2014 Hino 155 Series Truck Service Repair Manual by jn36248247hunk

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 systems in these vehicles.

Manual Name Chassis Workshop Manual J05E Engine Workshop Manual

Trouble shooting Workshop Manual

Pub. No. S1-LXJE03A EWD S5-LJ05E04A S7-LXJE03A 1/7 S7-LXJE03A 2/7 S7-LXJE03A 3/7 S7-LXJE03A 4/7 S7-LXJE03A 5/7 S7-LXJE03A 6/7 S7-LXJE03A 7/7

FOREWORD.fm

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CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. MANUAL NO. CHAPTER

MODELS Production Code

S1-LXJE03A (U.S.A.), S1-LXJE04A (CANADA) HINO 155, 155h, 195, 195h XFC710, XFC720, XFC740, XJC700, XJC710, XJC720, XJC740

GENERAL INTRODUCTION

1-001

HYBRID

3-001

TRANSMISSION

4-001

PROPELLER SHAFT

6-001

AXLE

7-001

DIFFERENTIAL

8-001

BRAKE

9-001

STEERING

10-001

SUSPENSION

11-001

FRAME AND FRAME ACCESSORY

12-001

CAB MOUNTING AND CAB SUSPENSION

13-001

BODY INSIDE ACCESSORY

15-001

BODY OUTSIDE ACCESSORY

16-001

AIR BAG AND SEAT BELT

17-001

HEATER AND AIR CONDITIONER

18-001

ELECTRICAL

19-001

CONTROL SYSTEM

20-001

INDEX_new.fm

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INDEX: CHASSIS GROUP 1/2

GENERAL INTRODUCTION ENGINE HYBRID SYSTEM

WORKSHOP MANUAL

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

INDEX_new.fm

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INDEX: CHASSIS GROUP 2/2

ELECTRICAL CONTROL SYSTEM

INDEX_EN.fm

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INDEX: ENGINE GROUP 1/2

GENERAL INTRODUCTION STANDARD VALUE REQUIRED ITEMS

WORKSHOP MANUAL

TROUBLESHOOTING MOUNTING AND DISMOUNTING THE ENGINE ENGINE CONTROL FUEL SYSTEM EMISSION CONTROL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION SPEED CONTROL SYSTEM IGNITION STARTING/CHARGING TURBOCHARGER

AIR COMPRESSOR

INDEX_EN.fm

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INDEX: ENGINE GROUP 2/2

ENGINE PTO (POWER TAKE-OFF)

INDEX_new.fm

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INDEX: CHASSIS GROUP

GENERAL INTRODUCTION WIRING DIAGRAM ACCORDING TO SYSTEM WIRE TO WIRE CONNECTOR

WORKSHOP MANUAL

JUNCTION CONNECTOR LOCATION RELAY LOCATION/FUSE AND RELAY BLOCK INDEX

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GENERAL INTRODUCTION

1–1

GENERAL INTRODUCTION 1-001

HOW TO IDENTIFY VEHICLE TYPE .............. 1-2

LUBRICANTS ................................................ 1-35

HOW TO IDENTIFY VEHICLE TYPE ........................... 1-2 VEHICLE MODEL ................................................... 1-2 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE ..........................................................1-3

LUBRICANTS.............................................................1-35 RECOMMENDED LUBRICANTS .........................1-35

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 ..........................1-9 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.........................................1-19 TIGHTENING OF BOLTS AND NUTS .......................1-20 BOLTS AND NUTS ...............................................1-20 PURPOSES OF TIGHTENING TORQUE.............1-20 CAUTIONS TO PREVENT LOOSENESS.............1-20 TYPES AND IDENTIFICATION.............................1-21 COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS).......................................... 1-22 STRENGTH CLASSES AND SYMBOLS.............. 1-23 PART No................................................................1-24 LIST OF TIGHTENING TORQUE ......................... 1-25 TIGHTENING OF FLARE NUTS AND HOSES .... 1-27 HANDLING OF LIQUID GASKET..............................1-28 LIQUID GASKET...................................................1-28

GLOSSARY ................................................... 1-29 DEFINITION OF ABBREVIATION IN THIS MANUAL.......................................................1-29 LIST OF ABBREVIATION ..................................... 1-29 GLOSSARY OF SAE AND HINO TERMS ............1-32

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1–2

GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE

HOW TO IDENTIFY VEHICLE TYPE HOW TO IDENTIFY VEHICLE TYPE

VEHICLE MODEL EN01E01ZZZ010102001001

ԟ L

࡯

REPORTED MODEL Ԙ ԙ㧦ENGINE MODEL

CLASSIFICATION ԡ㧦DECK HEIGHT

Ԛ㧦VEHICLE MODEL C HEAVY DUTY TRACK

X F J05E-UG (HV)

K HIGH FLOOR

X J J05E-TP (Diesel)

ԛ Ԝ㧦CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE CAB WIDTH

DRIVE

FRAME FORM

WHEEL BASE

MEDIUM

Ԣ㧦TRANSMISSION T 6AT FRAME ASSEMBLY WIDTH 840 mm {33 in.}

7 0

WIDE

2WD

OPEN

7 1

WIDE

2WD

OPEN

LONG

3,500 mm {138 in.}

ԣ㧦LOADING CAPACITY, GVW, REAR TIRES

7 2

WIDE

2WD

OPEN

SUPER LONG

3,800 mm {150 in.}

6.58 t {14,500 lbs}

REAR DOUBLE

7 4

WIDE

2WD

OPEN

SUPER LONG

4,400 mm {173 in.} T

8.14 t {17,950 lbs}, 8.85 t {19,500 lbs}

REAR DOUBLE

2,900 mm {114 in.}

Ԥ㧦ENGINE HORSEPOWER, FUEL

ԝ㧦TYPE OF SUSPENSION 0 FRONT RIGID, REAR RIGID

FUEL M DIESEL OIL

ԟ㧦STEERING WHEEL POSITION

HORSEPOWER

EXHAUST

VERY HIGH

US10

ԥ㧦DESTINATION

L LEFT HAND DRIVE DESTINATION Ԡ㧦CAB FORM, BRAKE TYPE CAB FORM

A U.S., CANADA

BRAKE TYPE

SINGLE CAB

CREW CAB

VACUUM

SINGLE CAB

HYDRAULIC

CREW CAB

HYDRAULIC

SINGLE CAB

VACUUM

SINGLE CAB

HYDRAULIC

VACUUM Ԧ㧦DECK FORM 3 CHASSIS WITH CAB

SHTS01ZZZ0100001

(3) K

(4)

SERIES

(7)

4400mm{173 in.} 2900mm{114 in.}

COE SINGLE CAB COE SINGLE CAB

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

HINO 195h HINO 195

HINO 155

HINO 155h

HINO 155

HINO 195h HINO 195

HINO 155h HINO 155 HINO 155h HINO 155

4400mm{173 in.} 3800mm{150 in.}

COE SINGLE CAB

4400mm{173 in.}

COE CREW CAB COE SINGLE CAB

3800mm{150 in.}

3500mm{138 in.}

3800mm{150 in.}

COE CREW CAB

COE SINGLE CAB

4400mm{173 in.}

COE CREW CAB

HINO 195h HINO 195

3800mm{150 in.}

XJC720 XFC740 XJC740

COE CREW CAB

XFC720

HINO 155 HINO 155h HINO 155

2900mm{114 in.}

COE SINGLE CAB

HINO 155h

3500mm{138 in.}

COE SINGLE CAB

WHEEL BASE

XJC700

XJC710

HINO 195

CAB TYPE

(6)

VDS

ENGINE MODEL

(5)

HINO 195

XFC710

HINO 195h

PRODUCTION CODE

INCOMPLETE VEHICLE

HINO MOTORS CANADA, LTD.

2AY

CODE CLASS MODEL

INCOMPLETE VEHICLE

HINO MOTORS, LTD.

JHN

TYPE

MANUFACTURER

CODE

MODEL, CAB TYPE, WHEEL BASE, BRAKE SYSTEM

MANUFACTURER ,TYPE

(2)

WMI

(1) 5

(9)

VACUUM

HYDRAULIC

VACUUM

HYDRAULIC

VACUUM

HYDRAULIC

(11)

HINO

8,140 - 8,850 kg {17,950 - 19,500 lbs.}

6,580 kg {14,500 lbs.}

J05E

3 4

CODE

2021

2020

2019

2018

2017

Diesel

Hybrid

(14) 0

(15) 0

(16)

HINO MOTORS, LTD. Hamura Plant in Japan

Canada Plant W.V Plant

HINO MOTORS, LTD. HINO PLANT IN JAPAN

(17)

ASSEMBLY PLANT

SEQUENTIAL NUMBER

VIS

YEAR

(13)

CODE ENGINE MODEL APPLICATION

CODE

SERIES GVWR

MAKE

2016

2015

2013 2014

D E

2012

CODE YEAR

CODE

(12)

ASSEMBLY PLANT

(10)

MODEL YEAR

CHECK DIGIT

BRAKE SYSTEM

MAKE

(8)

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GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE 1–3

VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE EN01E01ZZZ010102001002

SHTS01ZZZ0100002

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1–4

２０１２年１１月２１日水曜日午後６時３７分

GENERAL INTRODUCTION/APPEARANCE OF VEHICLE

APPEARANCE OF VEHICLE APPEARANCE

APPEARANCE OF VEHICLE EN01E01ZZZ020102003001

SHTS01ZZZ0200001

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GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–5

SAFETY INSTRUCTIONS AND READINESS TO WORK WARNING

GENERAL PRECAUTIONS EN01E01ZZZ030101001001

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 malfunction of the vehicle which may result in personal injury and/or property damage. If you have any question about performing 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 chapter.

• • • •

Always wear safety glasses or goggles to protect your eyes.

•

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, radiator, muffler, exhaust pipe and tail pipe.

• • •

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

• •

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

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.

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. 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.

• •

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

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 leave any tool in the engine compartment. The tool may be hit by moving parts, which can cause personal injury.

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1–6

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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.

• • •

Stop the engine and block the wheels.

•

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.

•

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

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.

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

F B

E G SHTS01ZZZ0300001

DEFINITION OF SAFETY TERMS Indicates an extremely hazardous situation if proper procedures are not followed and could result in death or serious injury. Indicates a potential hazardous situation if proper procedures are not followed and could result in death or serious injury. Indicates a hazardous situation if proper procedures are not followed and could result in serious injury or damage to parts/equipment. Indicates the need to follow proper procedures and to pay attention to precautions so that efficient service is provided.

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

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GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

1–7

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. (1)

Towing procedures Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and entry of dirt or foreign matter. Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the frame. The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and vertical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in towing a vehicle trapped in a gutter. Keep the gear shift lever in Neutral. Make sure that the starter switch is kept in the "ON" position, if the engine is not running. Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum will be available for the brake. This is dangerous, as the brake system does not function if the engine is not running. In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to turn, making it impossible to control the vehicle. Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed. Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.

(2) (3)

(4) (5) (6)

(7) (8) 2. (1)

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

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3–10

HYBRID/HYBRID SYSTEM

SERVICE PLUG

COMPONENT LOCATOR EN01E03ZZZ040402007001

A 1 2

SHTS03ZZZ0400003

Service plug

Service plug cover

Tightening torque A

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

9 {92, 6.6}

UNIT CHECK EN01E03ZZZ040402007002

INSPECTING THE SERVICE PLUG 1. (1)

INSPECTING THE SERVICE PLUG. Using a circuit tester, measure the resistance value between service plug terminals. Inspection terminal

Standard value

1-2

1Ω or less

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HYBRID/HYBRID SYSTEM

3–11

REPLACEMENT EN01E03ZZZ040402007003

REMOVING THE SERVICE PLUG 1. (1)

DISCONNECTING THE AUXILIARY BATTERY. Disconnect the auxiliary battery negative terminal.

2. (1)

REMOVING THE SERVICE PLUG COVER. Remove the bolts (4 pcs.) to remove the service plug cover.

3. (1)

REMOVING THE SERVICE PLUG. Wear insulated gloves to remove the service plug from the HV battery assembly.

SHTS03ZZZ0400004

! CAUTION To prevent another engineer from reconnecting the service plug you disconnected, carry that plug around with you in your pocket.

3 2

SHTS03ZZZ0400005

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3–12

HYBRID/HYBRID SYSTEM

MOUNTING THE SERVICE PLUG 1.

MOUNTING THE SERVICE PLUG.

! CAUTION Double check that you have not left any tools or parts inside before connecting the service plug, and double check the status of high-voltage connector tightening and the status of connector connections. (1)

Wear insulated gloves to mount the service plug to the HV battery assembly.

2. (1)

MOUNTING THE SERVICE PLUG COVER. Mount the service plug cover with the bolts (4 pcs.) Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft}

3. (1)

CONNECTING THE AUXILIARY BATTERY. Connect the negative battery terminal of the auxiliary battery.

1 2

SHTS03ZZZ0400006

SHTS03ZZZ0400007

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HYBRID/HYBRID SYSTEM

3–13

PCU

COMPONENT LOCATOR EN01E03ZZZ040402004001

SHTS03ZZZ0400008

Tightening torque A

115 {1,173, 84.8}

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

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3–14

HYBRID/HYBRID SYSTEM

1 2

SHTS03ZZZ0400009

Service hole cover

Front panel

Clip

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HYBRID/HYBRID SYSTEM

3–15

1 A

SHTS03ZZZ0400010

Inverter terminal cover

Tightening torque A

9 {92, 6.6}

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

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3–16

HYBRID/HYBRID SYSTEM

1 B

A B

SHTS03ZZZ0400011

Motor cable

Tightening torque A

8.1-9.9 {82-100, 5.9-7.3}

Unit: N⋅m {kgf⋅cm, lbf⋅ft} B

9 {92, 6.6}

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HYBRID/HYBRID SYSTEM

3–17

REPLACEMENT EN01E03ZZZ040402004002

REMOVING THE PCU 1. (1)

DISCONNECTING THE AUXILIARY BATTERY. Disconnect the auxiliary battery negative terminal.

REMOVING THE SERVICE PLUG. Reference: HYBRID, HYBRID SYSTEM, SERVICE PLUG, REPLACEMENT, REMOVING THE SERVICE PLUG (Page 3-10)

DISCONNECTING THE MOTOR CABLE AND 24V POWER CABLE. Unfasten clips (4 pcs.) to remove the under cover service hole cover.

(1)

SHTS03ZZZ0400012

(2)

SHTS03ZZZ0400013

Remove the bolts (4 pcs.) and remove the inverter terminal cover.

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3–18

HYBRID/HYBRID SYSTEM (3)

Remove bolts (6 pcs.) and detach the motor cable.

4. (1)

DISCONNECTING THE CONNECTOR. Unfasten the clips (2 pcs.) and remove the front panel.

(2)

Disconnect the connectors (2 locations).

CABLE SIDE

PIN SIDE

SHTS03ZZZ0400014

SHTS03ZZZ0400015

SHTS03ZZZ0400016

Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

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HYBRID/HYBRID SYSTEM 5. (1) (2)

SHTS03ZZZ0400017

REMOVING THE PCU. Set the engine lifter on the PCU. Remove the nuts (6 pcs.) to remove the PCU.

3–19

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3–20

HYBRID/HYBRID SYSTEM

MOUNTING THE PCU 1. (1) (2)

MOUNTING THE PCU. Set the engine lifter on the PCU. Mount the PCU using the nuts (6 pcs.). Tightening Torque: 115 N·m {1,173 kgf·cm, 84.8 lbf·ft}

2. (1)

CONNECTING THE CONNECTOR. Connect the connectors (2 locations).

(2)

Mount the front panel using the clips.

SHTS03ZZZ0400018

SHTS03ZZZ0400019

SHTS03ZZZ0400020

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HYBRID/HYBRID SYSTEM

3–21

3. (1)

CONNECTING THE MOTOR CABLE AND 24V POWER CABLE. Connect the motor cable using bolts (6 pcs.). Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft} (Cable side) 8.1-9.9 N·m {82-100 kgf·cm, 5.9-7.3 lbf·ft} (Terminal side)

(2)

Mount the inverter terminal cover with the bolts (4 pcs.) Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft}

(3)

Fasten clips (4 pcs.) to mount the under cover service hole cover.

MOUNTING THE SERVICE PLUG. Reference: HYBRID, HYBRID SYSTEM, SERVICE PLUG, REPLACEMENT, MOUNTING THE SERVICE PLUG (Page 3-11)

5. (1)

CONNECTING THE AUXILIARY BATTERY. Connect the negative battery terminal of the auxiliary battery.

CABLE SIDE

TERMINAL SIDE

SHTS03ZZZ0400021

SHTS03ZZZ0400022

SHTS03ZZZ0400023