported only by a jack.

If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.

Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.

Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when the engine is running.

Be careful not to damage lines and hoses by stepping or holding your feet on them.

Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can cause personal injury.

1–6

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

PRECAUTIONS IN TILTING AND LOWERING THE CAB

! WARNING Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may result in death, serious injury and/or property damage.

Park the vehicle on a level place and ensure ample space around the cab before tilting the cab.

Apply the parking brake firmly and place the gearshift lever in “N” position (“P” position if your vehicle is equipped with automatic transmission).

Stop the engine and block the wheels.

Remove any articles in or over the cab and close the doors firmly.

Make sure there is no one in or around the cab and there are no obstacles in front of the vehicle or above the cab.

The catch (E), stopper (F), stay (G) and other parts such as the engine, radiator, and exhaust pipe can be very hot while your vehicle is operated. Be sure to confirm they have been cooled down before you start working under the cab.

Never raise or lower the cab only by yourself if your cab is equipped with heavy component such as a roof rack.

Never put your body under the cab while raising or lowering the cab.

Make sure the cab stopper stay is securely locked by the catch (E) and raise the stopper (F) to lock the catch (E) completely after raising the cab.

Before lowering the cab, make sure that any object such as hand tools, gloves or cloth are not left under the cab.

Make sure the handle (B) is caught by the catch after lowering the cab. Read the Owner’s manual for details.

(B) is caught by the catch after lowering the cab. Read the Owner’s manual for details.
F B E
F
B
E

G

SHTS01ZZZ0300001

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–7

DEFINITION OF SAFETY TERMS

Indicates an extremely hazardous situation if proper procedures are not followed and could result in

Indicates an extremely hazardous situation if proper procedures are not followed and could result in death or serious injury.

Indicates a potential hazardous situation if proper procedures are not followed and could result in

Indicates a potential hazardous situation if proper procedures are not followed and could result in death or serious injury.

Indicates a hazardous situation if proper pr ocedures are not followed and could result in

Indicates a hazardous situation if proper procedures are not followed and could result in serious injury or damage to parts/equipment.

Indicates the need to follow proper procedur es and to pay attention to precautions so

Indicates the need to follow proper procedures and to pay attention to precautions so that efficient service is provided.

Provides additional information to help you to perform the repair efficiently.

Provides additional information to help you to perform the repair efficiently.

1–8

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

TOWING

When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with the bumper.

1. Towing procedures

(1)

Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle

(2)

shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and entry of dirt or foreign matter. Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the

(3)

frame. The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and ver-

(4)

tical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in towing a vehicle trapped in a gutter. Keep the gear shift lever in Neutral.

(5)

Make sure that the starter switch is kept in the "ON" position, if the engine is not running.

(6)

Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vac-

(7)

uum will be available for the brake. This is dangerous, as the brake system does not function if the engine is not running. In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to turn, making it impossible to control the vehicle. Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.

(8)

Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.

2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed for that purpose.

(1)

Front end towing (with front wheels raised off the ground)

(2)

When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of axle lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed for vehicles equipped with either manual or automatic transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with lubricant if necessary. Rear end towing When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight- ahead position.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–9

CLEAN AIR ACT

1. Heavy-duty engine rebuilding practices.

§

86.004-40

The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and are applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reas- sembly, and also may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine. Any deviation from the provisions contained in this section is a prohibited act under section 203(a) (3) of the Clean Air Act (42 U.S.C. 7522(a) (3)).

(1)

When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical basis for knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configura- tion (i.e., tolerances, calibrations, specifications) and the model year(s) of the resulting engine configuration must be identified. A reasonable basis would exist if:

a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and function of motor vehicle engines would reasonably believe that the parts perform the same function with respect to emissions control as the original parts; and

b. Any parameter adjustment or design element change is made only:

In accordance with the original engine manufacturer's instructions; or

(2)

Where data or other reasonable technical basis exists that such parameter adjustment or design element change, when performed on the engine or similar engines, is not expected to adversely affect in-use emis- sions. When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a

(3)

configuration of the same or later model year as the original engine. When an engine is being replaced, the replacement engine must be an engine of (or rebuilt to) a configuration of the same or later model year as the original engine. At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or

(4)

reset without diagnosing and responding appropriately to the diagnostic codes, regardless of whether the sys- tems are installed to satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface. Diagnostic systems must be free of all such codes when the rebuilt engine is returned to service. Such signals may not be rendered inoperative during the rebuilding process. When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt

(5)

engine, all critical emissions-related components listed in § 86.004-25(2) not otherwise addressed by para- graphs (1) through (3) of this section must be checked and cleaned, adjusted, repaired, or replaced as neces- sary, following manufacturer recommended practices. Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The records shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the engine and emissions-related control components including a listing of parts and components used, engine parameter adjustments, emissions-related codes or signals responded to and reset, and work performed under paragraph (4) of this section.

a. Parties may keep records in whatever format or system they choose as long as the records are understand- able to an EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an under- standable format when requested.

b. Parties are not required to keep records of information that is not reasonably available through normal busi- ness practices including information on activities not conducted by themselves or information that they cannot reasonably access.

c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual engine rebuilt in cases where those rebuild practices are followed routinely.

d. Records must be kept for a minimum of two years after the engine is rebuilt.

2. Maintenance instructions.

§ 86.010-38

(1) For each new diesel-fueled engine subject to the standards prescribed in § 86.007-11, as applicable, the manu-

facturer shall furnish or cause to be furnished to the ultimate purchaser a statement that "This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for highway diesel fuel, including a 15 ppm sulfur cap)."

1–10

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK A B SHTS01ZZZ0300007 IDENTIFICATION INFORMATION
A B SHTS01ZZZ0300007
A
B
SHTS01ZZZ0300007

IDENTIFICATION INFORMATION

EN01H01ZZZ030101001002

1. VEHICLE IDENTIFICATION NUMBER

(1)

The vehicle identification number (VIN) is stamped on the right frame, as shown in the illustration. This number has also been stamped on the manufacture's plate.

(2)

A: Vehicle Identification Number (VIN) B: Manufacturer's Plate VIN See VEHICLE IDENTIFICATION NUMBER (VIN) STRUC- TURE on the following page.

(3)

PRODUCTION CODE AND VEHICLE COMPONENTS

MODEL (CLASS)

HINO 155h (4)

HINO 155 (4)

HINO 195h (5)

HINO 195 (5)

   

XJC700

 

XJC700

PRODUCTION CODE

XFC710

XFC720

XFC740

XJC710

XJC720

XJC740

XFC710

XFC720

XFC740

XJC710

XJC720

XJC740

TRANSMISSION SERIES

 

A465

 
 

1st

 

3.742

 

2nd

 

2.003

 

TRANSMISSION RATIO

3rd

 

1.343

 

4th

 

1.000

 

5th

 

0.773

 

6th

 

0.634

 

REAR AXLE SERIES

 

SH13

 

REAR AXLE RATIO

4.333 / 4.625 / 4.875 / 5.142 / 5.571 / 5.857

SERVICE BRAKE

Vacuum

Hydraulic

PARKING BRAKE

ACTING ON DIFFERENTIAL OUTPUT SHAFT

SUSPENSION

 

LEAF

 

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–11

FOR ALL MODELS

FOR ALL MODELS
SHTS01ZZZ0300008 A
SHTS01ZZZ0300008
A
TO WORK 1–11 FOR ALL MODELS SHTS01ZZZ0300008 A SHTS01ZZZ0300009 A SHTS01ZZZ0300010 SHTS01ZZZ0300011 2.

SHTS01ZZZ0300009

A

A

SHTS01ZZZ0300010

SHTS01ZZZ0300008 A SHTS01ZZZ0300009 A SHTS01ZZZ0300010 SHTS01ZZZ0300011 2. VEHICLE NOISE EMISSION CONTROL

SHTS01ZZZ0300011

2. VEHICLE NOISE EMISSION CONTROL INFORMATION

The Vehicle Noise Emission Control Information is affixed to the left pillar of the cab. The name of manufacturer, production year and month, and noise emission applicable to medium and heavy trucks in conformity with U.S. EPA Regulations are displayed.

3. ENGINE SERIAL NUMBER

(1)

The engine serial number is stamped on the cylinder block,

as shown in the illustration.

A: J05E

4. TRANSMISSION SERIAL NUMBER

(1)

The transmission serial number is stamped on the transmis- sion, as shown in the illustration.

A: A465

5. CLEAN IDLE CERTIFIED LABEL FOR U.S.

Make sure that the following clean engine idling certified label is affixed to the outside of the left door. By the CARB below, the label must be affixed there to prove that the new vehicle with diesel engine manufactured from Jan., 2008 conforms to this low.

CARB § 1956.8. Exhaust Emission Standard and Test Procedure (a) (b) Heavy-Duty Diesel Engine Idling Requirements

1–12

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

SAFETY INSTRUCTIONS FOR WORK

PRECAUTIONS

EN01H01ZZZ030101004001

1. SAFETY INSTRUCTIONS FOR HANDLING ELECTRICAL SYSTEMS

(1)

Removing the battery cable

HANDLING ELECTRICAL SYSTEMS (1) Removing the battery cable ! WARNING • Be sure to wait for

! WARNING

Be sure to wait for at least ten minutes after the starter key is turned to "LOCK" position before you disconnect the battery terminals from the battery, as the vehicle data is recorded on ECU and DCU starts working for the exhaust gas after treatment after the starter key is turned to "LOCK" position. Otherwise, the vehicle data will not be recorded on ECU properly and DCU will not complete working properly, which may result in the malfunc- tion of DPR system and DEF-SCR system.

The MIL (malfunction indicator light) may come on when the starter key is turned to "ON" position again, even if you wait for at least ten minutes before disconnecting the battery terminals from the battery after the starter key is turned to "LOCK" position. In this case, use HINO-DX to clear the DTC (P204F and P068A), to turn off the MIL and to conduct DPR regeneration manually.

a. Before electrical system work, remove the cable from the minus terminal of the battery in order to avoid burn- ing caused by short-circuiting.

b. To remove the battery cable, fully release the nut to avoid damage to the battery terminal. Never twist the ter- minal.

LOOSEN
LOOSEN

SHTS01ZZZ0300012

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–13

(2)

Handling of electronic parts

a. Never give an impact to electronic parts of a computer or relay.

b. Keep electronic parts away from high temperatures and humidity.

c. Never splash water onto electronic parts in washing the vehicle.

d. Do not remove the harness connector, electric component box, and cover except for repair and inspection. If removal is necessary, pay attention that water and foreign matters do not attach or enter to the connector, terminals, electric component box, and cover. In restoration, make sure there is no attachment or entry of water and foreign matters and mount them prop- erly, because it causes degradation of waterproof function.

INCORRECT

INCORRECT

(3)

Handling of wire harness

SHTS01ZZZ0300013

a. Perform marking on a clamp and a clip and secure then in original position so that the wire harness will not interfere with the end and acute angle section of the body and a bolt.

b. To attach a part, take care not to bite the wire harness.

INCORRECT INCORRECT INCORRECT
INCORRECT
INCORRECT
INCORRECT

SHTS01ZZZ0300014

1–14

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

(4)

Handling of connectors

a. When removing a connector, hold a connector (area shown in an arrow in the figure) and then pull it off. Do not pull wire harnesses.

b. Pull off a lockable connector after unlocking.

c. When connecting a lockable connector, make sure to insert a lockable connector until it makes a click sound.

d. When inserting a test lead, insert it from the back of a connector.

e. If it is difficult to insert a test lead from the back of a connector, make and use an inspection harness.

INCORRECT CORRECT INCORRECT
INCORRECT
INCORRECT
INCORRECT CORRECT INCORRECT

CORRECT

INCORRECT

INCORRECT CORRECT INCORRECT

(5)

Installation of battery disconnect switch

SHTS01ZZZ0300015

WARNINGInstallation of battery disconnect switch SHTS01ZZZ0300015 • Installation of the battery disconnect switch on the

Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF-SCR (DCU) may damage or result in the malfunction of DEF-SCR system.

Be sure to read and follow the procedures and instructions on the service bulletin before the installation of the battery disconnect switch.

(6)

Handling of battery disconnect switch

WARNINGdisconnect switch. (6) Handling of battery disconnect switch • Wait for at least ten minute before

Wait for at least ten minute before using the battery disconnect switch after the starter key is turned to "LOCK" position. Otherwise, the vehicle data will not be recorded on ECU properly, which may result in the malfunction of DPR system.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–15

2. PRECAUTION FOR ELECTRIC WELDING Electrical components such as the alternator and tachograph are directly connected to the battery and one end is earthed to the chassis frame. Under these conditions, welding current will flow back along the earth circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, electrical components, etc. Consequently, the following precautions are always to be taken during welding.

(1) Disconnect the earth terminal of the battery at the frame fitment and earth the welding equipment securely to the frame itself. (Do not fit the welding equipment earth to such things as the tire rims, brake pipes or fuel pipes and leaf spring, etc.)

a. Turn the starter switch off.

b. Disconnect the battery’s negative terminal of the battery.

c. Earth welding equipment securely, near to the area to be welded.

d. Put back battery negative ground as original condition.

e. Finally check the functioning of all instruments.

COMPUTER ALTERNATOR etc. BATTERY Disconnect the ground terminal for battery at the connecting point on
COMPUTER
ALTERNATOR
etc.
BATTERY
Disconnect the ground terminal for
battery at the connecting point on the
frame and disconnect the ground for
computer as well.
CHASSIS FRAME
CHASSIS FRAME
ARC WELDING
MACHINE
Connect the ground of the ARC welding
machine near the place on the frame to be
welded but not connect it to plated parts such
as fuel pipes, brake pipes and leaf spring.

(2)

SHTS01ZZZ0300016

In order to prevent damage to ancillary equipment components from sparks during welding, take steps such as putting fire-resistant covers over things like the engine, meters, steering wheel, hoses, leaf spring and tires.

1–16

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

GENERAL INFORMATION

INTRODUCTION TO WORKSHOP MANUAL

GENERAL

1. SCOPE OF REPAIR DESCRIPTIONS

EN01H01ZZZ030102002001

(1)

There are three major processes in repair work: i.e. "trouble shooting", "removal/installation, replacement, over-

(2)

haul, assembly, inspection and adjustment" and "final inspection". This document covers only the first process (trouble shooting) and the second process (removal/installation,

(3)

replacement, overhaul, assembly, inspection and adjustment) and omits the third process (final inspection). The element tasks listed below are omitted from this document but must be done in actual repair work.

a. Jacking and lifting

b. Cleaning and washing of removed parts as required

c. Visual check

2. STANDARD VALUE

(1)

Standard values, limits, required actions and tightening torques are tabulated in this document.

3. REQUIRED ITEMS

(1)

Special tools, tools, instruments, oil and grease and other items to be prepared before starting work are listed in the section titled "REQUIRED ITEMS". Note that general tools, jacks, rigid racks and other required items sup-

posedly available at a general service shop are omitted from the list.

4. REPRESENTATION OF SECTION AND TITLE

(1)

Under a title containing a system name such as "ENGINE CONTROL SYSTEM", the descriptions cover

(2)

"INSPECTION", "ADJUSTMENT", "REPLACEMENT" and "OVERHAUL" of components. Under a title containing a part name such as "AIR COMPRESSOR ASSEMBLY", the descriptions cover "REPLACEMENT" and "OVERHAUL".

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–17

INTRODUCTION TO DESCRIPTIONS

EN01H01ZZZ030102002002

1. TROUBLE SHOOTING FOR EACH TROUBLE SYMPTOM WITH REFERENCE TO THE CHART

A possible cause and remedy/prevention are indicated for every item, respectively.
A possible cause and remedy/prevention are indicated for
every item, respectively.

SHTS01ZZZ0300017

1–18

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

2. INTRODUCTION TO TROUBLE SHOOTING

(1)

This document covers the trouble shooting steps 2 and 3 listed below.

(1) Hearing

"Step 1"

Identify a fact through adequate hearings on the situation and environment where a trouble has occurred.

(2) Prior check (3) Reproducing technique

"Step 2"

Conduct a diagnosis inspection, a symptom check, a func- tional inspection and a basic inspection to identify a symp- tom. If a symptom check does not gain enough reproducibility, use a reproducing technique.

(4) Trouble shooting for each diagnosis code (5) Trouble shooting for each trouble symptom

"Step 3"

Sort the inspection results obtained from the step 2 and con- duct an systematized inspection in accordance with the pro- cedures for trouble shooting for each trouble symptom.

(6) Verification test

"Step 4"

Verify that the same trouble will not occur after trouble shoot- ing. If a trouble is not reproducible enough, conduct a verifi- cation test under the reproduced conditions and environment.

(2)

Prior check

Take the following prior check steps. Diagnosis inspectiondiagnosis deletiontrouble symptom verification (use a reproducing technique if not reproducible.)diagnosis recheck

Prior to a reproduction test, identify a system suspected to have a trouble, attach a tester and other apparatuses and then conduct both a symptom check and an examination on a sus- pected trouble. For a suspected cause of a trouble symptom, the trouble shooting chart.

Instantaneous occurrence of a trouble symptom will also trigger a failure code. If no troubles are observed, use a reproducing technique in performing each trouble shooting activity.

Trouble symptom verification If not reproducible, take the steps 2, 3 and 4. If not reproducible, use a reproducing technique (e.g. adjust external conditions and inspect each wire harness and connector part).

Prior check

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–19

3. INTRODUCTION TO TROUBLE SHOOTING FOR EACH DIAGNOSIS MONITOR CODE (1) The "diagnosis code list" and the "trouble shooting for each code" are contained in this document to address each system for which a diagnosis monitor code will be output. If a diagnosis monitor code is already identified, it is possible to immediately proceed with a trouble shooting process based on the code list.

it is possible to immediately proceed with a trouble shooting process based on the code list.

SHTS01ZZZ0300018

1–20

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

DEFINITION OF TERM

DEFINITION OF TERM

Terms used in this document are defined as follows.

DIRECTION

1. CHASSIS RELATED

EN01H01ZZZ030102002003

(1)

Longitudinal direction

(2)

a. The forward direction and the reverse direction of a vehicle are respectively defined as front and rear in the installed position in a vehicle. Rotational direction

(3)

a. The clockwise direction and the counterclockwise direction viewed from the rear side of a vehicle are defined as right-handed and left-handed respectively. Vertical direction

(4)

a. The upward direction and the downward direction in the installed position in a vehicle are defined as an upper side and a lower side respectively. Lateral direction

a. The leftward direction and the rightward direction viewed from the back of a vehicle are respectively defined as a left side and a right side in the installed position in a vehicle.

2. INDIVIDUAL DEVICES

(1)

Longitudinal direction

(2)

a. The input side and the output side of motive power are defined as a front side and a rear side respectively. Rotational direction

(3)

a. The clockwise direction and the counterclockwise direction viewed from the back side are defined as right- handed and left-handed respectively. Vertical direction

(4)

a. The upward direction and the downward direction of a device in its installed position in a vehicle (chassis) are defined as an upper side and a lower side respectively. Lateral direction

a. The leftward direction and the rightward direction as viewed from the back side are defined as a left side and a right side respectively.

STANDARD VALUE

Represents a basic dimension (excluding a tolerance), and a clearance arising from tolerances when two parts are assem- bled.

REPAIR LIMIT

Represents a numerical value indicating need of correction. A symbol "+" or "-" indicated next to a repair limit represents an increase or a decrease from a standard value.

SERVICE LIMIT

Represents a numerical value indicating need of replacement. A symbol "+" or "-" indicated next to a repair limit represents an increase or a decrease from a standard value.

GENERAL INTRODUCTION/TROUBLE SHOOTING

1–21

TROUBLE SHOOTING

TROUBLESHOOTING WITH DIAGNOSIS MONITOR

TROUBLESHOOTING PROCEDURE

EN01H01ZZZ040301002001

NOTICE

Before reading the diagnosis code, turn the starter key to "ON" and check that the check engine warning light comes on.

Inspection is not available in check mode.

DLC3

TC TS CG
TC
TS
CG

SHTS01ZZZ0400001

1. CONNECTION OF DIAGNOSIS CHECK WIRE

(1)

Turn the starter key to the "LOCK" position.

(2)

Use a SST to short circuit DLC3 12(TS) or 13(TC) 4(CG) terminals.

SST: 09843-18040 Diagnosis check wire

HINT The terminals to be shorted vary depending on the device to be diagnosed.

to be shorted vary depending on the device to be diagnosed. ! CAUTION • Never fail

! CAUTION

Never fail to connect connectors to correct locations. Other wise failure may occur.

Use the dedicated diagnosis check wire.

1–22

GENERAL INTRODUCTION/TROUBLE SHOOTING

2. INDICATION OF DIAGNOSIS MONITOR CODE (1) A diagnosis monitor code can be identified by viewing the diagnosis monitor and the check engine light. The example shown below represents how to identify diagnosis monitor codes 32 and 21. Intervals between light flashings will iden- tify a diagnosis monitor code. For the first code, the number "3" in the ten's place of the first code will be represented by three 0.5-second flashings, followed by an interval of 1.5 sec- onds. Then, the light will flash twice. For the next code, after an interval of 4.3 seconds, two flashings will be followed by one flashing in the similar fashion to the first code. This flash- ing pattern will be repeated. If no system malfunctions are detected, the light will repeat a 0.3-second flashing pattern.

NOTICE As individual systems have different diagnosis monitor code out- putting patterns, follow the descriptions provided for each sys- tem.

HINT

This figure indicates a typical indication of diagnosis monitor codes. For details, refer to the descriptions provided for individ- ual systems.

If no malfunctions are detected, the "diagnosis monitor code 1" will be indicated.

Malfunction codes will be repeatedly output in the ascending order regardless of present or past malfunction codes.

INDICATION OF DIAGNOSIS MONITOR CODE (EXAMPLE)

WHEN CODES 32 AND 21 ARE INDICATED:

0.5 SECONDS 0.5 SECONDS 4.3 SECONDS 1.5 SECONDS CODE 21 CODE 32
0.5 SECONDS
0.5 SECONDS
4.3 SECONDS
1.5 SECONDS
CODE 21
CODE 32

WHEN THE SYSTEM IS NORMAL

0.3 SECONDS
0.3 SECONDS

LIGHT ON

LIGHT OFFSECONDS CODE 21 CODE 32 WHEN THE SYSTEM IS NORMAL 0.3 SECONDS LIGHT ON LIGHT ON

LIGHT ON LIGHT OFF THE OPERATION IS REPEATED
LIGHT ON
LIGHT OFF
THE OPERATION IS REPEATED

SHTS01ZZZ0400002

HINT

If no code is indicated (light not flashing), it is suspected that the TC or TS terminal line is broken or the computer is faulty.

If the check engine warning light is always on, it is suspected that the wire harness is shorted (for example, jammed) or the computer is faulty.

If any meaningless code is out, the computer is suspected of being faulty.

GENERAL INTRODUCTION/TROUBLE SHOOTING

1–23

If the check engine warning light is lit and no code is output at 1,000 r/min or more, once turn the starter key to "LOCK" and then recheck.

(2)

Release DLC3 12(TS) or 13(TS) 14(CG) terminals.

APPARATUS FOR TROUBLE SHOOTING

EN01H01ZZZ040301002002

1. TAG CODE AND SYSTEM NAME LIST FOR DEDICATED HARNESS

No.

Tag name

Name of system to be diagnosed

1

STD: ENG

Common rail

3

STD: AIR BAG

Not used

5

STD: ABS/ASR

ABS

7

STD: ES START

Not used

10

STD: VSC

Not used

11

STD: TIRE

Not used

2

OPT: RTD/4WD

Not used

4

OPT: SHAKAN

Not used

6

OPT: AIR SUS

Not used

8

OPT: IDL STOP

Not used

9

OPT: ATM

Not used

12

OPT: PRO SHIFT

Not used

DEDICATED HARNESS (S0963-02300) 2 1 4 3 10 6 5 8 7 12 11 9
DEDICATED HARNESS (S0963-02300)
2
1
4
3
10
6
5
8
7
12
11
9

SHTS01ZZZ0400003

1–24

GENERAL INTRODUCTION/TROUBLE SHOOTING

TROUBLESHOOTING WITH COMPUTER (HINO-DX)

SHOOTING TROUBLESHOOTING WITH COMPUTER (HINO-DX) SHTS01ZZZ0400004 STEP OF TROUBLE SHOOTING EN01H01ZZZ0 403010

SHTS01ZZZ0400004

STEP OF TROUBLE SHOOTING

EN01H01ZZZ040301003001

1. PREPARATION FOR CONNECTING HINO-DX

(1) The HINO-DX is a trouble shooting tool for the common rail fuel injection system and the chassis system. For connecting to a vehicle, the interface box (Hino-Bowie or DST-i) and the dedicated cable will be required.

SPECIAL TOOL: Computer interface

Part name

Part No.

Hino-Bowie

The main body and cables (for RS-232C and USB) 09993-E9070 *1

(Interface box)

Cable between vehicle and Hino-Bowie

S0904-21220

DENSO DST-i Set (Without LCD)

Without Bluetooth95171-01020

With Bluetooth95171-01040

DENSO DST-i Set (With LCD)

Without Bluetooth95171-0103

With Bluetooth95171-01050

HINO Diagnostic eXplorer (HINO-DX)

( * 1): To use Hino-Bowie (int erface box) "09993-E9070", update the hardware. For details, refer to the user's manual in the HINO-DX CD-ROM. Keep updating the firmware (software built in the Hino-Bowie) using the software in the HINO-DX CD-ROM. For details, refer to the user's manual in the HINO-DX CD-ROM.

HINT

A cable between the Hino-Bowie and a computer is supplied with Hino-Bowie. Use either RS-232C type or USB type.

Install the Hino Diagnostic eXplorer (HINO-DX) software in a computer. For detailed installation procedures, refer to the user's manual supplied with a CD.

TROUBLE SHOOTING CONNECTOR

TROUBLE SHOOTING CONNECTOR

SHTS01ZZZ0400005

2. CONNECTION OF HINO-DX

(1)

Connect the Hino-Bowie or DST-i to the trouble shooting con-

(2)

nector located in the electrical component box in the instru- ment panel or located in the electrical component box behind the rearmost seat. Connect a computer in which the HINO-DX has been

(3)

installed, to the Hino-Bowie or DST-i. Turn the starter key ON.

(4)

Turn on the computer power supply to start the HINO-DX.

HINT If the Hino-Bowie is used, connection to a vehicle will automati- cally turn the power supply ON and light the POWER light (red) on the Hino-Bowie.

GENERAL INTRODUCTION/TROUBLE SHOOTING

1–25

APPARATUS FOR TROUBLE SHOOTING

EN01H01ZZZ040301003002

1. APPARATUS FOR TROUBLE SHOOTING

Part name Part No. Illustration of appearance Outline/function Computer • Operating system (OS): (DOS/V standard)
Part name
Part No.
Illustration of appearance
Outline/function
Computer
• Operating system (OS):
(DOS/V standard)
Windows2000, Win-
dowsXP,
WindowsVista *2 ,
Windows7 *2
• CPU and memory:
To guarantee proper oper-
ations of the operating
systems listed above.
• Display: 800X600,
256 or more colors
Hino-Bowie
(Interface box)
09993-E9070 *1
The main body and cables
(for RS-232C and USB)
Cable between vehicle and
Hino-Bowie
Computer interface
S0904-21220
DENSO DST-i Set
(without LCD)
Without Bluetooth
95171-01020
With Bluetooth
95171-01040
DENSO DST-i Set
(with LCD)
Without Bluetooth
95171-01030
With Bluetooth
95171-01050
( * 1): To use Hino-Bowie (interface box) "09993-E9070", update the hardware. For details, refer to the user's manual in
the HINO-DX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HINO-DX CD-ROM. For details,
refer to the user's manual in the HINO-DX CD-ROM.
( * 2): When use DST-i, after HINO-DX. (Ver. 3.0.5)

1–26

GENERAL INTRODUCTION/GLOSSARY

GLOSSARY

DEFINITION OF ABBREVIATION

LIST OF ABBREVIATION

EN01H01ZZZ060102001001

 

Abbreviations

Meaning, or Official Name

A/C

Air Conditioner

ABS

Anti-lock Brake System

ACC

Accessory

AMT

Automated Manual Transmission

ATC

After Turbo Catalyst

ATF

Automatic Transmission Fluid

CA

Crank Angle

CAN

Controller Area Network

CD-ROM

Compact Disc Read Only Memory

CPU

Central Processing Unit

dB

Decibel

DC

Direct Current

D-CAT

Diesel-Clean Advanced Technology System

DC

motor

Direct Current Motor

DCU

Dosing Control Unit

DEF

Diesel Exhaust Fluid

DPR

Diesel Particulate active Reduction system

DSS

Driving Support System

ECU

Electronic Control Unit

EEPROM

Electronically Erasable and Programmable Read Only Memory

EGR

Exhaust Gas Recirculation

ELR

Emergency Locking Retractor

ENG

Engine

ES

START

Easy and Smooth start system

F/A

Front Axle

FCCB

Fuel Control Cylinder Balance

FCV

Fuel Cutoff Valve

FF shift

Feather touch & Finger shift

FL

Fusible link

GENERAL INTRODUCTION/GLOSSARY

1–27

Abbreviations

Meaning, or Official Name

Fr

Front

FRP

Fiber Reinforced Plastic

FUP

Front Underrun Protector

GND

Ground

GVW

Gross Vehicle Weight

Hi

High

HINO-DX

Hino Diagnostic eXplorer

HV

Hybrid Vehicle

HVAC

Heating, Ventilating and Air-Conditioning unit

I.S.C.

Idle Speed Control

IC

Integrated Circuits

ID

Identification

IPD

Intelligent Power Device

IS

Idling Stop

ISO

International Organization for Standardization

JIS

Japanese Industrial Standards

LED

Light Emitting Diode

LEV

Low Emission Vehicle

LH

Left Hand

LLC

Long Life Coolant

Lo

Low

MAX

Maximum

MIN

Minimum

MS evaporator

Multi-tank and Super slim structure evaporator

MT

Manual Transmission

No.

Number

NOx

Nitrogen Oxide

NMR

No load Maximum Revolution

OHC

Over Head Camshaft

PC

Personal Computer

PCD

Pitch Circle Diameter

PCS

Pre-Crash Safety

PCV

Pump Control Valve

PCV valve

Positive Crankcase Ventilation valve

PM

Particulate Matter

1–28

GENERAL INTRODUCTION/GLOSSARY

Abbreviations

Meaning, or Official Name

PPG

Glass-fiber-reinforced Polypropylene

ppm

Parts Per Million

PS pump

Power Steering Pump

PTO

Power Take-Off

PVD

Physical Vapor Deposit

PWR

Power

QR code

Quick Response Code

R/A

Rear Axle

RH

Right Hand

SCR

Selective Catalytic Reduction

SST

Special Service Tool

SW

Switch

T/M

Transmission

GENERAL INTRODUCTION/GLOSSARY

1–29

GLOSSARY OF SAE AND HINO TERMS

EN01H01ZZZ060102001002

This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as well as their HINO equivalents.

SAE ABBREVIATIONS

SAE TERMS

HINO TERMS( )--ABBREVIATIONS

A/T

AUTOMATIC TRANSMISSION

Automatic transmission

AAT

AMBIENT AIR TEMPERATURE

Ambient Air Temperature

ACL

AIR CLEANER

Air cleaner

ACL Element

ACL (Air Cleaner) Element

Air Cleaner element

ACL Element

AIR CLEANER Element

Air Cleaner element

ACL Housing

AIR CLEANER Housing

Air cleaner body assembly

ACL Housing Cover

AIR CLEANER Housing Cover

Air Cleaner Housing Cover

AFTDEF

AFTER TREATMENT DIESEL EXHAUST FLUID

DEF

AFTDEFDU

AFTER TREATMENT DIESEL EXHAUST FLUID DOSING UNIT

DCU

AFTDOC

AFTER TREATMENT DIESEL OXIDATION CATALYST

DOC (Diesel Oxidation Catalyst)

AFTDOS

AFTER TREATMENT DOSER AFTDOS

Dosing

AFTDPF

AFTER TREATMENT DIESEL PARTICU- LATE FILTER

DPR filter

AFTDPFDP

AFTER TREATMENT DIESEL PARTICU- LATE FILTER DIFFERENTIAL PRESSURE

DPR differential pressure

AFTEGT

AFTER TREATMENT EXHAUST GAS TEM- PERATURE

Exhaust gas temperature

AP

ACCELERATOR PEDAL

Accelerator pedal

AP Sensor

ACCELERATOR PEDAL Sensor

Accelerator Pedal Position Sensor

APP

ACCELERATOR PEDAL POSITION

Accelerator Pedal Position

CAC

CHARGE AIR COOLER

Intercooler

CPP Switch

CLUTCH PEDAL POSITION Switch

Clutch Switch

DCC

DIAGNOSTIC CONNECTOR, Cab

Diagnosis connector

DCU

DIAGNOSTIC CONNECTOR, Under-hood

Diagnosis connector

DRIVER

DRIVER

Driver

DTC

DIAGNOSTIC TROUBLE CODE

Diagnosis Trouble Code

DTM Switch

DIAGNOSTIC TEST MODE Switch

Diagnosis switch

EBP

EXHAUST BACK PRESSURE

Back pressure

EBP

EXHAUST BACK PRESSURE

Exhaust back pressure

EBP Sensor

EXHAUST BACK PRESSURE Sensor

Back Pressure Sensor

EBPR Valve

EXHAUST BACK PRESSURE REGULATOR Valve

Exhaust control valve

1–30

GENERAL INTRODUCTION/GLOSSARY

SAE ABBREVIATIONS

SAE TERMS

HINO TERMS( )--ABBREVIATIONS

EC

ENGINE CONTROL

Engine control

ECT

ENGINE COOLANT TEMPERATURE

Coolant Temperature

ECT

ENGINE COOLANT TEMPERATURE

Water Temperature

EFT

ENGINE FUEL TEMPERATURE

Fuel temperature

EFT Sensor

ENGINE FUEL TEMPERATURE Sensor

Fuel temperature sensor

EGR

EXHAUST GAS RECIRCULATION

EGR

EGR Valve

EXHAUST GAS RECIRCULATION Valve

EGR valve

EGRT

EXHAUST GAS RECIRCULATION TEM- PERATURE

EGR temperature

EGRT Sensor

EXHAUST GAS RECIRCULATION TEM- PERATURE Sensor

EGR exit temperature sensor

EGT

EXHAUST GAS TEMPERATURE

Exhaust gas temperature

EI

ELECTRONIC IGNITION

Ignition coil

EOP

ENGINE OIL PRESSURE

Oil Pressure

EOT

ENGINE OIL TEMPERATURE

Oil Temperature

FP

FUEL PUMP

Fuel pump

FUEL PRESSURE

   

Sensor

FUEL PRESSURE Sensor

Fuel Pressure sensor

GLOW PLUG

GLOW PLUG

Glow plug

GND

GROUND

GROUND

IA

INTAKE AIR

Air Intake

IA System

INTAKE AIR System

Air Intake System

IAT

INTAKE AIR TEMPERATURE

Intake temperature

IAT Sensor

INTAKE AIR TEMPERATURE Sensor

Intake temperature sensor

IDLE

IDLE

Idle

IMAT

INTAKE MANIFOLD AIR TEMPERATURE

Intake manifold Air temperature sensor

IMAT

INTAKE MANIFOLD TEMPERATURE

Intake manifold temperature sensor

INJ

INJECTOR

Injector

MAF Sensor

MASS AIR FLOW Sensor

Air flow sensor

MIL

MALFUNCTION INDICATOR LAMP

Check engine

OSS Sensor

OUTPUT SHAFT SPEED Sensor

Output Speed Sensor

OSS Sensor

OUTPUT SHAFT SPEED Sensor

Speed Sensor

PC Solenoid Valve

PRESSURE CONTROL Solenoid Valve

Solenoid control valves

PCV

POS CRANKCASE VENTILATION

PCV (Positive Crankcase Vent)

PCV Valve

POS CRANKCASE VENTILATION Valve

PCV (Positive Crankcase Vent) Valve

PCV Valve

POS CRANKCASE VENTILATION Valve

PCV Valve

GENERAL INTRODUCTION/GLOSSARY

1–31

SAE ABBREVIATIONS

SAE TERMS

HINO TERMS( )--ABBREVIATIONS

PCV Valve

POSITIVE CRANKCASE VENT Valve

PCV Valve

PNP

PARK/NEUTRAL POSITION

Neutral position

PNP Switch

PARK/NEUTRAL POSITION Switch

Neutral switch

RFP

RAIL FUEL PRESSURE

Common rail Pressure

RFP Sensor

RAIL FUEL PRESSURE Sensor

Common rail pressure sensor

SPARK PLUG

SPARK PLUG

Spark plug

SRI

SERVICE REMINDER INDICATOR

Check engine

ST

SCAN TOOL

Diagnostic tool

TC

TURBOCHARGER

Turbocharger

TCC

TORQUE CONVERTER CLUTCH

Torque Converter

TP Sensor

THROTTLE POSITION Sensor

Throttle Sensor

TSS Sensor

TURBINE SHAFT SPEED Sensor

Turbine Speed Sensor

VAF Sensor

VOLUME AIR FLOW Sensor

Air flow sensor

VLS

VEHICLE LIMITING SPEED

Speed Limiter Upper Limit

VSS

VEHICLE SPEED SENSOR

Vehicle Speed sensor

ENGINE (J05E)

2–1

ENGINE (J05E)

2

2-001

TROUBLESHOOTING

2-4

DTC:

P003A

2-126

 

DTC:

P0045

2-133

ENGINE ECU (J05E)

2-4

DTC:

P0047

2-138

PRECAUTIONS FOR DIAGNOSIS 2-4

DTC:

P0048

2-143

ELECTRICAL 2-6

DTC:

P006E

2-148

PRECAUTIONS

2-7

DTC:

P006F

2-153

COMPUTER (ECU) PIN ASSIGNMENT

2-11

DTC:

P007B

2-158

ENGINE ECU CONNECTOR 2-15

DTC: P007C and P007D

2-176

INSPECTION

2-19

DTC:

P0088

2-186

DIAGNOSIS USING THE PC DIAGNOSIS

DTC:

P0096

2-211

TOOL 2-20

DTC: P0097 and P0098

2-226

DIAGNOSTIC TROUBLE CODE (DTC)

 

DTC: P00AF

2-236

TABLE

2-21

DTC:

P0101

2-241

GROUP SHARING THE SENSOR SUPPLY

MALFUNCTION CODES IN CASE OF

DTC:

P0104

2-254

TERMINAL 2-42

DTC:

P0106

2-263

GROUP SHARING THE SENSOR

DTC:

P0108

2-271

GND TERMINAL 2-43

DTC: P0112 and P0113

2-279

DTC:

P0115

2-289

DISRUPTION OF CAN COMMUNICATION 2-44 PRE-INSPECTION FOR ENGINE CAN

DTC: P0117 and P0118

2-302

DTC:

P011A

2-312

COMMUNICATION LINE (250 k)

2-48

DTC: P011C

2-324

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k)

DTC: P0122 and P0123

2-332

DTC:

P0128

2-343

[DIESEL]

2-53

DTC:

P0148

2-351

DISCONNECTION INSPECTION FOR ENGINE

DTC: P016E and P016F

2-369

CAN_H COMMUNICATION L LINE (250 k)

DTC: P0182 and P0183

2-395

[HYBRID] 2-62

DTC:

P0191

2-405

PRE-INSPECTION FOR ENGINE CAN

 

DTC: P0192 and P0193

2-429

COMMUNICATION LINE (500 k) [DIESEL]

2-72

DTC:

P01A5

2-441

PRE-INSPECTION FOR ENGINE CAN

CAN_H COMMUNICATION L LINE (500 k)

DTC:

P01A6

2-450

COMMUNICATION LINE (500 k) [HYBRID] 2-77

DTC:

P0200

2-459

DISCONNECTION INSPECTION FOR ENGINE

DTC: P0201, P0202, P0203 and P0204

2-462

   

DTC:

P0217

2-469

2-83

DTC:

P0219

2-476

[DIESEL] DISCONNECTION INSPECTION FOR ENGINE

CAN_H COMMUNICATION L LINE (500 k)

DTC: P0222 and P0223

2-485

DTC:

P0234

2-497

[HYBRID] 2-88

DTC:

P0237

2-505

MALFUNCTION CODES FOR FAULTY ACTUATOR

DTC: P0263, P0266, P0269 and P0272

2-513

POWER RELAY ENG BASIC INSPECTION SHEET

DTC:

P0005

2-93

DTC: P026C and P026D

2-529

DTC:

P0299

2-548

(ENGINE INSPECTION CHECK SHEET)

2-94

DTC:

P0300

2-556

NO DTC

2-98

2-102

DTC: P0301, P0302, P0303 and P0304

2-566

 

DTC:

P0335

2-578

DTC: P0006 and P0007 2-108

DTC:

P0336

2-587

DTC:

P0016

2-115

DTC:

P0340

2-597

DTC:

P0027

2-119

DTC:

P0341

2-603

2–2

ENGINE (J05E)

DTC: P0381

2-613

DTC: P14B2

2-1007

DTC: P0401

2-621

DTC: P14B3 and P14B4

2-1012

DTC: P0402

2-641

DTC: P14B7 and P14B8

2-1019

DTC: P0404

2-655

DTC: P14BC and P14BD

2-1026

DTC: P0405 and P0406

2-662

DTC: P14BF

2-1033

DTC:

P041B

2-669

DTC: P1515

2-1040

DTC: P041C and P041D

2-686

DTC: P1530

2-1047

DTC: P0420

2-696

DTC: P1601

2-1052

DTC: P0421

2-699

DTC: P200C

2-1057

DTC: P0422

2-703

DTC: P2032 and P2033

2-1069

DTC: P0489 and P0490

2-707

DTC: P203F

2-1079

DTC:

P049D

2-714

DTC: P204F

2-1084

DTC: P04D5 and P04D6

2-721

DTC: P207F

2-1088

DTC: P0500 and P0501

2-731

DTC: P2080

2-1100

DTC: P0504

2-740

DTC: P2084

2-1110

DTC: P0519

2-747

DTC: P20CD

2-1120

DTC: P0521

2-752

DTC: P20CE

2-1126

DTC: P0524

2-758

DTC: P20CF 2-1131

DTC: P0545 and P0546

2-765

DTC: P20D8

2-1135

DTC: P0562 and P0563

2-775

DTC: P20DE 2-1141

DTC:

P05F1

2-783

DTC: P20DF 2-1146

DTC: P0605

2-794

DTC: P20E0

2-1154

DTC: P0606

2-797

DTC: P20EE 2-1163

DTC: P0607

2-800

DTC: P2100

2-1175

DTC: P0610

2-803

DTC: P2101

2-1183

DTC: P0611

2-807

DTC: P2103

2-1192

DTC: P0617

2-810

DTC: P2120

2-1200

DTC: P0628 and P0629

2-815

DTC: P2122 and P2123

2-1205

DTC:

P062F

2-825

DTC: P2127 and P2128

2-1216

DTC: P0630

2-830

DTC: P2135

2-1226

DTC: P0642

2-835

DTC: P2138

2-1232

DTC: P0643

2-843

DTC: P2146

2-1238

DTC:

P064C

2-853

DTC: P2147 and P2148

2-1247

DTC: P0652

2-860

DTC: P2149

2-1257

DTC: P0653

2-868

DTC: P2150 and P2151

2-1266

DTC: P0671 and P0672

2-877

DTC: P2184 and P2185

2-1276

DTC: P0673 and P0674

2-884

DTC: P2214

2-1286

DTC: P0683

2-891

DTC: P2227

2-1301

DTC: P0686

2-899

DTC: P2228 and P2229

2-1306

DTC: P06D3 and P06D4

2-905

DTC: P2269

2-1312

DTC:

P073D

2-917

DTC: P226C

2-1319

DTC:

P081A

2-922

DTC: P22D3

2-1328

DTC:

P081B

2-930

DTC: P240F

2-1333

DTC: P0A7B

2-935

DTC: P2428

2-1347

DTC: P0AC4

2-938

DTC: P242B

2-1353

DTC: P0CA1

2-941

DTC: P242C and P242D

2-1363

DTC: P1133

2-944

DTC: P244A

2-1373

DTC:

P119F

2-952

DTC: P244B

2-1399

DTC: P1426

2-960

DTC: P2457

2-1422

DTC: P1427

2-969

DTC: P2458

2-1440

DTC: P1428

2-978

DTC: P2459

2-1454

DTC: P1458

2-988

DTC: P2463

2-1458

DTC: P1459

2-995

DTC: P246F

2-1469

DTC: P14B0

2-1002

DTC: P2470 and P2471

2-1479

ENGINE (J05E)

2–3

DTC: P24A0

2-1489

DTC: P24A1

2-1493

DTC: P24A2

2-1496

DTC:

P2562

2-1510

DTC: P259E

2-1515

DTC:

P259F

2-1522

DTC:

P2635

2-1529

DTC: P268A and P2696

2-1554

DTC: P26C8

2-1561

DTC: P2BA9

2-1564

DTC:

U0073

2-1571

DTC: U010A

2-1574

DTC: U010C

2-1582

DTC: U010E

2-1590

DTC:

U0293

2-1599

DTC:

U029D (DIESEL)

2-1606

DTC: U029D (HYBRID)