2016 Hino 155 Series Truck Service Repair Manual by jn36248247hunk

FOREWORD.fm

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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 systems in these vehicles.

Manual Name Chassis Workshop Manual J05E Engine Workshop Manual

Trouble shooting Workshop Manual

Pub. No. S1-LXJE08A EWD S5-LJ05E10A S7-LXJE08A 1/5 S7-LXJE08A 2/5 S7-LXJE08A 3/5 S7-LXJE08A 4/5 S7-LXJE08A 5/5

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-LXJE08A (U.S.A.), S1-LXJE09A (CANADA) HINO 155, 155h, 195, 195h XFC710, XFC720, XFC730, XFC740, XJC700, XJC710, XJC720, XJC730, 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

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: 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: ENGINE GROUP 2/2

ENGINE PTO (POWER TAKE-OFF)

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

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

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

REAR DOUBLE

2,900 mm {114 in.}

7 3

WIDE

2WD

OPEN

SUPER LONG

4,100 mm {161 in.}

7 4

WIDE

2WD

OPEN

SUPER LONG

4,400 mm {173 in.}

ԝ㧦TYPE OF SUSPENSION

Ԥ㧦ENGINE HORSEPOWER, FUEL

0 FRONT RIGID, REAR RIGID

FUEL M DIESEL OIL

ԟ㧦STEERING WHEEL POSITION L LEFT HAND DRIVE

EXHAUST

VERY HIGH

US13 (13OBD)

ԥ㧦DESTINATION DESTINATION

Ԡ㧦CAB FORM, BRAKE TYPE CAB FORM

HORSEPOWER

A U.S., CANADA

BRAKE TYPE

SINGLE CAB

VACUUM

Ԧ㧦DECK FORM

CREW CAB

VACUUM

3 CHASSIS WITH CAB

SINGLE CAB

HYDRAULIC

CREW CAB

HYDRAULIC

SINGLE CAB

VACUUM

CREW CAB

HYDRAULIC

SHTS01ZZZ0100001

(3) K

(4)

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

4,400 mm {173 in.} 3,800 mm {150 in.}

COE SINGLE CAB COE SINGLE CAB

VACUUM

4,400 mm {173 in.} HYDRAULIC

COE CREW CAB

VACUUM

3,800 mm {150 in.} HYDRAULIC

3,500 mm {138 in.}

2,900 mm {114 in.}

4,400 mm {173 in.} HYDRAULIC

3,800 mm {150 in.} HYDRAULIC

VACUUM

COE CREW CAB

COE SINGLE CAB

4,400 mm {173 in.}

COE CREW CAB

XJC720 XFC740 XJC740

HINO 155 HINO 155h HINO 155

3,800 mm {150 in.}

COE CREW CAB VACUUM

2,900 mm {114 in.} HYDRAULIC

COE SINGLE CAB

XFC720

3,500 mm {138 in.} HYDRAULIC

HINO 155h

XJC710

HINO 195

COE SINGLE CAB

WHEEL BASE

(9)

2018

(12)

6,580 kg {14,500 lbs.} 8,140 - 8,850 kg {17,950 - 19,500 lbs.}

1 2

J05E-TP

J05E-UG

(14)

CODE

Diesel

(16)

HINO MOTORS, LTD. Hamura Plant in Japan

(17)

ASSEMBLY PLANT

HINO MOTORS, LTD. Hamura Plant in Japan

Canada Plant (COE)

ASSEMBLY PLANT

For Canada

CODE

For USA

2023

2022

2021

2020

2019

YEAR

Hybrid

(15)

SEQUENTIAL NUMBER

VIS

CODE ENGINE MODEL APPLICATION

SERIES GVWR

CODE

(13)

CODE

HINO

MAKE

2017

2015 2016

2014

CODE YEAR

CODE H

(11)

ASSEMBLY PLANT

(10)

MODEL YEAR

CHECK DIGIT

BRAKE SYSTEM

MAKE

(8)

4,100 mm {161 in.} HYDRAULIC

XJC700

XJC730 XFC710

HINO 195 HINO 195h

SERIES

(7)

COE SINGLE CAB

HINO 195

XFC730

HINO 195h

(6)

VDS

ENGINE MODEL

(5)

CAB TYPE

2AY

CODE CLASS MODEL

INCOMPLETE VEHICLE

HINO MOTORS CANADA, LTD.

PRODUCTION CODE

INCOMPLETE VEHICLE

HINO MOTORS, LTD.

JHN

TYPE

MANUFACTURER

CODE

MODEL, CAB TYPE, WHEEL BASE, BRAKE SYSTEM

MANUFACTURER ,TYPE

(2)

(1)

WMI

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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

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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. 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, radiator, 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.

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HYBRID/HYBRID SYSTEM

3–11

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.

INSPECTING THE SERVICE PLUG. (1) Using a circuit tester, measure the resistance value between service plug terminals. Inspection terminal

Standard value

1-2

1 or less

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3–12

HYBRID/HYBRID SYSTEM

REPLACEMENT EN01E03ZZZ040402007003

REMOVING THE SERVICE PLUG 1.

DISCONNECTING THE AUXILIARY BATTERY. (1) Disconnect the auxiliary battery negative terminal.

REMOVING THE SERVICE PLUG COVER. (1) Remove the bolts (4 pcs.) to remove the service plug cover.

REMOVING THE SERVICE PLUG. (1) 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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HYBRID/HYBRID SYSTEM

3–13

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.

1 2

SHTS03ZZZ0400006

SHTS03ZZZ0400007

MOUNTING THE SERVICE PLUG COVER. (1) Mount the service plug cover with the bolts (4 pcs.) Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft}

CONNECTING THE AUXILIARY BATTERY. (1) Connect the negative battery terminal of the auxiliary battery.

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3–14

HYBRID/HYBRID SYSTEM

PCU

COMPONENT LOCATOR EN01E03ZZZ040402004001

SHTS03ZZZ0400008

Tightening torque A

115 {1,173, 84.8}

Unit: Nm {kgfcm, lbfft}

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HYBRID/HYBRID SYSTEM

3–15

1 2

SHTS03ZZZ0400009

Service hole cover

Clip

Front panel

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3–16

HYBRID/HYBRID SYSTEM

1 A

SHTS03ZZZ0400010

Inverter terminal cover

Tightening torque A

9 {92, 6.6}

Unit: Nm {kgfcm, lbfft}

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HYBRID/HYBRID SYSTEM

3–17

1 B

A B

SHTS03ZZZ0400011

Motor cable

Tightening torque A

7.2-10.8 {73-110, 5.3-8.0}

Unit: Nm {kgfcm, lbfft} B

9 {92, 6.6}

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3–18

HYBRID/HYBRID SYSTEM

REPLACEMENT EN01E03ZZZ040402004002

REMOVING THE PCU 1.

DISCONNECTING THE AUXILIARY BATTERY. (1) Disconnect the auxiliary battery negative terminal.

REMOVING THE SERVICE PLUG. Reference: HYBRID, HYBRID SYSTEM, SERVICE PLUG, REPLACEMENT, REMOVING THE SERVICE PLUG (Page 3-12)

DISCONNECTING THE MOTOR CABLE AND 24V POWER CABLE. (1) Unfasten clips (4 pcs.) to remove the under cover service hole cover.

SHTS03ZZZ0400012

(2)

SHTS03ZZZ0400013

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

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HYBRID/HYBRID SYSTEM (3)

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

CABLE SIDE

TERMINAL SIDE

SHTS03ZZZ0400014

DISCONNECTING THE CONNECTOR. (1) Unfasten the clips (2 pcs.) and remove the front panel.

SHTS03ZZZ0400015

(2)

SHTS03ZZZ0400016

Disconnect the connectors (2 locations).

3–19

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3–20

HYBRID/HYBRID SYSTEM 5.

SHTS03ZZZ0400017

REMOVING THE PCU. (1) Set the engine lifter on the PCU. (2) Remove the nuts (6 pcs.) to remove the PCU.

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HYBRID/HYBRID SYSTEM

MOUNTING THE PCU 1.

MOUNTING THE PCU. (1) Set the engine lifter on the PCU. (2) Mount the PCU using the nuts (6 pcs.). Tightening Torque: 115 N·m {1,173 kgf·cm, 84.8 lbf·ft}

CONNECTING THE CONNECTOR. (1) Connect the connectors (2 locations).

SHTS03ZZZ0400018

SHTS03ZZZ0400019

(2)

SHTS03ZZZ0400020

Mount the front panel using the clips.

3–21

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3–22

HYBRID/HYBRID SYSTEM 3.

CABLE SIDE

CONNECTING THE MOTOR CABLE AND 24V POWER CABLE. (1) Connect the motor cable using bolts (6 pcs.). Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft} (Cable side) 7.2-10.8 N·m {73-110 kgf·cm, 5.3-8.0 lbf·ft} (Terminal side)

TERMINAL SIDE

SHTS03ZZZ0400021

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

SHTS03ZZZ0400022

(3)

SHTS03ZZZ0400023

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 3-13)

CONNECTING THE AUXILIARY BATTERY. (1) Connect the negative battery terminal of the auxiliary battery.

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HYBRID/HYBRID SYSTEM

3–23

HV BATTERY

COMPONENT LOCATOR EN01E03ZZZ040402003001

A A A

3 4 4 B SHTS03ZZZ0400024

HV battery

Under cover

Clip*

Clip

*: Nonreusable part Tightening torque A

31 {316, 22.9}

Unit: Nm {kgfcm, lbfft} B

13 {133, 9.6}

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3–24

HYBRID/HYBRID SYSTEM

A 1

SHTS03ZZZ0400025

Terminal cover

Tightening torque A

9 {92, 6.6}

Unit: Nm {kgfcm, lbfft}

426A_USA Chassis.book 25 ページ

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HYBRID/HYBRID SYSTEM

3–25

REPLACEMENT EN01E03ZZZ040402003002

REMOVING THE HV BATTERY ASSEMBLY 1.

REMOVING THE PCU Reference: HYBRID, HYBRID SYSTEM, PCU, REPLACEMENT, REMOVING THE PCU (Page 3-18)

DISCONNECTING THE HARNESS. (1) Disconnect the connector clamp and connector.

SHTS03ZZZ0400026

(2)

Unfasten the nuts (4 pcs.) and remove the terminal cover.

(3) (4) (5)

Unfasten the nuts (2 pcs.) to disconnect the harness. Disconnect the hose clamp of the snorkel hose. Disconnect the grommets (3 locations).

SHTS03ZZZ0400027

SHTS03ZZZ0400028

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3–26

HYBRID/HYBRID SYSTEM 3.

REMOVING THE UNDER COVER. (1) Remove the bolts (3 pcs.) and clips (10 pcs.). (2) Pull the under cover to the front, and remove the clips (5 pcs.) and under cover. NOTICE Clips (5 pcs.) inside the under cover are not reusable.

UNDER COVER

SHTS03ZZZ0400029

REMOVING THE BOTTOM OF PCU. (1) Unfasten the bolts (10 pcs.) and remove the bottom of PCU.

HV BATTERY ASSEMBLY

PCU LOWER

SHTS03ZZZ0400030

NOTICE • Be careful not to get the check valve at the bottom of the HV battery assembly caught on anything or do not remove it.

CHECK VALVE

SHTS03ZZZ0400031

• While taking care not to damage the check valve, place the HV battery assembly on a bench as shown in the figure.

CHECK VALVE BENCH SHTS03ZZZ0400032