Hino Trucks MY2017-MY2020 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Hino Trucks MY2017-MY2020, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
HINO TRUCKS All Models MY2017-MY2020 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
2017
COE_HEV
17MY COE Owners Manual_H1-L054E01.pdf
2017 COE Chassis DT_SA_BE_HEV_AC.pdf
2017 COE Engine.pdf
2017 COE EWD.pdf
2017 COE Troubleshooting 1_ENG.pdf
2017 COE Troubleshooting 2_ENG.pdf
2017 COE Troubleshooting 3_ENG.pdf
2017 COE Troubleshooting 4_HEV_ATM_DT.pdf
2017 COE Troubleshooting 5_SA_BRAKE_ELEC.pdf
Conventional
17MY Conv Owners Manual_H1-A037E01.pdf
2017 CONV Chassis 1_DT_ABS.pdf
2017 CONV Chassis 2_EWD.pdf
2017 CONV Engine.pdf
2017 CONV Troubleshooting 1_ELEC_ENG_DPF.pdf
2017 CONV Troubleshooting 2_ENGINE.pdf
2017 CONV Troubleshooting 3_DEF_DPF.pdf
2018
COE_HEV
2018 COE Chassis DT_SA_BE_HEV_AC.pdf
2018 COE Engine.pdf
2018 COE EWD.pdf
2018 COE Troubleshooting 1_ENG.pdf
2018 COE Troubleshooting 2_ENG.pdf
2018 COE Troubleshooting 3_ENG.pdf
2018 COE Troubleshooting 4_HEV_ATM_DT.pdf
2018 COE Troubleshooting 5_SA_BRAKE_ELEC.pdf
2018MY COE Owners Manual.pdf
2019
2019 Conventional Service Manual
FOREWORD.pdf
Manual.pdf
S1-UNAE15A-1.pdf
S1-UNAE15A-2.pdf
S5-UJ08E15A.pdf
S7-UNAE15A-1.pdf
S7-UNAE15A-2.pdf
S7-UNAE15A-3.pdf
COE
19MY COE Owners Manual.pdf
2019 COE Chassis DT_SA_BE_HEV_AC.pdf
2019 COE Engine.pdf
2019 COE EWD.pdf
2019 COE Troubleshooting 1_ENG.pdf
2019 COE Troubleshooting 2_ENG.pdf
2019 COE Troubleshooting 3_ENG_HEV.pdf
2019 COE Troubleshooting 4_HEV_ATM_DT.pdf
2019 COE Troubleshooting 5_SA_BRAKE_ELEC.pdf
XL
2019 XL Chassis 1_DT_ST_ABS.pdf
2019 XL Chassis 2_RA.pdf
2019 XL Chassis 3_EWD_SUSP_WT.pdf
2019 XL ENGINE.pdf
2019 XL Troubleshooting 1_ELEC_ENG.pdf
2019 XL Troubleshooting 2_ENG.pdf
2019 XL Troubleshooting 3_ENG.pdf
2019 XL Troubleshooting 4_CAN_DEF_VCS_SUSP.pdf
FOREWORD.pdf
XL Owner's Manual.pdf
2020
COE
FOREWORD.pdf
Manual.pdf
S1-LXJE16A_EWD.pdf
S1-LXJE16A.pdf
S5-LJ05E19A.pdf
S7-LXJE16A-1.pdf
S7-LXJE16A-2.pdf
S7-LXJE16A-3.pdf
S7-LXJE16A-4.pdf
S7-LXJE16A-5.pdf
conventional
FOREWORD.pdf
Manual.pdf
S1-UNAE16A-1.pdf
S1-UNAE16A-2.pdf
S5-UJ08E16A-1.pdf
S7-UNAE16A-1.pdf
S7-UNAE16A-2.pdf
S7-UNAE16A-3.pdf
XL
2020 XL Chassis 1_DT_ST_ABS.pdf
2020 XL Chassis 2_RA.pdf
2020 XL Chassis 3_EWD_SUSP_WT.pdf
2020 XL ENGINE.pdf
2020 XL Troubleshooting 1_ELEC_ENG.pdf
2020 XL Troubleshooting 2_ENG.pdf
2020 XL Troubleshooting 3_ENG.pdf
2020 XL Troubleshooting 4_CAN_DEF_VCS_SUSP.pdf
FOREWORD.pdf
XL Owner's Manual.pdf
PRODUCT DETAILS:
Total Pages: 21,211 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
COE....1
FOREWORD....1
Manual....2
How to use....2
1....2
2....3
3....4
4....5
5....6
S1-LXJE16A....7
FOREWORD....7
CHAPTER REFERENCES....8
INDEX....9
GENERAL INTRODUCTION....11
HOW TO IDENTIFY VEHICLE TYPE....12
HOW TO IDENTIFY VEHICLE TYPE....12
VEHICLE MODEL....12
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE....13
APPEARANCE OF VEHICLE....14
APPEARANCE....14
APPEARANCE OF VEHICLE....14
SAFETY INSTRUCTIONS AND READINESS TO WORK....15
WARNING....15
GENERAL PRECAUTIONS....15
IDENTIFICATION INFORMATION....19
SAFETY INSTRUCTIONS FOR WORK....22
PRECAUTIONS....22
INTRODUCTION TO WORKSHOP MANUAL....26
GENERAL....26
INTRODUCTION TO DESCRIPTIONS....27
DEFINITION OF TERM....29
TIGHTENING OF BOLTS AND NUTS....30
BOLTS AND NUTS....30
PURPOSES OF TIGHTENING TORQUE....30
CAUTIONS TO PREVENT LOOSENESS....30
TYPES AND IDENTIFICATION....31
COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)....32
STRENGTH CLASSES AND SYMBOLS....33
PART No....34
LIST OF TIGHTENING TORQUE....35
TIGHTENING OF FLARE NUTS AND HOSES....37
HANDLING OF LIQUID GASKET....38
LIQUID GASKET....38
GLOSSARY....39
DEFINITION OF ABBREVIATION IN THIS MANUAL....39
LIST OF ABBREVIATION....39
GLOSSARY OF SAE AND HINO TERMS....42
LUBRICANTS....45
LUBRICANTS....45
RECOMMENDED LUBRICANTS....45
HYBRID....47
STANDARD VALUE....48
HYBRID SYSTEM....48
SERVICE PLUG....48
PCU....48
HV BATTERY....49
HV BATTERY COOLING FAN....49
HV BATTERY ECU....49
SYSTEM MAIN RELAY JUNCTION BLOCK....49
INVERTER....50
HV-ECU....50
HYBRID JUNCTION BLOCK....50
WATER PUMP....51
INVERTER RADIATOR....51
COOLANT....51
MOTOR CABLE....51
REQUIRED ITEMS....52
HYBRID SYSTEM....52
HYBRID SYSTEM....52
SERVICE PLUG....52
COOLANT....52
HYBRID SYSTEM....53
HYBRID SYSTEM....53
CAUTIONS....53
SERVICE PLUG....57
COMPONENT LOCATOR....57
UNIT CHECK....57
REPLACEMENT....58
PCU....60
COMPONENT LOCATOR....60
REPLACEMENT....64
HV BATTERY....69
COMPONENT LOCATOR....69
REPLACEMENT....71
HV BATTERY COOLING FAN....76
COMPONENT LOCATOR....76
REPLACEMENT....78
HV BATTERY ECU....81
COMPONENT LOCATOR....81
REPLACEMENT....82
SYSTEM MAIN RELAY JUNCTION BLOCK....86
COMPONENT LOCATOR....86
REPLACEMENT....87
INVERTER....89
COMPONENT LOCATOR....89
REPLACEMENT....90
HV-ECU....94
COMPONENT LOCATOR....94
REPLACEMENT....95
HYBRID JUNCTION BLOCK....97
COMPONENT LOCATOR....97
REPLACEMENT....98
WATER PUMP....102
COMPONENT LOCATOR....102
REPLACEMENT....103
INVERTER RADIATOR....107
COMPONENT LOCATOR....107
REPLACEMENT....108
COOLANT....110
REPLACEMENT....110
MOTOR CABLE....112
COMPONENT LOCATOR....112
REPLACEMENT....115
TRANSMISSION (A465)....121
STANDARD VALUE....122
MOUNTING AND DISMOUNTING THE TRANSMISSION....122
AUTOMATIC TRANSMISSION ASSEMBLY....122
TRANSMISSION CONTROL....124
SHIFT LEVER ASSEMBLY....124
TRANSMISSION MECHANICAL....124
TURBINE SENSOR....124
SPEED SENSOR....124
NEUTRAL SWITCH....125
EOP....125
VALVE BODY ASSEMBLY....125
REQUIRED ITEMS....126
MOUNTING AND DISMOUNTING THE TRANSMISSION....126
AUTOMATIC TRANSMISSION ASSEMBLY....126
NEUTRAL SWITCH....126
FRONT OIL SEAL....126
MOUNTING AND DISMOUNTING THE TRANSMISSION....127
AUTOMATIC TRANSMISSION ASSEMBLY....127
REPLACEMENT....127
TRANSMISSION CONTROL....169
CONTROL COMPUTER ASSEMBLY ....169
COMPONENT LOCATOR....169
OVERHAUL....170
SHIFT LEVER ASSEMBLY....177
COMPONENT LOCATOR....177
OVERHAUL....178
TRANSMISSION MECHANICAL....182
OIL PAN GASKET....182
COMPONENT LOCATOR....182
OVERHAUL....183
REAR CASE GASKET....185
COMPONENT LOCATOR....185
OVERHAUL....186
TURBINE SENSOR....190
COMPONENT LOCATOR....190
OVERHAUL....191
SPEED SENSOR....192
COMPONENT LOCATOR....192
OVERHAUL....193
NEUTRAL SWITCH....194
COMPONENT LOCATOR....194
OVERHAUL....195
EOP....197
OVERHAUL....197
VALVE BODY ASSEMBLY....205
OVERHAUL....205
FRONT OIL SEAL....215
OVERHAUL....215
PROPELLER SHAFT (LD)....217
STANDARD VALUE....218
PROPELLER SHAFT MECHANICAL....218
PROPELLER SHAFT ASSEMBLY....218
REQUIRED ITEMS....219
PROPELLER SHAFT MECHANICAL....219
PROPELLER SHAFT ASSEMBLY....219
PROPELLER SHAFT MECHANICAL....221
PROPELLER SHAFT ASSEMBLY....221
COMPONENT LOCATOR....221
OVERHAUL....223
AXLE....241
STANDARD VALUE....242
FRONT AXLE....242
STEERING KNUCKLE....242
FRONT AXLE HUB....243
REAR AXLE....244
REAR AXLE HUB....244
REAR AXLE SHAFT....245
REQUIRED ITEMS....246
FRONT AXLE....246
STEERING KNUCKLE....246
FRONT AXLE HUB....247
REAR AXLE....250
REAR AXLE HUB....250
REAR AXLE SHAFT....251
WHEEL AND TIRE....252
FRONT AXLE....253
STEERING KNUCKLE....253
COMPONENT LOCATOR....253
OVERHAUL....257
FRONT AXLE HUB....271
COMPONENT LOCATOR....271
OVERHAUL....273
FRONT AXLE HUB BOLT....285
COMPONENT LOCATOR....285
OVERHAUL....286
REAR AXLE....288
REAR AXLE HUB....288
COMPONENT LOCATOR....288
OVERHAUL....290
REAR AXLE SHAFT....300
COMPONENT LOCATOR....300
OVERHAUL....301
WHEEL AND TIRE....303
WHEEL AND TIRE....303
COMPONENT LOCATOR....303
INSPECTION....304
REPLACEMENT....306
OVERHAUL (TUBELESS TIRE)....311
DIFFERENTIAL (SH13)....318
STANDARD VALUE....319
DIFFERENTIAL....319
DIFFERENTIAL CARRIER....319
REQUIRED ITEMS....321
DIFFERENTIAL....321
DIFFERENTIAL CARRIER....321
DIFFERENTIAL....324
DIFFERENTIAL CARRIER....324
COMPONENT LOCATOR....324
OVERHAUL....332
BRAKE....370
STANDARD VALUE....372
BRAKE CONTROL....372
SERVICE BRAKE....372
BRAKE FLUID....372
BRAKE ACTUATOR....373
SPEED SENSOR....373
BRAKE PEDAL....374
BRAKE MASTER CYLINDER....374
BRAKE BOOSTER....374
HYDRO BOOSTER....375
ELECTRIC VACUUM PUMP....375
VACUUM PUMP....375
HYDRO PUMP....375
VACUUM RESERVOIR....376
FRONT FLEXIBLE HOSE....376
REAR FLEXIBLE HOSE....376
VACUUM WARNING BUZZER....376
VACUUM SENSOR (FOR SKID CONTROL)....376
DISC BRAKE ....377
FRONT DISC CALIPER....377
REAR DISC CALIPER....378
PARKING BRAKE....379
PARKING BRAKE....379
PARKING BRAKE CABLE No.2....379
PARKING BRAKE CABLE No.3....379
PARKING BRAKE LEVER....379
PARKING BRAKE DRUM....380
PARKING BRAKE SWITCH....380
REQUIRED ITEMS....381
SERVICE BRAKE....381
SERVICE BRAKE....381
BRAKE FLUID....381
SPEED SENSOR....381
BRAKE PEDAL....381
BRAKE BOOSTER....381
HYDRO BOOSTER....382
VACUUM RESERVOIR....382
DISC BRAKE....383
FRONT DISC CALIPER....383
REAR DISC CALIPER....383
PARKING BRAKE....384
PARKING BRAKE DRUM....384
BRAKE CONTROL....385
SERVICE BRAKE....385
INSPECTION AND ADJUSTMENT....385
BRAKE FLUID....390
REPLACEMENT....390
ABS ACTUATOR....393
COMPONENT LOCATOR....393
REPLACEMENT....394
UNIT CHECK....396
SPEED SENSOR....397
COMPONENT LOCATOR....397
UNIT CHECK....399
REPLACEMENT....400
BRAKE PEDAL....404
COMPONENT LOCATOR....404
REPLACEMENT....405
BRAKE MASTER CYLINDER....408
COMPONENT LOCATOR....408
REPLACEMENT....409
BRAKE BOOSTER....413
COMPONENT LOCATOR....413
REPLACEMENT....414
HYDRO BOOSTER....422
COMPONENT LOCATOR....422
REPLACEMENT....423
ELECTRIC VACUUM PUMP....429
COMPONENT LOCATOR....429
OVERHAUL....430
VACUUM PUMP....434
COMPONENT LOCATOR....434
OVERHAUL....435
HYDRO PUMP....437
COMPONENT LOCATOR....437
OVERHAUL....438
VACUUM RESERVOIR....439
COMPONENT LOCATOR....439
REPLACEMENT....440
FRONT FLEXIBLE HOSE....442
COMPONENT LOCATOR....442
REPLACEMENT....443
REAR FLEXIBLE HOSE....445
COMPONENT LOCATOR....445
REPLACEMENT....446
VACUUM WARNING BUZZER....448
BEHIND-THE-WHEEL INSPECTION....448
REPLACEMENT....448
VACUUM SENSOR (FOR SKID CONTROL)....449
COMPONENT LOCATOR....449
REPLACEMENT....450
DISC BRAKE....454
FRONT BRAKE CALIPER....454
COMPONENT LOCATOR....454
OVERHAUL....455
REAR BRAKE CALIPER....462
COMPONENT LOCATOR....462
OVERHAUL....463
PARKING BRAKE....470
PARKING BRAKE....470
INSPECTION AND ADJUSTMENT....470
PARKING BRAKE CABLE No.2....472
COMPONENT LOCATOR....472
REPLACEMENT....473
PARKING BRAKE CABLE No.3....479
COMPONENT LOCATOR....479
REPLACEMENT....480
PARKING BRAKE LEVER....486
COMPONENT LOCATOR....486
REPLACEMENT....487
PARKING BRAKE DRUM....491
COMPONENT LOCATOR....491
OVERHAUL....493
PARKING BRAKE SWITCH....505
COMPONENT LOCATOR....505
REPLACEMENT....506
STEERING....509
STANDARD VALUE....510
STEERING CONTROL....510
POWER STEERING SYSTEM....510
STEERING WHEEL....510
STEERING COLUMN....510
STEERING LINKAGE....511
POWER STEERING GEAR....511
POWER STEERING PUMP....511
REQUIRED ITEMS....512
STEERING CONTROL....512
POWER STEERING SYSTEM....512
STEERING WHEEL....512
STEERING COLUMN....513
STEERING LINKAGE....513
POWER STEERING GEAR....514
POWER STEERING PUMP....514
STEERING CONTROL....515
POWER STEERING SYSTEM....515
PERFORMANCE INSPECTION....515
STEERING WHEEL....518
COMPONENT LOCATOR....518
REPLACEMENT....519
STEERING COLUMN....522
COMPONENT LOCATOR....522
REPLACEMENT....523
STEERING LINKAGE....531
COMPONENT LOCATOR....531
REPLACEMENT....532
POWER STEERING GEAR....540
COMPONENT LOCATOR....540
REPLACEMENT....541
POWER STEERING PUMP....552
COMPONENT LOCATOR....552
REPLACEMENT ....553
SUSPENSION....555
STANDARD VALUE....556
FRONT SUSPENSION....556
SHOCK ABSORBER....556
LEAF SPRING....556
STABILIZER....557
WHEEL ALIGNMENT....557
REAR SUSPENSION....558
SHOCK ABSORBER....558
LEAF SPRING....558
REQUIRED ITEMS....559
FRONT SUSPENSION....559
SHOCK ABSORBER....559
LEAF SPRING....559
WHEEL ALIGNMENT....560
REAR SUSPENSION....561
SHOCK ABSORBER....561
LEAF SPRING....561
FRONT SUSPENSION....562
SHOCK ABSORBER....562
COMPONENT LOCATOR....562
REPLACEMENT....563
LEAF SPRING....566
COMPONENT LOCATOR....566
OVERHAUL....567
STABILIZER....576
COMPONENT LOCATOR....576
REPLACEMENT....577
WHEEL ALIGNMENT....579
ADJUSTMENT....579
REAR SUSPENSION....582
SHOCK ABSORBER....582
COMPONENT LOCATOR....582
REPLACEMENT....583
LEAF SPRING....586
COMPONENT LOCATOR....586
OVERHAUL....588
FRAME AND FRAME ACCESSORY....597
STANDARD VALUE....598
FRAME....598
CHASSIS FRAME....598
FRONT BUMPER....599
REQUIRED ITEMS....600
FRAME....600
CHASSIS FRAME & CHASSIS FRAME ACCESSORIES....600
FRAME....601
FRAME AND FRAME ACCESSORIES....601
COMPONENT LOCATOR....601
FRAME....602
INSPECTION....602
REPAIR....603
FRONT BUMPER....608
COMPONENT LOCATOR....608
REPLACEMENT....610
CAB MOUNTING AND CAB SUSPENSION....615
STANDARD VALUE....616
CAB MOUNTING AND CAB SUSPENSION....616
ASSEMBLY....616
CAB MOUNTING....616
TILT CAB STAY....617
MOUNTING AND DISMOUNTING CAB....618
CAB ASSEMBLY....618
REPLACEMENT....618
CAB MOUNTING AND CAB SUSPENSION....632
CAB MOUNTING....632
COMPONENT LOCATOR....632
PRECAUTIONS IN TILTING AND LOWERING THE CAB....636
REPLACEMENT....637
CAB TILT STAY....650
COMPONENT LOCATOR....650
PRECAUTIONS IN TILTING AND LOWERING THE CAB....653
REPLACEMENT....654
CAB DIMENSIONAL DRAWING....660
CAB ASSEMBLY....660
SINGLE CAB....660
CREW CAB....662
BODY INSIDE ACCESSORY....664
STANDARD VALUE....665
INSTRUMENT PANEL AND DRIVER INFORMATION....665
INSTRUMENT PANEL....665
INTERIOR ACCESSORY....665
ROOF ACCESSORY....665
SEAT....666
DRIVER'S SEAT....666
ASSISTANT'S SEAT....666
REAR SEAT....666
INSTRUMENT PANEL AND DRIVER INFORMATION....668
INSTRUMENT PANEL....668
COMPONENT LOCATOR....668
REPLACEMENT....670
COMBINATION METER....680
REPLACEMENT....680
INTERIOR ACCESSORY....681
INTERIOR ACCESSORY....681
COMPONENT LOCATOR....681
REPLACEMENT....683
FLOOR ACCESSORY....686
COMPONENT LOCATOR....686
REPLACEMENT....687
ROOF ACCESSORY....688
COMPONENT LOCATOR....688
REPLACEMENT....689
SEAT....696
DRIVER'S SEAT....696
COMPONENT LOCATOR....696
OVERHAUL....698
ASSISTANT'S SEAT....710
COMPONENT LOCATOR....710
OVERHAUL (THREE-SEATER)....713
OVERHAUL (CREW CAB)....721
REAR SEAT....727
COMPONENT LOCATOR....727
OVERHAUL....729
BODY OUTSIDE ACCESSORY....738
STANDARD VALUE....739
DOOR....739
DOOR HINGE....739
DOOR ACCESSORIES....739
REQUIRED ITEMS....740
DOOR....740
DOOR ACCESSORIES....740
POWER WINDOW....740
AUTO DOOR LOCK SYSTEM....740
WINDOW GLASS....741
GLASS....741
MIRROR....742
POWER MIRROR....742
DOOR....743
DOOR HINGE....743
INSPECTION AND ADJUSTMENT....743
DOOR ACCESSORY....747
COMPONENT LOCATOR....747
OVERHAUL....753
POWER WINDOW....776
SINGLE UNIT INSPECTION....776
AUTO DOOR LOCK SYSTEM....778
PERFORMANCE INSPECTION....778
SINGLE UNIT INSPECTION....779
KEYLESS ENTRY....781
PERFORMANCE INSPECTION....781
WINDOW GLASS....782
GLASS....782
COMPONENT LOCATOR....782
REPLACEMENT....784
MIRROR....796
REAR VIEW MIRROR....796
COMPONENT LOCATOR....796
REPLACEMENT....797
POWER MIRROR....798
SINGLE UNIT INSPECTION....798
ACCESSORY....799
OUTSIDE ACCESSORY....799
COMPONENT LOCATOR....799
REPLACEMENT....800
AIR BAG AND SEAT BELT....805
STANDARD VALUE....806
SEAT BELT....806
SEAT BELT....806
CENTER SEAT BELT....806
REAR SEAT BELT....807
SEAT BELT....808
SEAT BELT....808
COMPONENT LOCATOR....808
REPLACEMENT....809
CENTER SEAT BELT....811
COMPONENT LOCATOR....811
REPLACEMENT....812
REAR SEAT BELT....813
COMPONENT LOCATOR....813
REPLACEMENT....814
HEATER AND AIR CONDITIONER....818
STANDARD VALUE....819
AIR CONDITIONER....819
AIR CONDITIONER....819
V-BELT....820
COOLER COMPRESSOR....820
CONDENSER....820
HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)....821
HEATER CONTROL....821
REAR HEATER (CREW CAB)....821
REAR COOLER (CREW CAB)....822
REQUIRED ITEMS....823
AIR CONDITIONER....823
AIR CONDITIONER....823
V-BELT....823
COOLER COMPRESSOR....824
CONDENSER....824
AIR CONDITIONER....825
AIR CONDITIONER....825
SAFETY INSTRUCTIONS FOR WORK....825
COLLECTION/FILLING OF REFRIGERANT....829
MAINTENANCE....837
V-BELT....840
COMPONENT LOCATOR....840
REPLACEMENT....841
COOLER COMPRESSOR....846
COMPONENT LOCATOR....846
REPLACEMENT....847
CONDENSER....852
COMPONENT LOCATOR....852
REPLACEMENT....853
HVAC (HEATING, VENTILATING AND AIR CONDITIONING UNIT)....857
COMPONENT LOCATOR....857
REPLACEMENT....859
HEATER CONTROL....866
COMPONENT LOCATOR....866
REPLACEMENT....867
REAR HEATER (CREW CAB)....871
COMPONENT LOCATOR....871
REPLACEMENT....872
REAR HEATER BLOWER SWITCH (CREW CAB)....878
COMPONENT LOCATOR....878
REPLACEMENT....879
REAR COOLER (CREW CAB)....881
COMPONENT LOCATOR....881
REPLACEMENT....882
COOLER CONTROL SWITCH (CREW CAB)....890
COMPONENT LOCATOR....890
REPLACEMENT....891
ELECTRICAL....895
STANDARD VALUE....896
LIGHTING....896
HEADLIGHT....896
WIPER AND WASHER....896
WIPER....896
WASHER....896
REQUIRED ITEMS....897
LIGHTING....897
COMBINATION SWITCH....897
LIGHTING....898
HEADLIGHT....898
COMPONENT LOCATOR....898
OPTICAL AXIS ADJUSTMENT....899
REPLACEMENT....900
FOG LIGHT....901
REPLACEMENT....901
ID LIGHT....902
COMPONENT LOCATOR....902
REPLACEMENT....903
ROOM LIGHT....904
COMPONENT LOCATOR....904
REPLACEMENT....905
COMBINATION SWITCH....906
COMPONENT LOCATOR....906
REPLACEMENT....907
INSPECTION....907
WIPER AND WASHER....910
WIPER....910
COMPONENT LOCATOR....910
REPLACEMENT....911
WASHER....915
COMPONENT LOCATOR....915
REPLACEMENT ....916
COMPUTER....918
COMPUTER....918
MOUNTING POSITION....918
SWITCH....920
SWITCH....920
MOUNTING POSITION....920
FUSE AND RELAY....921
FUSE BLOCK....921
MOUNTING POSITION....921
RELAY....923
MOUNTING POSITION....923
CONTROL SYSTEM....924
REQUIRED ITEMS....925
HINO STOP&START SYSTEM....925
SLOPE LEARNING....925
HINO STOP&START SYSTEM....926
HINO STOP&START SYSTEM....926
SLOPE LEARNING....926
CRUISE CONTROL....928
CRUISE MAIN SWITCH....928
COMPONENT LOCATOR....928
REPLACEMENT....929
SINGLE UNIT INSPECTION....930
S1-LXJE16A_EWD....932
FOREWORD....932
CHAPTER REFERENCES....933
INDEX....934
GENERAL INTRODUCTION....935
HOW TO USE THIS MANUAL....936
GRAPHICAL SYMBOLS FOR WIRING DIAGRAMS, ABBREVIATIONS AND TERMS....936
WIRING DIAGRAM....941
WIRE TO WIRE CONNECTOR....942
JUNCTION CONNECTOR....943
LOCATION....944
RELAY LOCATION / FUSE AND RELAY BLOCK....945
ABOUT CONNECTOR....949
WIRING DIAGRAM ACCORDING TO SYSTEM....951
WIRING DIAGRAM....952
WIRING HARNESS CODE....952
AC. POWER SUPPLY CIRCUIT....954
AF. GROUND CIRCUIT....958
AH. CHARGING CIRCUIT....960
AK. ENGINE STARTING CIRCUIT....962
AN. CAN COMMUNICATION CIRCUIT....964
AO. CAN COMMUNICATION CIRCUIT [HV]....966
BG. ENGINE ECU CIRCUIT [J05] 1/2....970
BH. ENGINE ECU CIRCUIT [J05] 2/2....974
BI. DEF SCR CIRCUIT....982
BJ. HYDRO BOOST SYSTEM CIRCUIT....984
BN. GLOW PLUG CIRCUIT....986
BP. FUEL HEATER CIRCUIT....988
CC. AT CIRCUIT [A465]....990
CE. CLUTCH ECU CIRCUIT....996
CF. HV PCU CIRCUIT....1000
DA. ABS/PAB+VSC CIRCUIT....1002
DD. VEHICLE CONTROL ECU CIRCUIT....1004
EC. POWER DOOR LOCK CIRCUIT....1006
ED. KEYLESS ENTRY CIRCUIT....1008
EG. POWER WINDOW CIRCUIT [FRONT]....1010
EH. POWER WINDOW CIRCUIT [REAR]....1012
FA. COMBINATION METER CIRCUIT....1014
FB. PARKING BRAKE WARNING CIRCUIT....1018
FC. WEAR INDICATOR CIRCUIT....1020
FD. HORN RELAY CIRCUIT....1022
FE. COOLANT LEVEL WARNING CIRCUIT....1024
FF. DIAGNOSIS MONITOR CIRCUIT....1026
FJ. RHEOSTAT CIRCUIT....1028
FK. TELEMATICS CIRCUIT....1030
GA. HEADLIGHT CIRCUIT....1032
GD. HEADLIGHT SUB CIRCUIT ....1034
GG. TAIL LIGHT CIRCUIT....1036
GH. STOP LIGHT CIRCUIT....1038
GJ. TURN / HAZARD CIRCUIT....1040
GL. COMBINATION LIGHT CIRCUIT....1042
GM. FOG LIGHT CIRCUIT [FRONT]....1044
HA. ROOM LIGHT CIRCUIT....1046
JA. WIPER AND WASHER CIRCUIT....1048
JD. MIRROR HEATER CIRCUIT....1050
JE. REMOTE CONTROL MIRROR CIRCUIT....1052
KA. RADIO CIRCUIT....1054
KB. CIGAR LIGHTER CIRCUIT....1056
LB. HEATER AND AIR CONDITIONER CIRCUIT....1058
LF. REAR HEATER AND AIR CONDITIONER CIRCUIT....1062
MA. OUTLET POWER SUPPLY CIRCUIT....1064
MB. PASS THROUGH CIRCUIT....1066
MC. VAN LIGHT CIRCUIT....1068
MD. TRAILER BRAKE CIRCUIT....1070
WIRE TO WIRE CONNECTOR....1072
WIRE TO WIRE CONNECTOR....1073
WIRE TO WIRE CONNECTOR LIST....1073
JUNCTION CONNECTOR....1090
JUNCTION CONNECTOR....1091
JUNCTION CONNECTOR LIST....1091
LOCATION....1108
CONNECTOR LOCATION....1109
CONTENTS....1109
QUICK REFERENCE....1110
IP-1 [INSTRUMENT PANEL (1 of 6)]....1111
IP-2 [INSTRUMENT PANEL (2 of 6)]....1113
IP-3 [INSTRUMENT PANEL (3 of 6)]....1115
IP-4 [INSTRUMENT PANEL (4 of 6)]....1117
IP-5 [INSTRUMENT PANEL (5 of 6)]....1121
IP-6 [INSTRUMENT PANEL (6 of 6)]....1123
CA-1 [CAB (1 of 2)] (Models: Single cab (Floor / Cowl))....1125
CA-2 [CAB (2 of 2)] (Models: Single cab (Roof / Door))....1127
CA-3 [CAB (1 of 2)] (Models: Crew cab (Floor))....1129
CA-4 [CAB (2 of 2)] (Models: Crew cab (Roof / Door))....1131
EG-1 [ENGINE (1 of 4)] (Models: J05E Engine)....1133
EG-2 [ENGINE (2 of 4)] (Models: J05E Engine)....1135
EG-3 [ENGINE (3 of 4)] (Models: J05E Engine)....1137
EG-4 [ENGINE (4 of 4)] (Models: J05E Engine)....1139
EG-5 [ENGINE] (Models: J05E Engine (Right rear))....1141
EG-6 [ENGINE (1 of 4)] (Models: J05E Engine HV)....1143
EG-7 [ENGINE (2 of 4)] (Models: J05E Engine HV)....1145
EG-8 [ENGINE (3 of 4)] (Models: J05E Engine HV)....1147
EG-9 [ENGINE (4 of 4)] (Models: J05E Engine HV)....1149
EG-10 [ENGINE] (Models: J05E Engine HV (Right rear))....1151
RR-1 [REAR] (Models: Except HV)....1153
RR-2 [REAR] (Models: HV)....1155
RELAY LOCATION/FUSE AND RELAY BLOCK....1157
RELAY LOCATION....1158
INSTRUMENT PANEL....1158
CHASSIS....1159
FUSE AND RELAY BLOCK....1160
CHASSIS RELAY BLOCK....1160
CAB RELAY....1163
RELAY BLOCK No.2....1164
RELAY BLOCK No.3....1165
JUNCTION BLOCK....1166
JUNCTION BLOCK....1166
WIRE TO WIRE BOX....1168
WIRE TO WIRE ALIGNMENT....1168
INDEX....1169
CONNECTOR INDEX....1170
ELECTRICAL EQUIPMENT CONNECTOR....1170
WIRE TO WIRE CONNECTOR....1187
JUNCTION CONNECTOR....1191
S5-LJ05E19A....1195
FOREWORD....1195
CHAPTER REFERENCES....1196
INDEX....1197
GENERAL INTRODUCTION....1199
HOW TO IDENTIFY VEHICLE TYPE....1200
VEHICLE MODEL....1200
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE....1201
APPEARANCE OF VEHICLE....1202
APPEARANCE OF VEHICLE....1202
SAFETY INSTRUCTIONS AND READINESS TO WORK....1203
WARNING....1203
IDENTIFICATION INFORMATION....1207
SAFETY INSTRUCTIONS FOR WORK....1210
INTRODUCTION TO WORKSHOP MANUAL....1213
TIGHTENING OF BOLTS AND NUTS....1217
HANDLING OF LIQUID GASKET....1227
GLOSSARY....1228
DEFINITION OF ABBREVIATION IN THIS MANUAL....1228
LUBRICANTS....1234
RECOMMENDED LUBRICANTS....1234
STANDARD VALUE (J05E)....1235
MOUNTING AND DISMOUNTING THE ENGINE....1237
ENGINE ASSEMBLY....1237
ENGINE CONTROL....1238
ENGINE ECU....1238
ENGINE SPEED MAIN SENSOR....1238
ENGINE SPEED SUB SENSOR....1238
ACCELERATOR PEDAL....1239
BLOCK HEATER....1239
FUEL SYSTEM....1240
FUEL TANK....1240
FUEL SENDER GAUGE....1240
FUEL FILTER AND CASE (ENGINE SIDE)....1241
SUPPLY PUMP....1242
INJECTOR....1242
COMMON RAIL....1243
FUEL FILTER AND CASE (VEHICLE SIDE)....1243
FUEL COOLER....1243
EMISSION CONTROL....1244
EGR VALVE & COOLER....1244
CLOSED VENTILATOR....1244
INTAKE....1245
INTAKE MANIFOLD....1245
DIESEL THROTTLE....1245
INTAKE PIPE (EXHAUST SIDE)....1245
STACK DUCT....1245
AIR CLEANER....1246
INTAKE TEMPERATURE SENSOR....1246
BOOST PRESSURE SENSOR....1246
AIR FLOW SENSOR....1246
ENGINE MECHANICAL....1247
HEAD COVER....1247
ROCKER ARM ASSEMBLY....1247
CAMSHAFT ASSEMBLY....1248
CYLINDER HEAD ASSEMBLY....1249
VALVE SYSTEM....1250
CRANKSHAFT PULLEY....1251
FRONT OIL SEAL RETAINER....1251
FLYWHEEL ASSEMBLY....1251
FLYWHEEL HOUSING....1251
TIMING GEAR AND CAM IDLE GEAR....1252
PISTON AND CONNECTING ROD....1254
CRANKSHAFT....1255
CYLINDER LINER....1256
CYLINDER BLOCK....1256
ENGINE MOUNTING AND BRACKET....1257
GLOW PLUG....1257
EXHAUST....1258
EXHAUST MANIFOLD....1258
EXHAUST PIPE....1258
EXHAUST PIPE (ATC)....1258
DEF-SCR....1259
DPR CLEANER....1259
AFTERTREATMENT FUEL INJECTOR....1260
AFTERTREATMENT FUEL CUTOFF VALVE....1260
DEF PUMP....1260
DEF INJECTOR....1261
DEF TANK....1261
COOLANT CUTOFF VALVE....1261
DCU....1262
DPR DIFFERENTIAL PRESSURE SENSOR....1262
SCR UPSTREAM NOx SENSOR....1262
SCR DOWNSTREAM NOx SENSOR....1262
PM SENSOR....1263
EXHAUST TEMPERATURE SENSOR 1 (ATC INLET)....1263
EXHAUST TEMPERATURE SENSOR 2 (ATC OUTLET)....1263
EXHAUST TEMPERATURE SENSOR 3 (DOC INLET)....1264
EXHAUST TEMPERATURE SENSOR 4 (DPR INLET)....1264
EXHAUST TEMPERATURE SENSOR 5 (DPR OUTLET)....1264
DEF SCR TEMPERATURE SENSOR (SCR INLET)....1265
EXHAUST BRAKE....1266
EXHAUST BRAKE MAGNETIC VALVE....1266
COOLING....1267
RADIATOR....1267
RADIATOR CAP....1267
RESERVE TANK....1267
INTERCOOLER....1268
THERMOSTAT CASE AND THERMOSTAT....1268
COOLANT PUMP....1269
COOLING FAN AND FAN CLUTCH....1269
COOLANT TEMPERATURE SENSOR....1269
LUBRICATION....1270
OIL FILTER....1270
OIL COOLER....1270
OIL PUMP....1271
OIL PAN....1272
OIL STRAINER....1272
OIL PRESSURE SWITCH....1272
OIL LEVEL GAUGE AND GUIDE....1272
STARTING/CHARGING....1273
STARTER....1273
V-BELT....1273
ALTERNATOR (130 A)....1274
TURBOCHARGER....1275
TURBOCHARGER ASSEMBLY....1275
REQUIRED ITEMS (J05E)....1276
MOUNTING AND DISMOUNTING THE ENGINE....1277
ENGINE ASSEMBLY....1277
ENGINE CONTROL....1278
ENGINE ECU....1278
ENGINE MAIN REVOLUTION SENSOR....1278
ENGINE SUB REVOLUTION SENSOR....1279
ACCELERATOR PEDAL....1280
IDLE SET VOLUME....1280
FUEL SYSTEM....1281
FUEL SENDER GAUGE....1281
WATER LEVEL WARNING SWITCH....1281
SUPPLY PUMP....1282
INJECTOR....1283
COMMON RAIL....1284
FUEL FILTER AND CASE (VEHICLE SIDE)....1284
EMISSION CONTROL....1285
EGR VALVE AND COOLER....1285
INTAKE....1286
DIESEL THROTTLE....1286
BOOST PRESSURE SENSOR....1287
AIR FLOW SENSOR....1288
ENGINE MECHANICAL....1289
HEAD COVER....1289
ROCKER ARM ASSEMBLY....1289
CAMSHAFT ASSEMBLY....1289
CYLINDER HEAD ASSEMBLY....1290
VALVE SYSTEM....1291
CRANKSHAFT FRONT OIL SEAL....1292
FRONT OIL SEAL RETAINER....1292
FLYWHEEL ASSEMBLY....1292
CRANKSHAFT REAR OIL SEAL....1293
FLYWHEEL HOUSING....1293
TIMING GEAR AND CAM IDLE GEAR....1294
PISTON AND CONNECTING ROD....1296
CRANKSHAFT....1298
CYLINDER LINER....1299
CYLINDER BLOCK....1300
GLOW PLUG....1300
EXHAUST....1301
EXHAUST MANIFOLD....1301
DPR CLEANER....1301
AFTERTREATMENT FUEL INJECTOR....1302
DEF PUMP....1302
DEF INJECTOR....1302
DEF TANK....1303
DEF SENSOR....1303
DPR DIFFERENTIAL PRESSURE SENSOR....1303
SCR UPSTREAM NOx SENSOR....1303
SCR DOWNSTREAM NOx SENSOR....1304
EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)....1304
EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET)....1304
EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)....1305
EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)....1305
EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET)....1305
DEF SCR TEMPERATURE SENSOR (SCR INLET)....1306
EXHAUST BRAKE....1306
EXHAUST BRAKE MAGNETIC VALVE....1306
COOLING....1307
RADIATOR CAP....1307
THERMOSTAT CASE AND THERMOSTAT....1307
COOLANT PUMP....1308
COOLANT TEMPERATURE SENSOR....1308
LUBRICATION....1309
OIL FILTER....1309
OIL COOLER....1309
OIL PUMP....1310
OIL PAN....1310
OIL PRESSURE SWITCH....1310
STARTING/CHARGING....1311
STARTER....1311
V-BELT....1311
ALTERNATOR (130A)....1311
TURBOCHARGER....1312
TURBOCHARGER ASSEMBLY....1312
MOUNTING AND DISMOUNTING THE ENGINE (J05E)....1314
ENGINE ASSEMBLY....1315
PRECAUTIONS IN TILTING AND LOWERING THE CAB....1315
MEASUREMENT OF COMPRESSION PRESSURE....1315
ADJUSTING THE VALVE CLEARANCE....1318
REPLACEMENT....1320
ENGINE CONTROL (J05E)....1329
CONTROL PARTS....1330
SYSTEM BLOCK DIAGRAM....1330
ENGINE ECU....1331
COMPONENT LOCATOR....1331
REPLACEMENT....1332
VEHICLE CONTROL ECU....1338
REPLACEMENT....1338
ENGINE SPEED MAIN SENSOR....1339
COMPONENT LOCATOR....1339
INSPECTION....1340
REPLACEMENT....1340
ENGINE SPEED SUB SENSOR....1341
COMPONENT LOCATOR....1341
INSPECTION....1342
REPLACEMENT....1342
ACCELERATOR PEDAL....1343
COMPONENT LOCATOR....1343
REPLACEMENT....1344
BLOCK HEATER....1345
COMPONENT LOCATOR....1345
REPLACEMENT....1346
FUEL SENDER GAUGE....1347
REPLACEMENT....1347
INTAKE TEMPERATURE SENSOR....1347
REPLACEMENT....1347
DIESEL THROTTLE....1347
REPLACEMENT....1347
BOOST PRESSURE SENSOR....1348
REPLACEMENT....1348
AIR FLOW SENSOR....1348
REPLACEMENT....1348
DPR DIFFERENTIAL PRESSURE SENSOR....1349
REPLACEMENT....1349
SCR UPSTREAM NOx SENSOR....1349
REPLACEMENT....1349
SCR DOWNSTREAM NOx SENSOR....1349
REPLACEMENT....1349
PM SENSOR....1350
REPLACEMENT....1350
EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)....1350
REPLACEMENT....1350
EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET)....1351
REPLACEMENT....1351
EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)....1351
REPLACEMENT....1351
EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)....1352
REPLACEMENT....1352
EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET)....1352
REPLACEMENT....1352
DEF SCR TEMPERATURE SENSOR (SCR INLET)....1353
REPLACEMENT....1353
AMBIENT AIR TEMPERATURE SENSOR....1353
REPLACEMENT....1353
COOLANT TEMPERATURE SENSOR....1354
REPLACEMENT....1354
OIL PRESSURE SWITCH....1354
REPLACEMENT....1354
FUEL SYSTEM (J05E)....1355
FUEL SYSTEM....1356
FUEL SYSTEM DIAGRAM....1356
FUEL TANK....1357
COMPONENT LOCATOR....1357
REPLACEMENT (30 GALLON)....1358
REPLACEMENT (33 GALLON)....1361
FUEL SENDER GAUGE....1365
COMPONENT LOCATOR....1365
REPLACEMENT....1366
FUEL FILTER AND CASE (ENGINE SIDE)....1368
COMPONENT LOCATOR....1368
REPLACEMENT....1370
SUPPLY PUMP....1379
COMPONENT LOCATOR....1379
REPLACEMENT....1380
INJECTOR....1390
COMPONENT LOCATOR....1390
REPLACEMENT....1391
COMMON RAIL....1400
COMPONENT LOCATOR....1400
INSPECTION....1401
REPLACEMENT....1402
FUEL FILTER AND CASE (VEHICLE SIDE)....1407
COMPONENT LOCATOR....1407
REPLACEMENT....1408
FUEL COOLER....1415
COMPONENT LOCATOR....1415
REPLACEMENT....1416
EMISSION CONTROL (J05E)....1418
EGR VALVE & COOLER....1419
COMPONENT LOCATOR....1419
INSPECTION....1420
REPLACEMENT....1420
CLOSED VENTILATOR....1427
COMPONENT LOCATOR....1427
REPLACEMENT....1429
INTAKE (J05E)....1433
INTAKE MANIFOLD....1434
COMPONENT LOCATOR....1434
REPLACEMENT....1435
DIESEL THROTTLE....1440
COMPONENT LOCATOR....1440
INSPECTION....1441
REPLACEMENT....1441
INTAKE PIPE (EXHAUST SIDE)....1443
COMPONENT LOCATOR....1443
REPLACEMENT....1444
INTERCOOLER....1450
OVERHAUL....1450
STACK DUCT....1451
COMPONENT LOCATOR....1451
CLEANING THE PRECLEANER HOUSING....1452
REPLACEMENT....1453
AIR CLEANER....1455
COMPONENT LOCATOR....1455
REPLACEMENT....1457
CLEANING THE AIR CLEANER ELEMENT....1461
INTAKE TEMPERATURE SENSOR....1462
COMPONENT LOCATOR....1462
REPLACEMENT....1464
BOOST PRESSURE SENSOR....1465
COMPONENT LOCATOR....1465
INSPECTION....1466
REPLACEMENT....1466
AIR FLOW SENSOR....1468
COMPONENT LOCATOR....1468
INSPECTION....1469
REPLACEMENT....1471
ENGINE MECHANICAL (J05E)....1472
HEAD COVER....1473
COMPONENT LOCATOR....1473
REPLACEMENT....1474
ROCKER ARM ASSEMBLY....1477
COMPONENT LOCATOR....1477
OVERHAUL....1478
CAMSHAFT ASSEMBLY....1485
COMPONENT LOCATOR....1485
OVERHAUL....1487
CYLINDER HEAD ASSEMBLY....1492
COMPONENT LOCATOR....1492
REPLACEMENT....1493
OVERHAUL....1501
VALVE SYSTEM....1507
COMPONENT LOCATOR....1507
OVERHAUL....1508
CRANKSHAFT PULLEY....1517
COMPONENT LOCATOR....1517
REPLACEMENT....1518
CRANKSHAFT FRONT OIL SEAL....1520
COMPONENT LOCATOR....1520
REPLACEMENT....1521
FRONT OIL SEAL RETAINER....1524
COMPONENT LOCATOR....1524
REPLACEMENT....1525
FLYWHEEL ASSEMBLY....1527
COMPONENT LOCATOR....1527
OVERHAUL....1528
CRANKSHAFT REAR OIL SEAL....1532
COMPONENT LOCATOR....1532
REPLACEMENT....1533
FLYWHEEL HOUSING....1536
COMPONENT LOCATOR....1536
REPLACEMENT....1537
TIMING GEAR & CAM IDLE GEAR....1541
COMPONENT LOCATOR....1541
CONFIGURATION DIAGRAM....1542
OVERHAUL....1543
PISTON AND CONNECTING ROD....1560
COMPONENT LOCATOR....1560
OVERHAUL....1561
CRANKSHAFT....1577
COMPONENT LOCATOR....1577
REPLACEMENT....1579
CYLINDER LINER....1588
COMPONENT LOCATOR....1588
REPLACEMENT....1589
CYLINDER BLOCK....1593
COMPONENT LOCATOR....1593
OVERHAUL....1594
ENGINE MOUNTING AND BRACKET....1602
COMPONENT LOCATOR....1602
REPLACEMENT....1603
GLOW PLUG....1605
COMPONENT LOCATOR....1605
REPLACEMENT....1606
GCU....1608
COMPONENT LOCATOR....1608
REPLACEMENT....1608
EXHAUST (J05E)....1609
EXHAUST MANIFOLD....1611
COMPONENT LOCATOR....1611
REPLACEMENT....1612
EXHAUST PIPE....1615
COMPONENT LOCATOR....1615
REPLACEMENT....1616
EXHAUST PIPE (ATC)....1624
COMPONENT LOCATOR....1624
REPLACEMENT....1625
DEF-SCR & DPR....1627
CONFIGURATION DIAGRAM....1627
HANDLING OF DEF....1628
CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING ....1629
DEF-SCR....1631
COMPONENT LOCATOR....1631
REPLACEMENT....1632
DPR CLEANER....1636
COMPONENT LOCATOR....1636
DPR INSPECTION....1637
INSPECTION PROCEDURE FOLLOWED WHEN “EXHAUST GAS AFTER TREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT” LIGHT UP....1638
INSPECTION BY WAY OF HINO DXⅡ....1639
INSPECTION PROCEDURE FOLLOWED WHEN MALFUNCTION INDICATOR LIGHT ILLUMINATES (ABNORMAL)....1643
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX Ⅱ....1646
CHECKING THE DPR STATE....1646
REPLACEMENT....1647
OVERALL OPERATION FLOW....1652
AIR CLEANING FLOW....1659
AFTERTREATMENT FUEL INJECTOR....1660
COMPONENT LOCATOR....1660
REPLACEMENT....1661
AFTERTREATMENT FUEL CUTOFF VALVE....1670
COMPONENT LOCATOR....1670
REPLACEMENT....1671
DEF PUMP....1673
COMPONENT LOCATOR....1673
REPLACEMENT....1674
DEF INJECTOR....1684
COMPONENT LOCATOR....1684
REPLACEMENT....1685
DEF TANK....1690
COMPONENT LOCATOR....1690
INSPECTION....1691
REPLACEMENT....1692
DEF SENSOR....1700
COMPONENT LOCATOR....1700
REPLACEMENT....1701
COOLANT CUTOFF VALVE....1703
COMPONENT LOCATOR....1703
REPLACEMENT....1704
DCU....1706
COMPONENT LOCATOR....1706
REPLACEMENT....1707
DPR DIFFERENTIAL PRESSURE SENSOR....1713
COMPONENT LOCATOR....1713
REPLACEMENT....1714
SCR UPSTREAM NOx SENSOR....1716
COMPONENT LOCATOR....1716
REPLACEMENT....1717
SCR DOWNSTREAM NOx SENSOR....1719
COMPONENT LOCATOR....1719
REPLACEMENT....1720
PM SENSOR....1722
COMPONENT LOCATOR....1722
REPLACEMENT....1723
EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET)....1725
COMPONENT LOCATOR....1725
REPLACEMENT....1726
EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET)....1728
COMPONENT LOCATOR....1728
REPLACEMENT....1729
EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET)....1731
COMPONENT LOCATOR....1731
REPLACEMENT....1732
EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)....1734
COMPONENT LOCATOR....1734
REPLACEMENT....1735
EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET)....1737
COMPONENT LOCATOR....1737
REPLACEMENT....1738
DEF SCR TEMPERATURE SENSOR (SCR INLET)....1740
COMPONENT LOCATOR....1740
REPLACEMENT....1741
AMBIENT AIR TEMPERATURE SENSOR....1744
COMPONENT LOCATOR....1744
REPLACEMENT....1745
EXHAUST BRAKE....1746
COMPONENT LOCATOR....1746
REPLACEMENT....1747
EXHAUST BRAKE MAGNETIC VALVE....1750
COMPONENT LOCATOR....1750
REPLACEMENT....1751
COOLING (J05E)....1753
COOLING SYSTEM....1754
COOLING SYSTEM DIAGRAM....1754
RADIATOR....1755
COMPONENT LOCATOR....1755
INSPECTION....1756
REPLACEMENT....1757
RADIATOR CAP....1767
COMPONENT LOCATOR....1767
REPLACEMENT....1768
RESERVE TANK....1770
COMPONENT LOCATOR....1770
REPLACEMENT....1771
INTERCOOLER....1772
COMPONENT LOCATOR....1772
OVERHAUL....1773
THERMOSTAT CASE AND THERMOSTAT....1775
COMPONENT LOCATOR....1775
OVERHAUL....1776
COOLANT PUMP....1782
COMPONENT LOCATOR....1782
REPLACEMENT....1783
COOLING FAN AND FAN CLUTCH....1785
COMPONENT LOCATOR....1785
OVERHAUL....1786
COOLANT TEMPERATURE SENSOR....1789
COMPONENT LOCATOR....1789
REPLACEMENT....1790
LUBRICATION (J05E)....1792
LUBRICATION SYSTEM....1793
LUBRICATION SYSTEM DIAGRAM....1793
OIL FILTER....1794
COMPONENT LOCATOR....1794
REPLACEMENT....1795
OIL COOLER....1798
COMPONENT LOCATOR....1798
OVERHAUL....1799
OIL PUMP....1806
COMPONENT LOCATOR....1806
OVERHAUL....1807
OIL PAN....1813
COMPONENT LOCATOR....1813
REPLACEMENT....1814
OIL STRAINER....1818
COMPONENT LOCATOR....1818
REPLACEMENT....1819
OIL PRESSURE SWITCH....1820
COMPONENT LOCATOR....1820
REPLACEMENT....1821
OIL LEVEL GAUGE AND GUIDE....1823
COMPONENT LOCATOR....1823
REPLACEMENT....1824
STARTING/CHARGING (J05E)....1826
STARTER....1827
COMPONENT LOCATOR....1827
REPLACEMENT....1828
V-BELT....1833
COMPONENT LOCATOR....1833
REPLACEMENT....1834
ALTERNATOR (130A)....1837
COMPONENT LOCATOR....1837
OVERHAUL....1838
TURBOCHARGER (J05E)....1852
TURBOCHARGER ASSEMBLY....1853
COMPONENT LOCATOR....1853
INSPECTION....1854
REPLACEMENT....1856
S7-LXJE16A-1....1865
FOREWORD....1865
CHAPTER REFERENCES....1866
INDEX....1867
GENERAL INTRODUCTION....1869
HOW TO IDENTIFY VEHICLE TYPE....1870
HOW TO IDENTIFY VEHICLE TYPE....1870
VEHICLE TYPE ....1870
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE....1871
APPEARANCE OF VEHICLE....1872
APPEARANCE....1872
APPEARANCE OF VEHICLE....1872
SAFETY INSTRUCTIONS AND READINESS TO WORK....1873
WARNING....1873
GENERAL PRECAUTIONS....1873
IDENTIFICATION INFORMATION....1878
SAFETY INSTRUCTIONS FOR WORK....1881
PRECAUTIONS....1881
INTRODUCTION TO WORKSHOP MANUAL....1885
GENERAL....1885
INTRODUCTION TO DESCRIPTIONS....1886
DEFINITION OF TERM....1889
TROUBLE SHOOTING....1890
TROUBLESHOOTING WITH DIAGNOSIS MONITOR....1890
TROUBLESHOOTING PROCEDURE....1890
APPARATUS FOR TROUBLE SHOOTING....1892
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXII)....1893
STEP OF TROUBLE DIAGNOSIS....1893
APPARATUS FOR TROUBLE DIAGNOSIS....1894
GLOSSARY....1895
DEFINITION OF ABBREVIATION....1895
LIST OF ABBREVIATION....1895
GLOSSARY OF SAE AND HINO TERMS....1898
ENGINE (J05E)....1901
TROUBLESHOOTING....1904
ENGINE ECU (J05E)....1904
PRECAUTIONS FOR DIAGNOSIS....1904
ELECTRICAL....1906
PRECAUTIONS....1907
COMPUTER (ECU) PIN ASSIGNMENT....1911
ENGINE ECU CONNECTOR....1917
INSPECTION....1921
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)....1922
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....1923
GROUP SHARING THE SENSOR SUPPLY TERMINAL....1951
GROUP SHARING THE SENSOR GND TERMINAL....1952
MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION....1953
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)....1956
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [DIESEL]....1961
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k) [HYBRID]....1971
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [DIESEL]....1982
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k) [HYBRID]....1987
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [DIESEL]....1993
DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k) [HYBRID]....1998
MALFUNCTION OF STARTER....2003
MALFUNCTION OF ALTERNATOR....2010
MALFUNCTION CODES FOR FAULTY ACTUATOR POWER RELAY....2014
ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....2015
NO DTC....2019
DTC: P0005....2023
DTC: P0006 and P0007....2027
DTC: P0016....2033
DTC: P0027....2036
DTC: P003A....2041
DTC: P0045....2046
DTC: P0047....2050
DTC: P0048....2054
DTC: P006E....2058
DTC: P006F....2062
DTC: P007B....2066
DTC: P007C and P007D....2080
DTC: P0088....2088
DTC: P0096....2096
DTC: P0097 and P0098 ....2107
DTC: P0101....2116
DTC: P0104....2125
DTC: P0106....2132
DTC: P0107....2138
DTC: P0108....2144
DTC: P0111....2150
DTC: P0112 and P0113....2156
DTC: P0115....2164
DTC: P0117 and P0118....2173
DTC: P011A....2181
DTC: P0122 and P0123....2190
DTC: P0126....2200
DTC: P0128....2204
DTC: P0148 ....2209
DTC: P016E and P016F ....2220
DTC: P0182 and P0183 ....2230
DTC: P0191....2238
DTC: P0192 and P0193 ....2246
DTC: P01A5....2256
DTC: P01A6....2263
DTC: P0200....2270
DTC: P0201, P0202, P0203 and P0204....2273
DTC: P0217....2278
DTC: P0219....2283
DTC: P0222 and P0223....2291
DTC: P0234....2301
DTC: P0263, P0266, P0269 and P0272....2307
DTC: P026C and P026D....2318
DTC: P0299....2331
DTC: P0300....2337
DTC: P0301, P0302, P0303 and P0304....2345
DTC: P0335....2354
DTC: P0336....2361
DTC: P0340....2369
DTC: P0341....2373
DTC: P0381....2381
DTC: P0401....2387
DTC: P0402....2403
DTC: P0404....2413
DTC: P0405 and P0406....2418
DTC: P041B....2424
DTC: P041C and P041D....2437
DTC: P0420....2445
DTC: P0421....2447
DTC: P0422....2461
DTC: P0489 and P0490....2464
DTC: P049D....2470
DTC: P04D5 and P04D6....2475
DTC: P04DA....2483
DTC: P04DB....2492
DTC: P0500 and P0501....2500
DTC: P0504....2507
DTC: P0506....2512
DTC: P0507....2516
DTC: P0521....2520
DTC: P0524....2524
DTC: P0545 and P0546....2529
DTC: P054E....2537
DTC: P054F....2541
DTC: P0562 and P0563....2545
DTC: P0605....2550
DTC: P0606....2552
DTC: P0607....2554
DTC: P0610....2556
DTC: P0611....2559
DTC: P0617....2561
DTC: P0628 and P0629....2565
DTC: P062F....2573
DTC: P0630....2577
DTC: P0642....2581
DTC: P0643....2586
DTC: P064C....2592
DTC: P0652....2597
DTC: P0653....2603
DTC: P0671 and P0672 ....2610
DTC: P0673 and P0674....2616
DTC: P0683....2622
DTC: P0686....2628
DTC: P0698....2633
DTC: P0699....2636
DTC: P06A4....2639
DTC: P06A5....2642
DTC: P06D3 and P06D4....2645
DTC: P0700....2653
DTC: P073D....2655
DTC: P081A....2659
DTC: P081B....2665
DTC: P0A7B....2669
DTC: P0AC4....2671
DTC: P0CA1....2673
DTC: P104E....2675
DTC: P104F....2679
DTC: P1133....2683
DTC: P119F....2690
DTC: P1426....2696
DTC: P1427....2703
DTC: P1428....2710
DTC: P1458....2718
DTC: P1459....2723
DTC: P146F (2 digit diagnosis code: 01)....2728
S7-LXJE16A-2....2733
FOREWORD....2733
CHAPTER REFERENCES....2734
INDEX....2735
ENGINE (J05E)....2737
TROUBLESHOOTING....2740
ENGINE ECU (J05E)....2740
DTC: P14B0....2740
DTC: P14B2....2744
DTC: P14B3 and P14B4....2748
DTC: P14B7 and P14B8....2754
DTC: P14BC and P14BD....2760
DTC: P14BF....2766
DTC: P1515....2771
DTC: P1530....2776
DTC: P2002....2780
DTC: P200C....2802
DTC: P2032 and P2033....2811
DTC: P203F....2819
DTC: P204F....2823
DTC: P206B....2826
DTC: P207F....2851
DTC: P2080....2859
DTC: P2084....2867
DTC: P20CD....2875
DTC: P20CE....2880
DTC: P20D8....2884
DTC: P20DE....2890
DTC: P20DF....2894
DTC: P20E0....2900
DTC: P20EE....2906
DTC: P20EF....2914
DTC: P2100....2916
DTC: P2101....2922
DTC: P2103....2929
DTC: P2120....2934
DTC: P2122 and P2123....2938
DTC: P2127 and P2128....2948
DTC: P2135....2957
DTC: P2138....2962
DTC: P2146....2967
DTC: P2147 and P2148....2974
DTC: P2149....2982
DTC: P2150 and P2151....2989
DTC: P2184 and P2185....2997
DTC: P2201....3005
DTC: P2227....3050
DTC: P2228 and P2229....3054
DTC: P2269....3059
DTC: P226C....3063
DTC: P229F....3069
DTC: P22D3....3117
DTC: P240F....3121
DTC: P2428....3131
DTC: P242B....3135
DTC: P242C and P242D....3143
DTC: P244A....3151
DTC: P244B....3172
DTC: P2457....3182
DTC: P2458....3197
DTC: P2459....3210
DTC: P2463....3213
DTC: P246F....3220
DTC: P2470 and P2471....3228
DTC: P2481 and P2482....3236
DTC: P2483....3244
DTC: P24A0....3252
DTC: P24A1....3255
DTC: P24A2....3263
DTC: P24AE (2 digit diagnosis code: 04, 05, 06, 14, 25, 26, 27, 28)....3273
DTC: P24AF (2 digit diagnosis code: 23)....3275
DTC: P24B0 (2 digit diagnosis code: 19, 20, 21)....3278
DTC: P24B1 (2 digit diagnosis code: 18)....3280
DTC: P24B4 (2 digit diagnosis code: 10, 11, 15, 17)....3282
DTC: P24B7 (2 digit diagnosis code: 08)....3284
DTC: P24C7 (2 digit diagnosis code: 09)....3287
DTC: P24D0 (2 digit diagnosis code: 02)....3291
DTC: P24D1 (2 digit diagnosis code: 12)....3295
DTC: P24DA (2 digit diagnosis code: 07)....3297
DTC: P24FE....3301
DTC: P2562....3320
DTC: P259E....3324
DTC: P259F....3330
DTC: P2635....3335
DTC: P268A and P2696....3344
DTC: P26C8....3350
DTC: P2A00....3352
DTC: P2A01....3356
DTC: P2BA9....3360
DTC: U0073....3365
DTC: U010A....3368
DTC: U010C....3373
DTC: U010E....3378
DTC: U0293....3384
DTC: U029D (DIESEL)....3389
DTC: U029D (HYBRID)....3395
DTC: U029E (DIESEL)....3401
DTC: U029E (HYBRID)....3407
DTC: U02A2....3413
DTC: U02A3....3419
DTC: U0301....3422
DTC: U1001....3425
DTC: U110A....3432
ENGINE (COMMON ITEMS)....3439
TROUBLESHOOTING....3441
DCU....3441
PRECAUTIONS FOR DIAGNOSIS....3441
DIAGRAM....3443
SIGNAL CHECK HARNESS....3444
INSPECTION....3444
TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DXⅡ)....3446
DTC: P0071....3453
DTC: P0072....3463
DTC: P0073....3469
DTC: P0562....3475
DTC: P0563....3479
DTC: P060B....3483
DTC: P060C....3486
DTC: P062F....3488
DTC: P0667....3490
DTC: P068A....3492
DTC: P06AD....3497
DTC: P06AE....3499
DTC: P142A....3501
DTC: P142B....3512
DTC: P14C1....3523
DTC: P14C2....3537
DTC: P14C3....3542
DTC: P202E....3547
DTC: P203C....3552
DTC: P203D....3555
DTC: P2044....3558
DTC: P2045....3561
DTC: P2047....3564
DTC: P2048....3568
DTC: P2049....3573
DTC: P204B....3578
DTC: P204C....3581
DTC: P204D....3586
S7-LXJE16A-3....3592
FOREWORD....3592
CHAPTER REFERENCES....3593
INDEX....3594
ENGINE (COMMON ITEMS)....3596
TROUBLESHOOTING....3596
DCU....3596
DTC: P205B....3598
DTC: P205C....3607
DTC: P205D....3610
DTC: P206A....3613
DTC: P206C....3616
DTC: P206D....3619
DTC: P208A....3622
DTC: P208B....3628
DTC: P208C....3631
DTC: P208D....3636
DTC: P20A0....3641
DTC: P20A1....3646
DTC: P20A2....3650
DTC: P20A3....3655
DTC: P20B1....3660
DTC: P20B2....3665
DTC: P20B3....3674
DTC: P20B4....3679
DTC: P20BD, P20B9 and P20C1....3684
DTC: P20C0, P20BC and P20C4....3692
DTC: P20E8....3698
DTC: P20E9....3709
DTC: P20F4....3715
DTC: P21C2....3720
DTC: P21C3....3724
DTC: P21C4....3729
DTC: P2202....3734
DTC: P2203....3737
DTC: P2204....3740
DTC: P2209....3747
DTC: P22A0....3755
DTC: P22A1....3758
DTC: P22A2....3761
DTC: P22A7....3768
DTC: P2510....3776
DTC: P2BAE....3781
DTC: U0029....3789
DTC: U0038....3795
DTC: U0100....3801
DTC: U029D (DIESEL)....3805
DTC: U029D (HYBRID)....3811
DTC: U029E (DIESEL)....3817
DTC: U029E (HYBRID)....3823
DTC: U02A2....3829
VEHICLE CONTROL ECU....3835
CAUTIONS ON TROUBLESHOOTING....3835
SYSTEM BLOCK DIAGRAM....3836
COMPUTER PIN ASSIGNMENT....3837
TROUBLESHOOTING WITH COMPUTER (HINO DXII)....3841
DIAGNOSIS CODE TABLE....3842
DTC: C1244....3844
DTC: C1245....3849
DTC: C1249....3851
DTC: C1418....3857
DTC: C1491....3861
DTC: P0335....3863
DTC: P0501....3866
DTC: P0503....3872
DTC: P0555....3877
DTC: P0562....3879
DTC: P0563....3883
DTC: P0572....3886
DTC: P0573....3892
DTC: P0577....3898
DTC: P05BF....3902
DTC: P0604....3905
DTC: P0605 ....3907
DTC: P0605 ....3909
DTC: P0606....3911
DTC: P0617....3913
DTC: P062F....3916
DTC: P0702....3918
DTC: P081D....3920
DTC: P161F....3925
DTC: P1649....3930
DTC: P165A....3934
DTC: P165B....3937
DTC: P2525....3940
DTC: P2526....3943
DTC: P258D....3946
DTC: U0101....3949
DTC: U0105....3952
DTC: U0121....3955
DTC: U0155....3958
DTC: U0293....3961
DTC: U0418....3964
DTC: U1136....3967
HYBRID....3970
TROUBLE SHOOTING....3973
HYBRID CONTROL SYSTEM....3973
TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM....3973
SAFETY MEASURES FOR HIGH-VOLTAGE WORK....3982
LIST OF CONNECTOR SYMBOLS....3985
HV SYSTEM WIRING DIAGRAM....3989
HEARING SHEET....3991
HYBRID ECU....3992
DIAGNOSIS CODE TABLE....3992
FREEZE FRAME DATA LIST....4002
LIST OF DATA MONITOR ITEMS....4005
ACTIVE TEST....4008
COMMON INSPECTION CHART....4009
DTC: C0081 (TCA0)....4014
DTC: P0500 (TC51)....4016
DTC: P0501 (TC5B)....4023
DTC: P0562 (TC71)....4027
DTC: P060B (TCB2)....4033
DTC: P0617 (TC59)....4035
DTC: P062F (TCB3)....4041
DTC: P0810 (TC9C)....4043
DTC: P0810 (TC9D)....4046
DTC: P0A01 (TC7B)....4049
DTC: P0A02 (TC78)....4055
DTC: P0A03 (TC79)....4061
DTC: P0A06 (TC7F)....4066
DTC: P0A07 (TC7E)....4074
DTC: P0A0F (TC31) ....4077
DTC: P0A1D (TC12)....4080
DTC: P0A1D (TC17)....4082
DTC: P0A78 (TC21)....4084
DTC: P0A78 (TC22)....4086
DTC: P0A7E (TC48)....4088
DTC: P0A82 (TC67)....4092
DTC: P0A84 (TC66)....4102
DTC: P0A85 (TC65)....4113
DTC: P0A90 (TC2A)....4118
DTC: P0A92 (TC29)....4127
DTC: P0A93 (TC7A)....4136
DTC: P0AFD (TC6B)....4141
DTC: P0BC9 (TC69)....4144
DTC: P0BCA (TC68)....4156
DTC: P0C73 (TC80)....4162
DTC: P3000 (TC42)....4167
DTC: P3001 (TC41)....4173
DTC: P3001 (TC43)....4175
DTC: P3001 (TC45)....4177
DTC: P3001 (TC46)....4179
DTC: P3001 (TC47)....4182
DTC: P3001 (TC4A)....4185
DTC: P3001 (TC4B)....4188
DTC: P3001 (TC4C)....4190
DTC: P3001 (TC4D)....4192
DTC: P3009 (TC49)....4195
DTC: P3010 (TC4E)....4205
DTC: P3010 (TC4F)....4207
DTC: P3128 (TC7D)....4210
DTC: P3129 (TC7C)....4218
DTC: P314C (TC82)....4222
DTC: P314D (TC81)....4226
DTC: P324B (TC62)....4234
DTC: P324C (TC61)....4238
DTC: P33B1 (TC64)....4243
DTC: P33B2 (TC63)....4247
DTC: U0073 (TC11)....4251
DTC: U0074 (TC16)....4255
DTC: U0100 (TC13)....4258
DTC: U0101 (TC18)....4261
DTC: U0110 (TC14)....4266
DTC: U0111 (TC15)....4272
DTC: U0121 (TC24)....4278
DTC: U0155 (TC25)....4283
DTC: U110A (TC26)....4288
DTC: U1136 (TC27)....4293
INVERTER....4298
DIAGNOSIS CODE TABLE....4298
FREEZE FRAME DATA LIST....4304
DATA MONITOR ITEM LIST....4306
CONNECTION DIAGRAM....4309
INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR....4310
DTC: P0562 (TC96) ....4312
DTC: P0562 (TCA0) ....4319
DTC: P0604 (TC18) ....4326
DTC: P0604 (TCD2)....4328
DTC: P0605 (TC17) ....4330
DTC: P0605 (TCD1) ....4332
DTC: P060B (TC1A)....4334
DTC: P060C (TC1C)....4337
DTC: P062F (TC41)....4339
DTC: P0A0D (TC20)....4341
DTC: P0A1B (TC16)....4346
DTC: P0A1B (TC92)....4351
DTC: P0A1B (TC97)....4353
DTC: P0A1B (TC3F)....4355
DTC: P0A1B (TCA1)....4357
DTC: P0A1B (TCA2)....4359
DTC: P0A1B (TCA3)....4361
DTC: P0A1B (TCA4)....4363
DTC: P0A1B (TCA5)....4365
DTC: P0A1B (TCA6)....4367
DTC: P0A1B (TCA7)....4369
DTC: P0A1B (TCA8) ....4371
DTC: P0A1B (TCA9)....4373
DTC: P0A1B (TCAA)....4375
DTC: P0A1B (TCBB)....4379
DTC: P0A1B (TCBC)....4381
DTC: P0A1B (TCBD)....4383
DTC: P0A1B (TCBE)....4385
DTC: P0A1B (TCBF)....4387
DTC: P0A1B (TCD3)....4389
DTC: P0A1B (TCD4)....4391
DTC: P0A1B (TCD5)....4393
DTC: P0A1D (TC21)....4395
DTC: P0A2B (TCE9)....4398
DTC: P0A2B (TCED)....4405
DTC: P0A2C (TCDA)....4412
DTC: P0A2D (TCDB)....4418
S7-LXJE16A-4....4426
FOREWORD....4426
CHAPTER REFERENCES....4427
INDEX....4428
HYBRID....4430
TROUBLE SHOOTING....4433
INVERTER....4433
DTC: P0A2F (TC33) ....4433
DTC: P0A3C (TC34)....4439
DTC: P0A3F (TCB7)....4452
DTC: P0A41 (TCC0)....4458
DTC: P0A42 (TCC1)....4466
DTC: P0A51 (TCD6)....4474
DTC: P0A51 (TCD7)....4476
DTC: P0A78 (TC13)....4478
DTC: P0A78 (TC14)....4485
DTC: P0A78 (TC15)....4496
DTC: P0AA1 (TCD8)....4501
DTC: P0AA4 (TCD9)....4505
DTC: P0ADB (TC1F)....4509
DTC: P0ADC (TC93)....4514
DTC: P0ADF (TC1E)....4520
DTC: P0AE0 (TC95)....4525
DTC: P0AE6 (TC1D)....4531
DTC: P0AE7 (TC94)....4536
DTC: P0AEE (TC22)....4542
DTC: P0AEE (TC23)....4544
DTC: P0AEF (TC24)....4546
DTC: P0AF0 (TC25)....4549
DTC: P0BEA (TCB3)....4552
DTC: P0BEA (TCB4)....4554
DTC: P0BEB (TC9A)....4556
DTC: P0BEC (TC9B)....4558
DTC: P0BEE (TCB5)....4560
DTC: P0BEE (TCB6)....4562
DTC: P0BEF (TC9C)....4564
DTC: P0BF0 (TC9D)....4566
DTC: P3126 (TC12)....4568
DTC: U0073 (TC91)....4575
DTC: U0074 (TC3E)....4579
DTC: U0293 (TC31)....4582
BATTERY ECU....4589
DIAGNOSIS CODE TABLE....4589
LIST OF FREEZE FRAME DATA....4593
LIST OF DATA MONITOR ITEMS....4595
CONNECTION DIAGRAM....4598
DTC: P0562....4599
DTC: P0604....4603
DTC: P0605....4605
DTC: P060B....4607
DTC: P062F....4609
DTC: P0A1F....4611
DTC: P0A7D....4613
DTC: P0A7F....4616
DTC: P0A80....4621
DTC: P0A95....4626
DTC: P0A9C....4630
DTC: P0A9D....4635
DTC: P0A9E....4639
DTC: P0ABF....4643
DTC: P0AC0....4648
DTC: P0AC1....4653
DTC: P0AC2....4658
DTC: P0AC6....4663
DTC: P0AC7....4668
DTC: P0AC8....4672
DTC: P0ACB....4676
DTC: P0ACC....4681
DTC: P0ACD....4685
DTC: P0AE9....4689
DTC: P0AEA....4694
DTC: P0AEB....4698
DTC: P0AFC....4702
DTC: P0B25....4704
DTC: P0B3D....4707
DTC: P0B42....4711
DTC: P0B47....4715
DTC: P0B4C....4719
DTC: P0B51....4723
DTC: P0B56....4727
DTC: P0B5B....4731
DTC: P0B60....4735
DTC: P0B65....4739
DTC: P0B6A....4743
DTC: P0B6F....4747
DTC: P0B74....4751
DTC: P0B79....4755
DTC: P0B7E....4759
DTC: P0B83....4763
DTC: P0B88....4767
DTC: P0B8D....4771
DTC: P0B92....4775
DTC: P0B97....4779
DTC: P0B9C....4783
DTC: P0BA1....4787
DTC: P0C30....4791
DTC: P3004....4798
DTC: P3011....4800
DTC: P3012....4805
DTC: P3013....4810
DTC: P3014....4815
DTC: P3015....4820
DTC: P3016....4825
DTC: P3017....4830
DTC: P3018....4835
DTC: P3019....4840
DTC: P301B....4845
DTC: P3020....4847
DTC: P3021....4852
DTC: P3022....4857
DTC: P3023....4862
DTC: P3024....4867
DTC: P3025....4872
DTC: P3026....4877
DTC: P3027....4882
DTC: P3028....4887
DTC: P3029....4892
DTC: P302F....4897
DTC: P3065....4902
DTC: P308A....4907
DTC: U0074....4911
DTC: U0293....4914
TRANSMISSION....4918
TROUBLESHOOTING....4920
TROUBLE SHOOTING BY TRANSMISSION SYMPTOM....4920
AUTOMATIC TRANSMISSION....4920
TROUBLESHOOTING....4922
AUTOMATIC TRANSMISSION....4922
PRECAUTIONS FOR DIAGNOSIS....4922
AT LEARNED VALUE INITIALIZATION....4923
INSPECTING/CLEARING DIAGNOSIS CODES....4927
SYSTEM BLOCK DIAGRAM....4930
COMPUTER PIN ASSIGNMENT....4931
DIAGNOSIS CODE TABLE....4934
DTC: P0500/DIAGNOSIS MONITOR CODE: 42....4936
DTC: P0562/DIAGNOSIS MONITOR CODE: 11....4942
DTC: P0705/DIAGNOSIS MONITOR CODE: 43....4945
DTC: P0706/DIAGNOSIS MONITOR CODE: 44....4953
DTC: P0710/DIAGNOSIS MONITOR CODE: 38....4958
DTC: P0715/DIAGNOSIS MONITOR CODE: 12....4965
DTC: P0720/DIAGNOSIS MONITOR CODE: 61....4971
DTC: P0725/DIAGNOSIS MONITOR CODE: 86....4977
DTC: P0730/DIAGNOSIS MONITOR CODE: 37....4983
DTC: P0746/DIAGNOSIS MONITOR CODE: 31....4991
DTC: P0748/DIAGNOSIS MONITOR CODE: 25....4997
DTC: P0751/DIAGNOSIS MONITOR CODE: 45....5002
DTC: P0756/DIAGNOSIS MONITOR CODE: 46....5008
DTC: P0761/DIAGNOSIS MONITOR CODE: 47.48....5014
DTC: P0776/DIAGNOSIS MONITOR CODE: 32....5024
DTC: P0778/DIAGNOSIS MONITOR CODE: 26....5030
DTC: P0810/DIAGNOSIS MONITOR CODE: 88....5035
DTC: P0973/DIAGNOSIS MONITOR CODE: 62....5039
DTC: P0974/DIAGNOSIS MONITOR CODE: 62....5044
DTC: P0976/DIAGNOSIS MONITOR CODE: 63....5049
DTC: P0977/DIAGNOSIS MONITOR CODE: 63....5054
DTC: P0979/DIAGNOSIS MONITOR CODE: 64....5059
DTC: P0980/DIAGNOSIS MONITOR CODE: 64....5064
DTC: P0985/DIAGNOSIS MONITOR CODE: 65....5069
DTC: P0986/DIAGNOSIS MONITOR CODE: 65....5074
DTC: P0A40/DIAGNOSIS MONITOR CODE: 88....5079
DTC: P1604/DIAGNOSIS MONITOR CODE: 24....5083
DTC: P1604/DIAGNOSIS MONITOR CODE: 54....5087
DTC: P2545/DIAGNOSIS MONITOR CODE: 88....5091
DTC: P2716/DIAGNOSIS MONITOR CODE: 28....5095
DTC: P2740/DIAGNOSIS MONITOR CODE: 17....5101
DTC: P2757/DIAGNOSIS MONITOR CODE: 33....5106
DTC: P2759/DIAGNOSIS MONITOR CODE: 27....5112
DTC: P2764/DIAGNOSIS MONITOR CODE: 36....5118
DTC: U0100/DIAGNOSIS MONITOR CODE: 88....5122
DTC: U110A/DIAGNOSIS MONITOR CODE: 88....5131
TROUBLESHOOTING....5140
CLUTCH ECU....5140
SYSTEM BLOCK DIAGRAM....5140
COMPUTER PIN ASSIGNMENT....5141
DIAGNOSIS CODE TABLE....5143
CAUTIONS ON HV DAMPER REPLACEMENT....5145
DTC: P0560....5146
DTC: P0563....5150
DTC: P0604....5152
DTC: P0605....5154
DTC: P062F....5156
DTC: P0775....5158
DTC: P0778....5163
DTC: P0811....5168
DTC: P081E....5170
DTC: P0883....5172
DTC: P0948....5176
DTC: P1538....5181
DTC: P1539....5191
DTC: P18F2....5198
DTC: P18F3....5208
DTC: P18F5....5218
DTC: P18F7....5228
DTC: P18F8....5238
DTC: P18F9....5248
DTC: P18FB....5258
DTC: P18FC....5263
DTC: P18FD....5268
DTC: P191A....5273
DTC: P2859....5275
DTC: P3156....5277
DTC: P3157....5287
DTC: U0073....5291
DTC: U0101....5294
DTC: U0110....5297
DTC: U0293....5300
DTC: U110A....5303
AXLE....5306
TROUBLESHOOTING....5307
TROUBLE SHOOTING BY AXLE SYMPTOM....5307
FRONT AXLE....5307
REAR AXLE....5308
WHEEL AND TIRE....5308
DIFFERENTIAL....5310
TROUBLESHOOTING....5311
TROUBLE SHOOTING BY DIFFERENTIAL SYMPTOM....5311
REAR DIFFERENTIAL....5311
S7-LXJE16A-5....5313
FOREWORD....5313
CHAPTER REFERENCES....5314
INDEX....5315
BRAKE....5317
TROUBLESHOOTING....5318
TROUBLE SHOOTING BY BRAKE SYMPTOM....5318
BRAKE....5318
ABS WITH EBD....5320
CAUTIONS....5320
TROUBLESHOOTING PROCEDURE....5321
ACT PART No. CORRESPONDENCE....5323
HEARING TABLE....5323
PRIOR CHECK....5324
LIST OF DIAGNOSIS CODE....5336
PARTS ARRANGEMENT....5339
ECU TERMINAL ARRANGEMENT....5341
SYMPTOM LIST....5344
ELECTRIC CIRCUIT DIAGRAM....5345
ABS WARNING LIGHT ALWAYS ON....5346
BRAKE WARNING LIGHT ALWAYS ON....5350
ABS ACTIVATION TOO FAST (ABS OPERATES BEFORE THE WHEEL LOCKS)....5354
THE BRAKE PEDAL GETS STUCK....5355
DTC: C1203 (Diagnosis monitor code 59)....5357
DTC: C1225 (Diagnosis monitor code 25)....5361
DTC: C1241 (Diagnosis monitor code 41)....5365
DTC: C1249 (Diagnosis monitor code 49)....5377
DTC: C1265 (Diagnosis monitor code 65)....5381
DTC: C1300 (Diagnosis monitor code 62)....5391
DTC: C1337 (Diagnosis monitor code 37)....5394
DTC: C1361 (Diagnosis monitor code 91)....5398
DTC: C1401 (Diagnosis monitor code 31)....5406
DTC: C1402 (Diagnosis monitor code 32)....5415
DTC: C1403 (Diagnosis monitor code 33)....5424
DTC: C1404 (Diagnosis monitor code 34)....5433
DTC: C1405 (Diagnosis monitor code 31)....5442
DTC: C1406 (Diagnosis monitor code 32)....5451
DTC: C1407 (Diagnosis monitor code 33)....5460
DTC: C1408 (Diagnosis monitor code 34)....5469
DTC: C1413 (Diagnosis monitor code 35)....5478
DTC: C1414 (Diagnosis monitor code 36)....5485
DTC: C1415 (Diagnosis monitor code 38)....5491
DTC: C1416 (Diagnosis monitor code 39)....5500
DTC: C1417 (Diagnosis monitor code 41)....5509
DTC: C1421 (Diagnosis monitor code 46)....5521
DTC: C1422 (Diagnosis monitor code 46)....5525
DTC: C1423 (Diagnosis monitor code 46)....5529
DTC: C1424 (Diagnosis monitor code 46)....5533
DTC: C1425 (Diagnosis monitor code 49)....5537
DTC: C1427 (Diagnosis monitor code 51)....5541
DTC: C1428 (Diagnosis monitor code 51)....5545
DTC: C1468 (Diagnosis monitor code 21)....5549
DTC: C1469 (Diagnosis monitor code 22)....5553
DTC: C146A (Diagnosis monitor code 23)....5557
DTC: C146B (Diagnosis monitor code 24)....5561
DTC: C146C (Diagnosis monitor code 13)....5565
DTC: C146D (Diagnosis monitor code 14)....5572
DTC: C146E (Diagnosis monitor code 11)....5579
DTC: C146F (Diagnosis monitor code 12)....5585
DTC: U0073 (Diagnosis monitor code 94)....5591
ELECTRIC VACUUM PUMP SYSTEM....5594
CAUTIONS FOR TROUBLESHOOTING....5594
SYSTEM BLOCK DIAGRAM....5595
ELECTRIC CIRCUIT DIAGRAM....5596
CONNECTOR TERMINAL ARRANGEMENT....5597
SYSTEM SELF-DIAGNOSTIC....5598
RESETTING THE ELECTRIC VACUUM PUMP OPERATION COUNT AND OPERATION TIME AND THE ELECTRIC VACUUM PUMP RELAY ACTUATION COUNT....5599
ACTIVE TEST....5599
DATA MONITOR....5599
DIAGNOSIS CODE TABLE....5600
EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP (DIAGNOSIS CODE P165A)....5601
EXCESSIVE OPERATION OF ELECTRIC VACUUM PUMP RELAY (DIAGNOSIS CODE P165B)....5602
ABNORMALITY IN VACUUM SENSOR CIRCUIT (DIAGNOSIS CODE P2525)....5603
FALSE DETECTION OF VACUUM SENSOR PRESSURE (DIAGNOSIS CODE P2526)....5607
ELECTRIC VACUUM PUMP RELAY CONTACT STUCK AT ON (DIAGNOSIS CODE P258D)....5619
HOW TO VERIFY AND CHANGE VEHICLE INFORMATION VALUES....5621
STEERING....5623
TROUBLESHOOTING....5624
TROUBLE SHOOTING BY STEERING SYMPTOM....5624
STEERING....5624
SUSPENSION....5630
TROUBLESHOOTING....5631
TROUBLE SHOOTING BY SUSPENSION SYMPTOM....5631
LEAF SUSPENSION....5631
ELECTRICAL....5632
TROUBLESHOOTING....5633
TROUBLE SHOOTING BY ELECTRICAL SYMPTOM....5633
SIMULTANEOUS MALFUNCTION OF MULTIPLE ELECTRIC SYSTEMS....5633
INTEGRATED UNIT....5638
SYSTEM BLOCK DIAGRAM....5638
COMPUTER PIN ASSIGNMENT....5641
TROUBLE SHOOTING....5642
CONTROL SYSTEM....5649
TROUBLESHOOTING....5652
CAN COMMUNICATION....5652
INSPECTION IN THE EVENT OF ABNORMALITY IN CAN COMMUNICATION LINE....5652
ECU INDIVIDUAL CODELIST (DIESEL)....5654
ECU INDIVIDUAL CODELIST (HYBRID)....5655
BASIC TROUBLESHOOTING PROCEDURE ON CAN COMMUNICATION....5658
ENGINE CAN COMMUNICATION LINE (DIESEL)....5660
ENGINE CAN LINE....5660
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....5662
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....5666
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....5671
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....5681
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....5691
INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE....5696
INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE....5699
INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE....5706
INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE....5713
INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE....5716
INSPECTING THE PM SENSOR CAN COMMUNICATION LINE....5720
ENGINE CAN COMMUNICATION LINE (HYBRID)....5726
ENGINE CAN LINE....5726
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....5728
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....5732
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....5737
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....5748
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....5759
INSPECTING THE EGR CONTROLLER CAN COMMUNICATION LINE....5764
INSPECTING THE NOx SENSOR 1 CAN COMMUNICATION LINE....5767
INSPECTING THE NOx SENSOR 2 CAN COMMUNICATION LINE....5774
INSPECTING THE VNT CONTROLLER CAN COMMUNICATION LINE....5781
INSPECTING THE DEF SENSOR CAN COMMUNICATION LINE....5784
INSPECTING THE PM SENSOR CAN COMMUNICATION LINE....5788
DIAGNOSIS CAN COMMUNICATION LINE (DIESEL)....5795
DIAGNOSIS CAN LINE....5795
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....5797
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....5803
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....5806
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....5814
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....5821
INSPECTING THE AT ECU CAN COMMUNICATION LINE....5824
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....5827
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....5832
DIAGNOSIS CAN COMMUNICATION LINE (HYBRID)....5836
DIAGNOSIS CAN LINE....5836
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....5839
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....5846
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....5852
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....5863
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....5874
INSPECTING THE AT ECU CAN COMMUNICATION LINE....5877
INSPECTING THE ENGINE ECU CAN COMMUNICATION LINE....5880
INSPECTING THE INVERTER CAN COMMUNICATION LINE....5883
INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE....5886
INSPECTING THE BATTERY ECU CAN COMMUNICATION LINE....5889
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....5892
CONTROL CAN COMMUNICATION LINE (DIESEL)....5895
CONTROL CAN LINE....5895
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....5897
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....5902
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....5906
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....5912
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....5918
INSPECTING THE AT ECU CAN COMMUNICATION LINE....5921
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....5924
CONTROL CAN COMMUNICATION LINE (HYBRID)....5927
CONTROL CAN LINE....5927
PRIOR INSPECTION OF THE CAN COMMUNICATION LINE....5931
INSPECTING THE CAN H LINE AND L LINE FOR DISCONNECTION....5936
INSPECTING THE CAN H LINE FOR SHORT CIRCUIT....5943
INSPECTING THE CAN L LINE FOR SHORT CIRCUIT....5954
INSPECTING THE ABS ECU CAN COMMUNICATION LINE....5965
INSPECTING THE AT ECU CAN COMMUNICATION LINE....5968
INSPECTING THE HV ECU CAN COMMUNICATION LINE....5971
INSPECTING THE INVERTER CAN COMMUNICATION LINE....5974
INSPECTING THE CLUTCH ECU CAN COMMUNICATION LINE....5978
INSPECTING THE VEHICLE CONTROL ECU CAN COMMUNICATION LINE....5981
CAN COMMUNICATION (HYBRID SYSTEM)....5984
SAFETY MEASURES TO BE TAKEN IN HIGH VOLTAGE WORK....5984
LIST OF CONNECTOR MARKINGS....5987
CONNECTION DIAGRAM....5988
LIST OF DTC CODES FOR CAN SYSTEM-RELATED ABNORMALITIES....5989
CAN COMMUNICATION FAILURE....5991
BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN DIAG CAN SYSTEM....5995
BASIC INSPECTION ITEMS IN CASE OF ABNORMALITY IN CONTROL CAN SYSTEM....6010
ABNORMALITY IN INVERTER (ECU SYSTEM) / DIAG CAN RESISTER SEIZURE (DTC CODE P0A1B / TC3F)....6019
ABNORMALITY IN THE INVERTER (ECU SYSTEM) / CONTROL CAN RESISTER SEIZURE (DTC CODE P0A1B / TC92)....6020
ABNORMALITY IN HV ECU FUNCTION / CONTROL CAN REGISTER SEIZURE (DTC CODE P0A1D / TC12)....6021
ABNORMALITY IN HV ECU FUNCTION / DIAG CAN REGISTER SEIZURE (DTC CODE P0A1D / TC17)....6022
HV ECU CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC11)....6023
CAN COMMUNICATION FAILURE (CONTROL CAN) / CONTROL CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0073 / TC91)....6025
HV ECU CAN COMMUNICATION FAILURE (DIAG CAN) / DIAG CAN COMMUNICATION SHUTDOWN DUE TO BUS OFF (DTC CODE U0074 / TC16)....6027
CAN COMMUNICATION FAILURE (DIAG CAN) / COMMUNICATION SHUTDOWN DUE TO DIAG CAN BUS OFF (DTC CODE U0074 / TC3E)....6028
ENGINE ECU CAN COMMUNICATION BLACKOUT / ENGINE ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0100 / TC13)....6029
TCM ECU CAN COMMUNICATION BLACKOUT / AT ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0101 / TC18)....6030
INVERTER CAN COMMUNICATION BLACKOUT / INVERTER CAN COMMUNICATION BLACKOUT (DTC CODE U0110 / TC14)....6032
BATTERY ECU CAN COMMUNICATION BLACKOUT / BATTERY ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0111 / TC15)....6035
ABS ECU CAN COMMUNICATION BLACKOUT / ABS ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0121/TC24)....6038
METER CAN COMMUNICATION BLACKOUT / METER CAN COMMUNICATION BLACKOUT (DTC CODE U0155 / TC25)....6040
HV ECU COMMUNICATION FAILURE (DTC CODE U0293)....6042
HV ECU CAN COMMUNICATION BLACKOUT / HV ECU CAN COMMUNICATION BLACKOUT (DTC CODE U0293 / TC31)....6044
VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT / VEHICLE CONTROL ECU CAN COMMUNICATION BLACKOUT (DTC CODE U110A / TC26)....6048
CLUTCH ECU CAN COMMUNICATION BLACKOUT / CLUTCH ECU CAN COMMUNICATION BLACKOUT (DTC CODE U1136 / TC27)....6050
COMMUNICATION DISABLED DUE TO DIAG CAN BUS OFF (DTC CODE U0074)....6052
XL....6054
2020 XL Chassis 1_DT_ST_ABS....6054
FOREWORD....6054
CHAPTER REFERENCES....6055
INDEX....6056
GENERAL INTRODUCTION (CHASSIS)....6060
GENERAL INTRODUCTION....6061
GENERAL PRECAUTIONS....6061
IDENTIFICATION INFORMATION....6064
HOW TO USE THIS WORKSHOP MANUAL....6068
PRECAUTIONS....6071
SEALANT ON THE TAPERED SCREW FORPIPING....6074
NYLON TUBE REPLACEMENT METHOD....6075
METRIC INFORMATION....6077
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....6079
SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS....6079
RECOMMENDED LUBRICANTS....6081
VEHICLE LIFT AND SUPPORT LOCATIONS....6083
SYMPTOM SIMULATION....6085
GLOSSARY....6087
GLOSSARY OF SAE AND HINO TERMS....6090
CLUTCH MAIN UNIT (EATON SOLO 1402)....6093
CLUTCH ASSEMBLY (EATON SOLO1402)....6094
DATA AND SPECIFICATIONS....6094
DESCRIPTION....6094
TROUBLESHOOTING....6095
SPECIAL TOOL....6097
COMPONENT LOCATOR....6098
OVERHAUL....6099
INSPECTION AND REPAIR....6108
CLUTCH CONTROL....6111
CLUTCH CONTROL UNIT....6112
DESCRIPTION....6112
INSPECTION AND ADJUSTMENT....6113
CLUTCH PEDAL AND RELEASE UNIT....6116
COMPONENT LOCATOR....6116
OVERHAUL....6117
INSPECTION AND REPAIR....6119
CLUTCH MASTER CYLINDER....6120
COMPONENT LOCATOR....6120
OVERHAUL....6121
INSPECTION AND REPAIR....6121
TRANSMISSION MAIN UNIT(EATON FAO-14810C)....6122
TRANSMISSION ASSEMBLY....6123
DATA AND SPECIFICATION....6123
DISMOUNTING AND MOUNTING....6124
TRANSMISSION MAIN UNIT(EATON RTLO-16913A)....6126
TRANSMISSION ASSEMBLY....6127
DATA AND SPECIFICATION....6127
DISMOUNTING AND MOUNTING....6128
AUTOMATIC TRANSMISSION(ALLISON 3000RDS, 3500RDS, 3000HS)....6130
AUTOMATIC TRANSMISSION ASSEMBLY....6131
TROUBLESHOOTING....6131
SPECIAL TOOL....6131
DISMOUNTING AND MOUNTING....6131
TRANSMISSION/TRANSFER CONTROL(EATON MANUAL TRANSMISSION)....6139
TRANSMISSION CONTROL UNIT....6140
TROUBLESHOOTING....6140
COMPONENT LOCATOR....6141
OVERHAUL....6143
TRANSMISSION/TRANSFER CONTROL(ALLISON AUTOMATIC TRANSMISSION)....6144
TRANSMISSION CONTROL UNIT....6145
TROUBLESHOOTING....6145
COMPONENT LOCATOR....6145
PROPELLER SHAFT (SPL 140HD, 170)....6147
PROPELLER SHAFT ASSEMBLY....6148
DATA AND SPECIFICATIONS....6148
DESCRIPTION....6148
TROUBLESHOOTING....6149
COMPONENT LOCATOR....6149
OVERHAUL....6150
BRAKE EQUIPMENT....6162
SERVICE BRAKE ASSEMBLY....6163
DESCRIPTION....6163
DATA AND SPECIFICATIONS....6164
WHEEL BRAKE CHAMBER LAYOUT....6165
DIAGRAM....6166
TROUBLESHOOTING (DRUM BRAKE)....6176
TROUBLESHOOTING (AIR DISC BRAKE)....6178
SERVICE BRAKE....6179
AIR DRYER AND RESERVOIR SYSTEM(MODEL: BENDIX AD-IS PuraGuard (Oil Coalescing))....6180
DESCRIPTION....6180
BENDIX AD-IS AIR DRYER AND RESERVOIR SYSTEMTROUBLESHOOTING CHART....6192
BRAKE PEDAL....6196
OVERHAUL....6196
BRAKE VALVE....6199
DATA AND SPECIFICATIONS....6199
DESCRIPTION....6199
COMPONENT LOCATOR....6200
INSPECTION AND REPAIR....6201
mBSP VALVE PACKAGE....6205
FUNCTION....6205
SPRING BRAKE MODULATING VALVE....6206
DESCRIPTION....6206
COMPONENT LOCATOR....6207
INSPECTION AND REPAIR....6208
SPRING BRAKE CONTROL VALVE....6210
DESCRIPTION....6210
COMPONENT LOCATOR....6211
INSPECTION AND REPAIR....6212
QR-L INLINE QUICK RELEASE VALVE....6215
DESCRIPTION AND MAINTENANCE....6215
DC-4 DOUBLE CHECK VALVE....6218
DESCRIPTION AND MAINTENANCE....6218
BRAKE CHAMBER (FRONT)....6221
DATA AND SPECIFICATIONS....6221
DESCRIPTION AND MAINTENANCE....6222
SPRING BRAKE CHAMBER (DRUM BRAKE)....6226
DESCRIPTION AND MAINTENANCE....6226
SPRING BRAKE CHAMBER (DISC BRAKE)....6234
DESCRIPTION AND MAINTENANCE....6234
WHEEL BRAKE (DRUM BRAKE)....6238
DATA AND SPECIFICATIONS....6238
DESCRIPTION....6240
COMPONENT LOCATOR....6241
INSPECTION AND REPAIR....6245
AUTOMATIC SLACK ADJUSTER Bendix Versajust....6274
DESCRIPTION....6274
INSPECTION AND REPAIR....6276
DIAGNOSTICS....6281
WHEEL BRAKE (Bendix ADB22X AIR DISC BRAKE)....6282
DESCRIPTION....6282
COMPONENT LOCATOR....6285
INSPECTION AND REPAIR....6287
TP-5 TRACTOR PROTECTION VALVE(TRAILER BRAKE CONNECTION)....6320
DESCRIPTION AND MAINTENANCE....6320
MV-3 DASH CONTROL MODULE(TRAILER BRAKE CONNECTION)....6324
DESCRIPTION AND MAINTENANCE....6324
TCS-9000 CONTROL BRAKE VALVE(TRAILER BRAKE CONNECTION)....6330
DESCRIPTION AND MAINTENANCE....6330
ABS (ASR, VSC)....6333
ABS (ASR, VSC)....6334
OVERVIEW....6334
COMPOSITION AND OPERATION....6336
OVERVIEW AND FUNCTION....6337
INSPECTION (FRONT WHEEL BRAKE)....6340
INSPECTION (REAR WHEEL BRAKE)....6342
DIAGNOSTICS, TROUBLESHOOTING AND TESTING....6347
WIRING DIAGRAMS AND CONNECTORS....6353
SPN FMI FAULT CODES....6358
STEERING EQUIPMENT....6421
STEERING SYSTEM....6422
TROUBLESHOOTING....6422
STEERING UNIT....6426
STEERING LINKAGE....6427
DESCRIPTION....6427
COMPONENT LOCATOR....6428
SPECIAL TOOL....6430
OVERHAUL....6431
INSPECTION AND REPAIR....6436
POWER STEERING....6438
POWER STEERING GEAR UNIT....6439
DATA AND SPECIFICATIONS....6439
DESCRIPTION....6440
OPERATION....6441
COMPONENT LOCATOR....6443
TORQUE CHART....6445
HAZARD WARNING DEFINITIONS....6445
DISCLAIMER....6446
PATENTS....6446
MAINTENANCE TIPS....6446
ON-VEHICLE SERVICE....6448
RESEAL & REPAIR....6458
POWER STEERING PUMP....6492
DATA AND SPECIFICATIONS....6492
DESCRIPTION....6492
OPERATION....6493
COMPONENT LOCATOR....6494
OVERHAUL....6496
INSPECTION AND REPAIR....6501
FRONT AXLE(E1252RW, E1462W, D-2000F)....6503
FRONT AXLE (E1252RW, E1462W, D-2000F)....6504
DESCRIPTION....6504
2020 XL Chassis 2_RA....6549
FOREWORD....6549
CHAPTER REFERENCES....6550
INDEX....6551
REAR AXLE(WITH DIFFERENTIAL CARRIER)....6555
AXLE MODEL [S21-140] (SINGLE DRIVE AXLE)....6556
INTRODUCTION....6556
AXLE MODEL [S21-172, S23-172] (SINGLE DRIVE AXLE)....6597
INTRODUCTION....6597
AXLE MODEL [23060SH] (SINGLE DRIVE AXLE)....6669
INTRODUCTION....6669
AXLE MODEL [DSH-40] (TANDEM DRIVE AXLE)....6720
INTRODUCTION....6720
AXLE MODEL [D40-157] (TANDEM DRIVE AXLE)....6830
INTRODUCTION....6830
AXLE MODEL [D-46-172] (TANDEM DRIVE AXLE)....6921
INTRODUCTION....6921
AXLE MODEL [D40-145] (TANDEM DRIVE AXLE)....7016
INTRODUCTION....7016
2020 XL Chassis 3_EWD_SUSP_WT....7114
FOREWORD....7114
CHAPTER REFERENCES....7115
INDEX....7116
WHEEL & TIRE....7120
WHEEL AND TIRE....7121
DATA AND SPECIFICATIONS....7121
TROUBLESHOOTING....7122
DESCRIPTION....7124
SPECIAL TOOL....7125
PRECAUTIONS....7126
INSPECTION....7127
INSPECTION AND REPAIR....7128
WHEEL....7129
OVERHAUL....7129
SUSPENSION....7134
LEAF SUSPENSION ASSEMBLY....7135
DATA AND SPECIFICATIONS....7135
DESCRIPTION....7137
TROUBLESHOOTING....7139
COMPONENT LOCATOR....7140
OVERHAUL....7144
INSPECTION AND REPAIR....7149
AIR SUSPENSION ASSEMBLY....7152
DATA AND SPECIFICATIONS....7152
SYSTEM DIAGRAM FOR HEIGHT CONTROL....7153
DESCRIPTION....7154
TROUBLESHOOTING....7156
COMPONENT LOCATOR....7157
OVERHAUL....7159
INSPECTION AND REPAIR....7163
RUBBER SUSPENSION....7165
DATA AND SPECIFICATIONS....7165
OVERHAUL....7166
CHASSIS FRAME....7224
CHASSIS FRAME....7225
DESCRIPTION....7225
TROUBLESHOOTING....7226
INSPECTION....7226
REPAIRS....7227
COUPLER (5TH WHEEL)....7232
COUPLER (5TH WHEEL) (HOLLAND FW17)....7233
DESCRIPTION....7233
OVERHAUL....7235
INSPECTION AND ADJUSTMENT....7241
COUPLER (5TH WHEEL) (HOLLAND FW35)....7244
DESCRIPTION....7244
OVERHAUL....7246
ADJUSTMENT....7253
CAB....7254
CAB ASSEMBLY....7255
DATA AND SPECIFICATIONS....7255
TROUBLESHOOTING....7256
DISMOUNTING AND MOUNTING....7257
INSPECTION AND REPAIR....7260
HOOD....7261
COMPONENT LOCATOR....7261
OVERHAUL....7262
FRP REPAIR PROCEDURE....7265
RADIATOR GRILLE....7270
COMPONENT LOCATOR....7270
OVERHAUL....7271
DOOR....7272
COMPONENT LOCATOR....7272
OVERHAUL....7273
FLOOR MAT....7278
COMPONENT LOCATOR....7278
DISMOUNTING AND MOUNTING....7279
SEAT....7280
COMPONENT LOCATOR....7280
INSTRUMENT PANEL....7283
COMPONENT LOCATOR....7283
DISMOUNTING AND MOUNTING....7285
HEATER AND AIR CONDITIONER....7286
COMPONENT LOCATOR....7286
SPECIAL TOOL....7286
AIR CONDITIONING SYSTEM....7287
SPECIFICATION DATA....7287
PRECAUTIONS REGARDING REFRIGERANT(HFC134a)....7287
PRECAUTIONS FOR REPLENISHING THEREFRIGERANT GAS....7288
TROUBLESHOOTING (FAULT DIAGNOSIS BY SYMPTOMS)....7288
GAS LEAKAGE INSPECTION....7297
PRECAUTIONS FOR REMOVING/INSTALLINGTHE AIR CONDITIONER....7300
RECOVERY AND REPLENISHMENT OFREFRIGERANT....7302
MAINTENANCE....7307
REPLACEMENT....7308
DISMOUNTING AND MOUNTING....7310
WINDSHIELD....7311
COMPONENT LOCATOR....7311
REPLACEMENT....7312
AFFIXING WEATHERSTRIP PROCEDURE....7313
FRONT BUMPER....7317
COMPONENT LOCATOR....7317
ELECTRICAL EQUIPMENT....7318
ELECTRICAL PARTS....7319
DATA AND SPECIFICATIONS....7319
COMPONENT LOCATOR....7320
TROUBLESHOOTING....7324
GENERAL INSTRUCTION....7325
HANDLING PRECAUTION....7330
INSPECTION....7333
INSPECTION AND ADJUSTMENT....7349
SPEEDOMETER CONVERSION RATE LIST....7350
ELECTRIC WIRE....7352
DIAGRAM....7353
HOW TO USE THIS CHAPTER....7353
SPECIFICATION SYMBOL LIST....7357
DIAGRAM....7363
CONNECTOR LIST....7531
OTHERS....7546
PCS....7547
DESCRIPTION....7547
Section 1: Introduction....7553
Section 2: Diagnostics, Troubleshooting and Testing....7558
Section 3: Component Replacement....7590
Section 4: Frequently Asked Questions....7591
2020 XL ENGINE....7595
FOREWORD....7595
CHAPTER REFERENCES....7596
INDEX....7597
GENERAL INTRODUCTION....7598
GENERAL INTRODUCTION....7599
GENERAL PRECAUTIONS....7599
HOW TO USE THIS WORKSHOP MANUAL....7602
IDENTIFICATION INFORMATION....7604
PRECAUTIONS....7605
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....7608
DISMOUNTING AND MOUNTING....7609
SYMPTOM SIMULATION....7612
GLOSSARY OF SAE AND HINO TERMS....7614
ENGINE INTRODUCTION (A09C)....7617
ENGINE ASSEMBLY....7618
REQUIRED ITEMS (A09C)....7618
MEASUREMENT OF COMPRESSION PRESSURE....7620
ADJUSTING THE VALVE CLEARANCE....7622
REPLACEMENT....7622
ENGINE MECHANICAL (A09C)....7635
HEAD COVER....7636
COMPONENT LOCATOR....7636
HEAD COVER....7636
REPLACEMENT....7637
ENGINE RETARDER....7641
COMPONENT LOCATOR....7641
ENGINE RETARDER....7643
OVERHAUL....7644
ROCKER ARM ASSEMBLY....7650
COMPONENT LOCATOR....7650
ROCKER ARM ASSEMBLY....7651
OVERHAUL....7652
CAMSHAFT ASSEMBLY....7664
COMPONENT LOCATOR....7664
CAM SHAFT ASSEMBLY....7665
OVERHAUL....7666
CYLINDER HEAD ASSEMBLY....7673
COMPONENT LOCATOR....7673
CYLINDER HEAD ASSEMBLY....7674
REPLACEMENT....7675
OVERHAUL....7687
VALVE SYSTEM....7696
COMPONENT LOCATOR....7696
VALVE SYSTEM....7698
OVERHAUL....7699
CRANKSHAFT DAMPER....7707
COMPONENT LOCATOR....7707
REPLACEMENT....7708
CRANKSHAFT FRONT OIL SEAL....7712
COMPONENT LOCATOR....7712
CRANKSHAFT FRONT OIL SEAL....7713
REPLACEMENT....7714
FRONT TIMING GEAR COVER AND TIMING GEAR....7717
COMPONENT LOCATOR....7717
FRONT TIMING GEAR COVER AND TIMING GEAR....7718
CONFIGURATION DIAGRAM....7719
OVERHAUL....7720
FLYWHEEL ASSEMBLY....7730
COMPONENT LOCATOR....7730
FLYWHEEL ASSEMBLY....7731
OVERHAUL....7732
CRANKSHAFT REAR OIL SEAL....7738
COMPONENT LOCATOR....7738
CRANKSHAFT REAR OIL SEAL....7739
REPLACEMENT....7739
FLYWHEEL HOUSING....7742
COMPONENT LOCATOR....7742
FLYWHEEL HOUSING....7742
REPLACEMENT....7743
REAR TIMING GEAR AND CAM IDLE GEAR....7749
COMPONENT LOCATOR....7749
REAR TIMING GEAR AND CAM IDLE GEAR....7750
CONFIGURATION DIAGRAM....7751
OVERHAUL....7752
PISTON AND CONNECTING ROD....7765
COMPONENT LOCATOR....7765
PISTON AND CONNECTING ROD....7766
CRANKSHAFT....7768
OVERHAUL....7769
CRANKSHAFT....7784
COMPONENT LOCATOR....7784
REPLACEMENT....7786
CYLINDER LINER....7793
COMPONENT LOCATOR....7793
CYLINDER LINER....7794
REPLACEMENT....7795
CYLINDER BLOCK....7798
COMPONENT LOCATOR....7798
CYLINDER BLOCK....7799
OVERHAUL....7800
ENGINE MOUNTING AND BRACKET....7810
COMPONENT LOCATOR....7810
REPLACEMENT....7811
AIR INTAKE SYSTEM (A09C)....7814
INTAKE PIPE (INTAKE SIDE)....7815
COMPONENT LOCATOR....7815
REPLACEMENT....7816
INTAKE PIPE (EXHAUST SIDE)....7819
COMPONENT LOCATOR....7819
REPLACEMENT....7820
INTERCOOLER....7824
OVERHAUL....7824
AIR CLEANER....7825
COMPONENT LOCATOR....7825
OVERHAUL....7827
BOOST PRESSURE SENSOR....7830
COMPONENT LOCATOR....7830
INSPECTION....7831
REPLACEMENT....7831
AIR HOSE....7833
COMPONENT LOCATOR....7833
OVERHAUL....7834
AIR FLOW SENSOR....7835
COMPONENT LOCATOR....7835
REPLACEMENT....7836
INTAKE MANIFOLD TEMPERATURE SENSOR....7837
COMPONENT LOCATOR....7837
REPLACEMENT....7838
AIR INTAKE HEATER....7839
COMPONENT LOCATOR....7839
REPLACEMENT....7840
INTAKE THROTTLE VALVE....7843
COMPONENT LOCATOR....7843
INSPECTION....7844
REPLACEMENT....7844
EXHAUST SYSTEM (A09C)....7845
EXHAUST MANIFOLD AND PIPE....7846
COMPONENT LOCATOR....7846
DISMOUNTING AND MOUNTING....7847
EXHAUST PIPE AND MUFFLER UNIT....7848
DESCRIPTION....7848
COMPONENT LOCATOR....7849
REPLACEMENT OF ATC....7856
OVERHAUL....7858
DPR (DIESEL PARTICULATE ACTIVE REDUCTION SYSTEM)....7871
SYSTEM CONFIGURATION....7871
STRUCTURE OF DPR-CLEANER....7872
SPECIAL TOOL....7873
DPR INSPECTION....7874
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY....7875
INSPECTION BY WAY OF HINO DX II....7876
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL)....7880
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX II....7883
CHECKING THE DPR STATE....7883
REPLACEMENT OF DPR FILTER....7884
OVERALL OPERATION FLOW....7888
DIFFERENTIAL PRESSURE SENSOR....7896
COMPONENT LOCATOR....7896
DISMOUNTING AND MOUNTING....7897
INSPECTION AND REPAIR....7897
AFTERTREATMENT FUEL INJECTOR....7899
COMPONENT LOCATOR....7899
SPECIAL TOOL....7900
OVERHAUL....7901
EXHAUST CONTROL CYLINDER....7911
COMPONENT LOCATOR....7911
REPLACEMENT....7913
EXHAUST GAS TEMPERATURE SENSOR 1 (ATC INLET) AND EXHAUST GAS TEMPERATURE SENSOR 2 (ATC OUTLET)....7916
COMPONENT LOCATOR....7916
OVERHAUL....7917
EXHAUST GAS TEMPERATURE SENSOR 3 (DOC INLET) AND EXHAUST GAS TEMPERATURE SENSOR 4 (DPR INLET)....7918
COMPONENT LOCATOR....7918
OVERHAUL....7919
EXHAUST GAS TEMPERATURE SENSOR 5 (DPR OUTLET)....7920
COMPONENT LOCATOR....7920
OVERHAUL....7921
EXHAUST GAS TEMPERATURE SENSOR (SCR INLET)....7922
COMPONENT LOCATOR....7922
OVERHAUL....7923
PM SENSOR....7924
COMPONENT LOCATOR....7924
OVERHAUL....7925
LUBRICATING SYSTEM (A09C)....7926
LUBRICATING SYSTEM....7927
LUBRICATING SYSTEM DIAGRAM....7927
OIL FILTER....7928
COMPONENT LOCATOR....7928
REPLACEMENT....7929
OIL COOLER....7933
COMPONENT LOCATOR....7933
OVERHAUL....7935
OIL PUMP....7942
COMPONENT LOCATOR....7942
OVERHAUL....7943
OIL PAN....7948
COMPONENT LOCATOR....7948
REPLACEMENT....7949
OIL STRAINER AND PLATE....7952
COMPONENT LOCATOR....7952
REPLACEMENT....7954
OIL PRESSURE SWITCH....7956
COMPONENT LOCATOR....7956
REPLACEMENT....7957
OIL LEVEL GAUGE AND GUIDE....7959
COMPONENT LOCATOR....7959
REPLACEMENT....7960
COOLING SYSTEM (A09C)....7962
COOLING SYSTEM....7963
COOLING SYSTEM DIAGRAM....7963
RADIATOR....7964
COMPONENT LOCATOR....7964
INSPECTION AND REPAIR....7965
INTERCOOLER....7966
COMPONENT LOCATOR....7966
OVERHAUL....7967
INSPECTION AND REPAIR....7968
THERMOSTAT CASE AND THERMOSTAT....7969
COMPONENT LOCATOR....7969
OVERHAUL....7970
COOLANT PUMP....7975
COMPONENT LOCATOR....7975
REPLACEMENT....7976
INSPECTION AND REPAIR....7981
COOLING FAN AND FAN CLUTCH....7982
COMPONENT LOCATOR....7982
REPLACEMENT....7983
COOLANT TEMPERATURE SENSOR....7985
COMPONENT LOCATOR....7985
REPLACEMENT....7986
HEADER TANK AND WATER LEVEL SWITCH....7988
COMPONENT LOCATOR....7988
REPLACEMENT....7989
FUEL SYSTEM (A09C)....7991
FUEL SYSTEM....7992
FUEL SYSTEM DIAGRAM....7992
FUEL TANK....7993
COMPONENT LOCATOR....7993
FUEL FILTER AND CASE....7995
COMPONENT LOCATOR....7995
OVERHAUL....7997
PRE FUEL FILTER....8004
COMPONENT LOCATOR....8004
SPECIAL TOOL....8004
OVERHAUL....8005
FUEL FILTER WATER LEVEL SENSOR....8013
COMPONENT LOCATOR....8013
REPLACEMENT....8014
SUPPLY PUMP....8016
COMPONENT LOCATOR....8016
INSPECTION....8019
REPLACEMENT....8019
INJECTOR....8032
COMPONENT LOCATOR....8032
SPECIAL TOOL....8034
REPLACEMENT....8035
COMMON RAIL....8041
COMPONENT LOCATOR....8041
SPECIAL TOOL....8042
INSPECTION....8043
REPLACEMENT....8043
FUEL TEMPERATURE SENSOR....8049
COMPONENT LOCATOR....8049
REPLACEMENT....8050
FUEL CUTOFF VALVE....8052
COMPONENT LOCATOR....8052
OVERHAUL....8053
TURBOCHARGER (A09C)....8054
TURBOCHARGER ASSEMBLY....8055
COMPONENT LOCATOR....8055
SPECIAL TOOL....8057
INSPECTION....8058
REPLACEMENT....8060
TURBOCHARGER CONTROL COMPUTER....8069
COMPONENT LOCATOR....8069
REPLACEMENT....8070
EMISSION CONTROL (A09C)....8072
EGR VALVE AND EGR COOLER....8073
COMPONENT LOCATOR....8073
DESCRIPTION....8074
SPECIAL TOOL....8075
DISMOUNTING AND MOUNTING....8076
CLOSED VENTILATOR....8082
DESCRIPTION....8082
REPLACEMENT OF CLOSED VENTILATOR....8083
CLOSED VENTILATOR ELEMENT....8085
REPLACING THE ELEMENT....8085
INSPECTION AND REPAIR....8085
SELECTIVE CATALYTIC REDUCTION (SCR)....8086
GENERAL DESCRIPTION....8086
COMPONENT LOCATOR....8088
INSPECTION....8089
SPECIAL TOOL....8090
DISMOUNTING AND MOUNTING....8091
INSPECTION AND REPAIR....8106
ALTERNATOR (A09C)....8107
ALTERNATOR (REMY 12V-130A, 135A, 180A, 200A)....8108
COMPONENT LOCATOR....8108
REPLACEMENT....8109
STARTER (A09C)....8119
STARTER....8120
DATA AND SPECIFICATIONS....8120
COMPONENT LOCATOR....8120
OVERHAUL....8122
INSPECTION AND REPAIR....8126
AIR COMPRESSOR (A09C)....8129
AIR COMPRESSOR (95x60)....8130
COMPONENT LOCATOR....8130
SPECIAL TOOL....8132
OVERHAUL....8132
ENGINE CONTROL (A09C)....8150
ACCELERATOR PEDAL....8151
DESCRIPTION....8151
REPLACEMENT....8152
INSPECTION....8153
ENGINE ECU....8154
COMPONENT LOCATOR....8154
REPLACEMENT....8155
2020 XL Troubleshooting 1_ELEC_ENG....8161
FOREWORD....8161
CHAPTER REFERENCES ....8162
INDEX....8163
GENERAL INTRODUCTION....8164
GENERAL INTRODUCTION....8165
GENERAL PRECAUTIONS....8165
IDENTIFICATION INFORMATION....8168
HOW TO USE THIS WORKSHOP MANUAL....8172
INTRODUCTION TO DESCRIPTIONS....8172
PRECAUTIONS....8175
SEALANT ON THE TAPERED SCREW FOR PIPING....8178
METRIC INFORMATION....8179
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....8181
SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS....8182
RECOMMENDED LUBRICANTS....8183
GLOSSARY....8185
GLOSSARY OF SAE AND HINO TERMS....8188
TROUBLE SHOOTING - COMPONENTS....8191
ENGINE BASIC....8192
ENGINE ASSEMBLY....8192
ENGINE ASSEMBLY (COMMON RAIL SYSTEM)....8199
TURBOCHARGER (A09C)....8200
TURBOCHARGER....8200
ALTERNATOR (A09C: REMY 12V-130A,135A, 180A, 200A)....8209
ALTERNATOR....8209
STARTER (A09C)....8210
STARTER....8210
AIR COMPRESSOR (A09C: 95X60)....8211
AIR COMPRESSOR....8211
CLUTCH MAIN UNIT....8212
CLUTCH ASSEMBLY (EATON SOLO1402)....8212
AUTOMATIC TRANSMISSION....8214
AUTOMATIC TRANSMISSION ASSEMBLY....8214
TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) ....8215
TRANSMISSION CONTROL UNIT....8215
TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)....8216
TRANSMISSION CONTROL UNIT....8216
PROPELLER SHAFT (SPL 140HD, 170)....8216
PROPELLER SHAFT ASSEMBLY....8216
DIFFERENTIAL CARRIER (DANA S21, S23,D40,D46,DSH40 AND 23060SH)....8217
DIFFERENTIAL CARRIER ASSEMBLY....8217
BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)....8218
SERVICE BRAKE ASSEMBLY (DRUM BRAKE)....8218
SERVICE BRAKE ASSEMBLY (AIR DISK BRAKE)....8220
SERVICE BRAKE (FULL AIR BRAKE)....8221
AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS PURA GUARD)....8221
STEERING EQUIPMENT....8225
STEERING SYSTEM....8225
FRONT AXLE (E1254I, E1462I, D-2000F)....8229
FRONT AXLE (E1254I, E1462I, D-2000F)....8229
REAR AXLE....8231
REAR AXLE....8231
WHEEL AND TIRE....8232
WHEEL AND TIRE....8232
SUSPENSION....8234
LEAF SUSPENSION ASSEMBLY....8234
AIR SUSPENSION ASSEMBLY....8234
CHASSIS FRAME....8235
CHASSIS FRAME....8235
CAB....8236
AIR SUSPENSION DUMP SYSTEM....8236
CAB ASSEMBLY....8236
AIR CONDITIONING SYSTEM....8238
ELECTRICAL EQUIPMENT....8247
ELECTRICAL PARTS....8247
TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM....8249
ABOUT HINO DX....8250
About HINO DXⅡ....8250
BASIC PROCEDURE FOR TROUBLESHOOTING....8252
BASIC PROCEDURE FOR TROUBLESHOOTING....8252
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....8254
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....8254
SYMPTOM SIMULATION....8257
SYMPTOM SIMULATION....8257
TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART....8259
TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART....8259
ELECTRONIC CIRCUIT INSPECTION PROCEDURE....8260
ELECTRONIC CIRCUIT INSPECTION PROCEDURE....8260
INSPECTION PROCEDURE FOR MULTIPLE DTCS....8265
INSPECTION PROCEDURE FOR MULTIPLE DTCS....8265
ENGINE CONTROL SYSTEM (A09C)....8266
ENGINE CONTROL SYSTEM....8269
PRECAUTIONS FOR DIAGNOSIS....8269
SYSTEM BLOCK DIAGRAM....8271
SYSTEM DIAGRAM....8272
PRECAUTIONS....8274
SENSOR LOCATION....8278
COMPUTER (ECU) PIN ASSIGNMENT....8283
ENGINE ECU CONNECTOR....8289
INSPECTION....8293
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....8294
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....8295
GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL....8322
GROUP SHARING THE SENSOR GND TERMINAL....8323
ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....8324
NO DTC....8328
SIMULTANEOUS MALFUNCTION OF MULTIPLE ELECTRIC SYSTEMS....8331
MALFUNCTION OF STARTER....8335
MALFUNCTION OF ALTERNATOR....8341
DTC: P0005....8345
DTC: P0006 and P0007....8349
DTC: P0016....8354
DTC: P0027....8357
DTC: P003A....8362
DTC: P0045....8367
DTC: P0047....8372
DTC: P0048....8377
DTC: P0049....8382
DTC: P006E....8387
DTC: P006F....8391
DTC: P007B....8395
DTC: P007C and P007D....8408
DTC: P0088....8416
DTC: P0096....8425
DTC: P0097 and P0098 ....8436
DTC: P0101....8444
DTC: P0104....8452
DTC: P0106....8459
DTC: P0107....8465
DTC: P0108....8472
DTC: P0111....8478
DTC: P0112 and P0113....8484
DTC: P0115....8490
DTC: P0117 and P0118....8498
DTC: P011A....8506
DTC: P0122 and P0123....8514
DTC: P0126....8523
DTC: P0128....8527
DTC: P0148 ....8532
DTC: P016E and P016F ....8543
DTC: P0187 and P0188....8554
DTC: P0191....8562
DTC: P0192 and P0193 ....8567
DTC: P01A5....8576
DTC: P01A6....8583
DTC: P0200....8590
DTC: P0201, P0202, P0203, P0204, P0205 and P0206....8592
DTC: P0217....8597
DTC: P0219....8602
DTC: P0222 and P0223....8608
DTC: P0234....8617
DTC: P0263....8623
DTC: P0266....8635
DTC: P0269....8647
DTC: P026C and P026D....8659
DTC: P0272....8671
DTC: P0275....8683
DTC: P0278....8695
DTC: P0299....8707
DTC: P0300....8712
DTC: P0301, P0302, P0303, P0304, P0305 and P0306....8720
DTC: P0335....8728
DTC: P0336....8733
DTC: P0340....8739
DTC: P0341....8744
DTC: P0381....8751
DTC: P0401....8756
DTC: P0402....8771
DTC: P0404....8781
DTC: P0405 and P0406....8786
2020 XL Troubleshooting 2_ENG....8793
FOREWORD....8793
CHAPTER REFERENCES ....8794
INDEX....8795
ENGINE CONTROL SYSTEM (A09C)....8796
ENGINE CONTROL SYSTEM....8799
DTC: P041B....8799
DTC: P041C and P041D....8807
DTC: P0420....8815
DTC: P0421....8817
DTC: P0422....8829
DTC: P0483....8832
DTC: P0489 and P0490....8839
DTC: P049D....8845
DTC: P04D5 and P04D6....8850
DTC: P04DA....8858
DTC: P04DB....8868
DTC: P0500 and P0501....8877
DTC: P0504....8883
DTC: P0506 and P0507....8889
DTC: P0524....8892
DTC: P0527....8897
DTC: P0528....8902
DTC: P0545 and P0546....8907
DTC: P054E and P054F....8916
DTC: P0562 and P0563....8919
DTC: P0605....8925
DTC: P0606....8927
DTC: P0607....8929
DTC: P0610....8931
DTC: P0611....8935
DTC: P0617....8937
DTC: P0628 and P0629....8941
DTC: P062F....8954
DTC: P0630....8958
DTC: P0642....8961
DTC: P0643....8965
DTC: P0652....8970
DTC: P0653....8975
DTC: P0686....8980
DTC: P0691....8984
DTC: P0692....8989
DTC: P0698....8994
DTC: P0699....8996
DTC: P06A4....8998
DTC: P06A5....9000
DTC: P06D3 and P06D4....9002
DTC: P073D....9010
DTC: P081A....9016
DTC: P081B....9020
DTC: P0850....9024
DTC: P104E....9029
DTC: P104F....9033
DTC: P1071....9037
DTC: P1072....9041
DTC: P1133....9045
DTC: P119F....9051
DTC: P1229....9056
DTC: P1266....9058
DTC: P1426....9060
DTC: P1427....9066
DTC: P1428....9072
DTC: P1458....9078
DTC: P1459....9083
DTC: P1462....9088
DTC: P1463....9094
DTC: P1467....9100
DTC: P1468....9106
DTC: P14B0....9112
DTC: P14B2....9116
DTC: P14B3 and P14B4....9120
DTC: P14B7 and P14B8....9126
DTC: P14BC and P14BD....9132
DTC: P14BF....9138
DTC: P1515....9143
DTC: P1530....9148
DTC: P2002....9152
DTC: P200C....9172
DTC: P2032 and P2033....9179
DTC: P203F....9187
DTC: P204F....9191
DTC: P206B....9193
DTC: P207F....9218
DTC: P2080....9244
DTC: P2084....9253
DTC: P20CD....9261
DTC: P20CE....9265
DTC: P20D8....9269
DTC: P20DE....9274
DTC: P20DF....9278
DTC: P20E0....9284
DTC: P20EE....9290
2020 XL Troubleshooting 3_ENG....9318
FOREWORD....9318
CHAPTER REFERENCES....9319
INDEX....9320
ENGINE CONTROL SYSTEM (A09C)....9321
ENGINE CONTROL SYSTEM....9324
DTC: P20EF....9324
DTC: P2100....9326
DTC: P2101....9332
DTC: P2103....9338
DTC: P2120....9344
DTC: P2122 and P2123....9348
DTC: P2127 and P2128....9357
DTC: P2135....9366
DTC: P2138....9371
DTC: P2146....9376
DTC: P2147 and P2148....9382
DTC: P2149....9389
DTC: P2150 and P2151....9395
DTC: P2184 and P2185....9402
DTC: P2201....9410
DTC: P2227....9449
DTC: P2228 and P2229....9453
DTC: P2269....9458
DTC: P226C....9463
DTC: P229F....9471
DTC: P22D3....9512
DTC: P240F....9516
DTC: P2428....9526
DTC: P242B....9530
DTC: P242C and P242D....9538
DTC: P244A....9546
DTC: P244B....9563
DTC: P2457....9590
DTC: P2458....9604
DTC: P2459....9614
DTC: P2463....9616
DTC: P246F....9621
DTC: P2470 and P2471....9629
DTC: P2481 and P2482....9637
DTC: P2483....9645
DTC: P24A0....9653
DTC: P24A1....9656
DTC: P24A2....9658
DTC: P24A3....9668
DTC: P24AE....9673
DTC: P24AF....9681
DTC: P24B0....9686
DTC: P24B1....9691
DTC: P24B4....9694
DTC: P24B7....9704
DTC: P24C7....9707
DTC: P24D0....9711
DTC: P24D1....9716
DTC: P24DA....9721
DTC: P24FE....9726
DTC: P2562....9744
DTC: P2563....9750
DTC: P2564 and P2565....9755
DTC: P259E....9762
DTC: P259F....9767
DTC: P2633 and P2634....9772
DTC: P268A and P2696....9781
DTC: P2A00....9787
DTC: P2A01....9797
DTC: P2BA9....9807
DTC: U0073....9811
DTC: U010A....9814
DTC: U010C....9817
DTC: U010E....9820
DTC: U029D....9823
DTC: U029E....9826
DTC: U02A2....9829
DTC: U02A3 ....9832
DTC: U0301....9835
DTC: U1001....9838
DTC: U110A....9841
2020 XL Troubleshooting 4_CAN_DEF_VCS_SUSP....9845
FOREWORD....9845
CHAPTER REFERENCES....9846
INDEX....9847
DEF SCR SYSTEM (DCU)....9848
DEF SCR SYSTEM....9849
PRECAUTIONS FOR DIAGNOSIS....9849
SYSTEM BLOCK DIAGRAM....9851
SYSTEM DIAGRAM....9852
SENSOR LOCATION....9854
COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT....9857
SIGNAL CHECK HARNESS....9858
INSPECTION....9858
MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN....9859
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....9860
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....9861
DTC: P0071....9868
DTC: P0072....9879
DTC: P0073....9887
DTC: P0562....9895
DTC: P0563....9898
DTC: P060B....9901
DTC: P060C....9903
DTC: P062F....9905
DTC: P0667....9907
DTC: P068A....9909
DTC: P06AD....9914
DTC: P06AE....9916
DTC: P142A....9918
DTC: P142B....9927
DTC: P14C1....9937
DTC: P14C2....9951
DTC: P14C3....9956
DTC: P202E....9962
DTC: P203C....9967
DTC: P203D....9970
DTC: P2044....9973
DTC: P2045....9976
DTC: P2047....9979
DTC: P2048....9983
DTC: P2049....9988
DTC: P204B....9994
DTC: P204C....9997
DTC: P204D....10003
DTC: P205B....10009
DTC: P205C....10018
DTC: P205D....10021
DTC: P206C....10024
DTC: P206D....10027
DTC: P208A....10030
DTC: P208B....10034
DTC: P208C....10037
DTC: P208D....10041
DTC: P20A0....10045
DTC: P20A1....10051
DTC: P20A2....10055
DTC: P20A3....10061
DTC: P20B1....10067
DTC: P20B2....10072
DTC: P20B3....10081
DTC: P20B4....10086
DTC: P20BD and P20B9....10091
DTC: P20C0 and P20BC....10099
DTC: P20E8....10105
DTC: P20E9....10116
DTC: P20F4....10121
DTC: P21C2....10125
DTC: P21C3....10130
DTC: P21C4....10134
DTC: P2202....10138
DTC: P2203....10141
DTC: P2204....10144
DTC: P2209....10152
DTC: P22A0....10159
DTC: P22A1....10162
DTC: P22A2....10165
DTC: P22A7....10174
DTC: P2510....10182
DTC: P2BAE....10187
DTC: U0029....10190
DTC: U0038....10193
DTC: U0100....10196
DTC: U029D....10200
DTC: U029E....10203
DTC: U02A2....10206
SUSPENSION CONTROL....10209
HEIGHT CONTROL....10210
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....10210
DTC: C17A0....10211
DTC: C17A1....10216
DTC: C17A2....10220
DTC: C17A3....10225
DTC: C17EA....10226
DTC: P0500....10227
DTC: U110A....10231
VEHICLE CONTROL SYSTEM (VCS)....10232
VEHICLE CONTROL SYSTEM....10233
PRECAUTIONS FOR DIAGNOSIS....10233
SYSTEM BLOCK DIAGRAM....10235
SIGNAL CHECK HARNESS....10236
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....10244
VEHICLE CONTROL ECU INSPECTION....10245
DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE....10251
DTC: P0500....10252
DTC: P0501....10256
DTC: P0617....10260
DTC: P0704....10263
DTC: P0850....10266
DTC: P1565....10272
DTC: U0101....10275
DTC: U0105 ....10278
DTC: U0121....10281
DTC: U0155....10284
NO ACTIVATION OF AUXILIARY BRAKE....10286
NO ACTIVATION/RELEASE OF CRUISE FUNCTION....10292
NO ACTIVATION/RELEASE OF ECO MODE....10298
CAN COMMUNICATION....10302
CAN COMMUNICATION TROUBLESHOOTING....10303
Outline....10303
Definition of Terms....10303
Troubleshooting Procedure....10304
Work Flow....10304
ECU individual code list....10305
CAN communication circuit diagram....10306
ENGINE CAN COMMUNICATION LINE....10309
ABNORMAL CAN COMMUNICATION DTC DETECTED....10309
CONNECTION DIAGRAM....10309
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE....10309
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE....10311
DISCONNECTION INSPECTION FOR ENGINE CAN H/L COMMUNICATION LINE....10315
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE....10327
INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE....10356
INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE....10361
INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE)....10366
INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE....10371
INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE....10377
INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE....10383
INSPECTION FOR PM SENSOR CAN COMMUNICATION LINE....10389
DIAGNOSIS CAN COMMUNICATION LINE....10395
ABNORMAL CAN COMMUNICATION DTC DETECTED....10395
CONNECTION DIAGRAM....10395
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE....10395
PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE....10397
DISCONNECTION INSPECTION FOR DIAGNOSIS CAN H/L COMMUNICATION LINE....10401
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H/L LINE....10407
INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)....10421
INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE....10425
CONTROL CAN COMMUNICATION LINE....10430
ABNORMAL CAN COMMUNICATION DTC DETECTED....10430
CONNECTION DIAGRAM....10430
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)....10431
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION)....10431
PRE-INSPECTION FOR CAN COMMUNICATION LINE....10432
DISCONNECTION INSPECTION FOR CAN H/L COMMUNICATION LINE....10436
INSPECTION FOR SHORT-CIRCUIT IN CAN H/L-LINE....10457
FOREWORD....10516
XL Owner's Manual....10517
conventional....11161
FOREWORD....11161
Manual....11162
How to use....11162
1....11162
2 ....11163
3....11164
4....11165
5....11166
S1-UNAE16A-1....11167
FOREWORD....11167
CHAPTER REFERENCES....11168
INDEX....11169
GENERAL INTRODUCTION (CHASSIS)....11173
GENERAL INTRODUCTION....11174
GENERAL PRECAUTIONS....11174
IDENTIFICATION INFORMATION....11177
HOW TO USE THIS WORKSHOP MANUAL....11185
PRECAUTIONS....11188
SEALANT ON THE TAPERED SCREW FOR PIPING....11191
NYLON TUBE REPLACEMENT METHOD....11192
METRIC INFORMATION....11194
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....11196
SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS....11196
RECOMMENDED LUBRICANTS....11198
VEHICLE LIFT AND SUPPORT LOCATIONS....11200
INFORMATION DISPLAY....11202
SYMPTOM SIMULATION....11207
GLOSSARY....11209
GLOSSARY OF SAE AND HINO TERMS....11212
CLUTCH MAIN UNIT (EATON 1402)....11215
CLUTCH ASSEMBLY (EATON SAS1402)....11216
DATA AND SPECIFICATIONS....11216
DESCRIPTION....11216
TROUBLESHOOTING....11217
SPECIAL TOOL....11219
COMPONENT LOCATOR....11220
OVERHAUL....11221
CLUTCH ASSEMBLY (EATON SOLO1402)....11230
DATA AND SPECIFICATIONS....11230
COMPONENT LOCATOR....11230
OVERHAUL....11231
INSPECTION AND REPAIR....11241
CLUTCH CONTROL....11244
CLUTCH CONTROL UNIT....11245
DESCRIPTION....11245
INSPECTION AND ADJUSTMENT....11246
CLUTCH PEDAL AND RELEASE UNIT....11249
COMPONENT LOCATOR....11249
OVERHAUL....11250
INSPECTION AND REPAIR....11252
CLUTCH MASTER CYLINDER....11253
COMPONENT LOCATOR....11253
OVERHAUL....11254
INSPECTION AND REPAIR....11254
TRANSMISSION MAIN UNIT....11255
TRANSMISSION ASSEMBLY....11256
DATA AND SPECIFICATION....11256
DISMOUNTING AND MOUNTING....11257
AUTOMATIC TRANSMISSION ....11259
AUTOMATIC TRANSMISSION ASSEMBLY....11260
TROUBLESHOOTING....11260
SPECIAL TOOL....11260
DISMOUNTING AND MOUNTING....11260
AUTOMATIC TRANSMISSION (ALLISON 3000RDS, 3500RDS)....11268
AUTOMATIC TRANSMISSION ASSEMBLY....11269
TROUBLESHOOTING....11269
SPECIAL TOOL....11269
DISMOUNTING AND MOUNTING....11269
TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION)....11276
TRANSMISSION CONTROL UNIT....11277
TROUBLESHOOTING....11277
COMPONENT LOCATOR....11278
OVERHAUL....11279
TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION) ....11280
TRANSMISSION CONTROL UNIT....11281
TROUBLESHOOTING....11281
COMPONENT LOCATOR....11281
OVERHAUL....11283
PROPELLER SHAFT (SPL 100, 140)....11284
PROPELLER SHAFT ASSEMBLY....11285
DATA AND SPECIFICATIONS....11285
DESCRIPTION....11285
TROUBLESHOOTING....11286
COMPONENT LOCATOR....11286
OVERHAUL....11288
DIFFERENTIAL CARRIER (MERITOR MS17.19.21&RS23)....11304
DIFFERENTIAL CARRIER ASSEMBLY....11305
DATA AND SPECIFICATIONS....11305
DESCRIPTION....11307
TROUBLESHOOTING....11310
SPECIAL TOOL....11311
COMPONENT LOCATOR....11313
OVERHAUL....11317
INSPECTION AND REPAIR....11357
DRIVER-CONTROLLED MAIN DIFFERENTIAL....11366
OVERHAUL....11366
INSPECTION AND REPAIR....11369
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)....11370
SERVICE BRAKE ASSEMBLY....11371
DESCRIPTION....11371
DIAGRAM....11372
TROUBLESHOOTING....11374
BRAKE SYSTEM AIR BLEEDING....11379
POWER STEERING SYSTEM AIR BLEEDING....11381
BRAKE TEST....11382
BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)....11383
SERVICE BRAKE ASSEMBLY....11384
DESCRIPTION....11384
DATA AND SPECIFICATIONS....11385
DIAGRAM....11386
TROUBLESHOOTING....11387
SERVICE BRAKE (HYDRAULIC BRAKE)....11389
AIR DRYER....11390
DATA AND SPECIFICATIONS....11390
DESCRIPTION....11390
COMPONENT LOCATOR....11391
OVERHAUL....11392
INSPECTION AND REPAIR....11394
HYDRAULIC BRAKE....11395
INSPECTION AND ADJUSTMENT....11395
HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER....11398
DATA AND SPECIFICATIONS....11398
DESCRIPTION....11398
PRINCIPLE OF OPERATION....11400
COMPONENT LOCATOR....11402
HYDRO-MAX BOOSTER....11403
OVERHAUL....11403
MASTER CYLINDER....11409
OVERHAUL....11409
PRESSURE TESTS....11411
ABS MODULATOR....11412
DATA AND SPECIFICATIONS....11412
DESCRIPTION....11412
WHEEL BRAKE (TYPE: 4 PISTON)....11413
DATA AND SPECIFICATIONS....11413
DESCRIPTION....11414
TROUBLESHOOTING....11415
SERVICE BRAKE (FULL AIR BRAKE)....11428
AIR DRYER AND RESERVOIR....11429
DESCRIPTION....11429
AD-IS AIR DRYER RESERVOIR SYSTEM TROUBLESHOOTING CHART....11440
CHECK VALVE....11444
DATA AND SPECIFICATIONS....11444
DESCRIPTION....11444
INSPECTION AND REPAIR....11445
BRAKE PEDAL....11447
OVERHAUL....11447
BRAKE VALVE....11450
DATA AND SPECIFICATIONS....11450
DESCRIPTION....11450
COMPONENT LOCATOR....11451
INSPECTION AND REPAIR....11452
RELAY VALVE....11456
DATA AND SPECIFICATIONS....11456
DESCRIPTION....11456
INSPECTION AND REPAIR....11456
SPRING BRAKE MODULATING VALVE....11460
DESCRIPTION....11460
COMPONENT LOCATOR....11461
INSPECTION AND REPAIR....11462
SPRING BRAKE CONTROL VALVE....11464
DESCRIPTION....11464
COMPONENT LOCATOR....11465
INSPECTION AND REPAIR....11466
BRAKE CHAMBER (FRONT)....11469
DATA AND SPECIFICATIONS....11469
DESCRIPTION....11469
COMPONENT LOCATOR....11470
OVERHAUL....11470
BRAKE CHAMBER (REAR)....11472
DATA AND SPECIFICATIONS....11472
DESCRIPTION....11473
COMPONENT LOCATOR....11474
INSPECTION AND REPAIR....11475
PROTECTION VALVE....11486
DATA AND SPECIFICATIONS....11486
DESCRIPTION....11486
INSPECTION....11487
WHEEL BRAKE....11489
DATA AND SPECIFICATIONS....11489
DESCRIPTION....11490
COMPONENT LOCATOR....11491
OVERHAUL....11493
INSPECTION AND REPAIR....11510
AUTOMATIC SLACK ADJUSTER....11512
DESCRIPTION....11512
DIAGNOSTICS....11513
COMPONENT LOCATOR....11514
OVERHAUL....11516
INSTALLING THE SLACK ADJUSTER ONTO THE CAMSHAFT....11524
CHECK & ADJUSTMENT....11526
ABS (ABS : HYDRAULIC (E VERSION))....11533
ABS....11534
OVERVIEW....11534
COMPOSITION AND OPERATION....11535
FUNCTION....11538
PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS....11539
OVERVIEW AND FUNCTION....11540
ABS (ABS : FULL AIR)....11552
ABS....11553
OVERVIEW....11553
COMPOSITION AND OPERATION....11554
FUNCTION....11557
PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS....11558
OVERVIEW AND FUNCTION....11559
INSPECTION (FRONT WHEEL BRAKE)....11564
INSPECTION (REAR WHEEL BRAKE)....11566
EXHAUST BRAKE....11572
EXHAUST BRAKE SYSTEM....11573
SYSTEM DIAGRAM....11573
TROUBLESHOOTING....11574
ADJUSTMENT....11574
BRAKE CYLINDER....11576
DATA AND SPECIFICATIONS....11576
DESCRIPTION....11576
PARKING BRAKE (BOSCH 12")....11577
PARKING BRAKE ASSEMBLY....11578
DATA AND SPECIFICATIONS....11578
DESCRIPTION....11578
TROUBLESHOOTING....11579
COMPONENT LOCATOR....11580
OVERHAUL....11582
INSPECTION AND REPAIR....11596
ADJUSTMENT....11597
S1-UNAE16A-2....11600
FOREWORD....11600
CHAPTER REFERENCES....11601
INDEX....11602
STEERING EQUIPMENT....11606
STEERING SYSTEM....11607
TROUBLESHOOTING....11607
STEERING UNIT....11611
STEERING LINKAGE....11612
DESCRIPTION....11612
COMPONENT LOCATOR....11613
SPECIAL TOOL....11614
OVERHAUL....11615
INSPECTION AND REPAIR....11620
POWER STEERING....11622
POWER STEERING GEAR UNIT....11623
DATA AND SPECIFICATIONS....11623
DESCRIPTION....11624
OPERATION....11625
COMPONENT LOCATOR....11627
TORQUE CHART....11629
HAZARD WARNING DEFINITIONS....11629
DISCLAIMER....11630
PATENTS....11630
MAINTENANCE TIPS....11630
ON-VEHICLE SERVICE....11632
RESEAL & REPAIR....11642
POWER STEERING PUMP....11676
DATA AND SPECIFICATIONS....11676
DESCRIPTION....11676
OPERATION....11677
COMPONENT LOCATOR....11678
OVERHAUL....11680
INSPECTION AND REPAIR....11685
FRONT AXLE (MFS)....11687
FRONT AXLE (MFS)....11688
DATA AND SPECIFICATIONS....11688
TROUBLESHOOTING....11690
COMPONENT LOCATOR....11692
SERVICE NOTES....11696
SPECIAL TOOLS....11697
INTRODUCTION....11702
INSPECTION....11703
DISASSEMBLY....11709
PREPARE PARTS FOR ASSEMBLY....11716
ASSEMBLY....11724
ADJUSTMENT....11736
LUBRICATION AND MAINTENANCE....11745
MAINTENANCE....11749
REAR AXLE....11750
REAR AXLE....11751
DATA AND SPECIFICATIONS....11751
TROUBLESHOOTING....11758
COMPONENT LOCATOR....11759
SPECIAL TOOL....11762
DISASSEMBLY....11764
PREPARE PARTS FOR ASSEMBLY....11766
ASSEMBLY....11770
ADJUSTMENT....11780
LUBRICATION AND MAINTENANCE....11782
WHEEL & TIRE....11784
WHEEL AND TIRE....11785
DATA AND SPECIFICATIONS....11785
TROUBLESHOOTING....11788
DESCRIPTION....11790
SPECIAL TOOL....11791
PRECAUTIONS....11792
INSPECTION....11793
INSPECTION AND REPAIR....11794
WHEEL....11795
OVERHAUL....11795
SUSPENSION....11800
LEAF SUSPENSION ASSEMBLY....11801
DATA AND SPECIFICATIONS....11801
DESCRIPTION....11803
TROUBLESHOOTING....11805
COMPONENT LOCATOR....11806
OVERHAUL....11810
INSPECTION AND REPAIR....11815
AIR SUSPENSION ASSEMBLY....11818
DATA AND SPECIFICATIONS....11818
SYSTEM DIAGRAM FOR HEIGHT CONTROL....11819
DESCRIPTION....11820
TROUBLESHOOTING....11821
COMPONENT LOCATOR....11822
OVERHAUL....11824
INSPECTION AND REPAIR....11828
CHASSIS FRAME....11830
CHASSIS FRAME....11831
TROUBLESHOOTING....11831
INSPECTION....11831
REPAIRS....11832
CAB....11837
CAB ASSEMBLY....11838
DATA AND SPECIFICATIONS....11838
TROUBLESHOOTING....11839
DISMOUNTING AND MOUNTING....11840
INSPECTION AND REPAIR....11843
HOOD....11844
COMPONENT LOCATOR....11844
OVERHAUL....11845
FRP REPAIR PROCEDURE....11848
RADIATOR GRILLE....11853
COMPONENT LOCATOR....11853
OVERHAUL....11854
DOOR....11855
COMPONENT LOCATOR....11855
OVERHAUL....11856
FLOOR MAT....11859
COMPONENT LOCATOR....11859
DISMOUNTING AND MOUNTING....11860
SEAT....11861
COMPONENT LOCATOR....11861
INSTRUMENT PANEL....11864
COMPONENT LOCATOR....11864
DISMOUNTING AND MOUNTING....11865
HEATER AND AIR CONDITIONER....11866
COMPONENT LOCATOR....11866
SPECIAL TOOL....11866
AIR CONDITIONING SYSTEM....11867
SPECIFICATION DATA....11867
PRECAUTIONS REGARDING REFRIGERANT (HFC134a)....11867
PRECAUTIONS FOR REPLENISHING THE REFRIGERANT GAS....11868
TROUBLESHOOTING (FAULT DIAGNOSIS BY SYMPTOMS)....11869
REFRIGERANT LEAKAGE INSPECTION....11878
PRECAUTIONS FOR REMOVING/INSTALLING THE AIR CONDITIONER....11881
RECOVERY AND REPLENISHMENT OF REFRIGERANT....11883
MAINTENANCE....11888
REPLACEMENT....11889
DISMOUNTING AND MOUNTING....11891
WINDSHIELD....11892
COMPONENT LOCATOR....11892
REPLACEMENT....11893
AFFIXING WEATHERSTRIP PROCEDURE....11894
FRONT BUMPER....11898
COMPONENT LOCATOR....11898
ELECTRICAL EQUIPMENT....11899
ELECTRICAL PARTS....11900
DATA AND SPECIFICATIONS....11900
COMPONENT LOCATOR....11901
TROUBLESHOOTING....11910
GENERAL INSTRUCTION....11911
HANDLING PRECAUTION....11916
INSPECTION....11919
INSPECTION AND ADJUSTMENT....11937
SPEEDOMETER CONVERSION RATE LIST....11938
ELECTRIC WIRE....11939
DIAGRAM....11940
HOW TO USE THIS CHAPTER....11940
SPECIFICATION SYMBOL LIST....11946
DIAGRAM....11954
POSITION OF CONNECTOR....12095
CONNECTOR....12120
PIN LIST OF WIRE TO WIRE CONNECTOR (IN THE BULK HEAD CONNECTOR BOX)....12146
PIN LIST OF WIRE TO WIRE CONNECTOR (OUT OF THE BULK HEAD CONNECTOR BOX)....12151
PIN LIST OF SIGNAL CHECK CONNECTOR....12156
CONNECTOR LIST....12158
S5-UJ08E16A-1....12175
FOREWORD....12175
CHAPTER REFERENCES....12176
INDEX....12177
GENERAL INTRODUCTION (ENGINE)....12179
GENERAL INTRODUCTION (ENGINE)....12180
GENERAL PRECAUTIONS....12180
HOW TO USE THIS WORKSHOP MANUAL....12183
IDENTIFICATION INFORMATION....12185
PRECAUTIONS....12186
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....12189
DISMOUNTING AND MOUNTING....12190
SYMPTOM SIMULATION....12193
GLOSSARY OF SAE AND HINO TERMS....12195
ENGINE INTRODUCTION (J08E)....12198
ENGINE ASSEMBLY....12199
DATA AND SPECIFICATIONS....12199
TROUBLESHOOTING....12201
TROUBLESHOOTING (COMMON RAIL SYSTEM)....12208
ENGINE TUNEUP....12209
SPECIAL TOOL....12215
OVERHAUL CRITERIA....12216
DISMOUNTING AND MOUNTING....12217
LIQUID GASKET AND APPLICATION POINTS....12219
ENGINE MECHANICAL (J08E)....12224
CYLINDER HEAD....12225
COMPONENT LOCATOR....12225
SPECIAL TOOL....12228
OVERHAUL....12229
INSPECTION AND REPAIR....12240
CRANKSHAFT FRONT END....12244
COMPONENT LOCATOR....12244
SPECIAL TOOL....12245
OVERHAUL....12246
FLYWHEEL AND FLYWHEEL HOUSING....12248
COMPONENT LOCATOR....12248
SPECIAL TOOL....12249
OVERHAUL....12249
INSPECTION AND REPAIR....12256
TIMING GEAR....12257
COMPONENT LOCATOR....12257
SPECIAL TOOL....12258
OVERHAUL....12259
INSPECTION AND REPAIR....12261
MAIN MOVING PARTS AND CYLINDER BLOCK....12263
COMPONENT LOCATOR....12263
SPECIAL TOOL....12266
OVERHAUL....12268
INSPECTION AND REPAIR....12281
AIR INTAKE SYSTEM (J08E)....12285
AIR INTAKE MANIFOLD AND PIPE....12286
COMPONENT LOCATOR....12286
DISMOUNTING AND MOUNTING....12287
AIR INTAKE....12288
COMPONENT LOCATOR....12288
AIR CLEANER....12289
DESCRIPTION....12289
OVERHAUL....12290
AIR HOSE....12291
COMPONENT LOCATOR....12291
OVERHAUL....12292
AIR FLOW SENSOR....12293
COMPONENT LOCATOR....12293
REPLACEMENT....12294
BOOST PRESSURE SENSOR....12295
COMPONENT LOCATOR....12295
REPLACEMENT....12296
EXHAUST SYSTEM (J08E)....12297
EXHAUST MANIFOLD AND PIPE....12298
COMPONENT LOCATOR....12298
DISMOUNTING AND MOUNTING....12299
EXHAUST PIPE AND MUFFLER UNIT....12300
DESCRIPTION....12300
COMPONENT LOCATOR....12301
REPLACEMENT OF ATC....12307
OVERHAUL....12309
DPR (DIESEL PARTICULATE ACTIVE REDUCTION SYSTEM)....12325
SYSTEM CONFIGURATION....12325
STRUCTURE OF DPR-CLEANER....12326
DPR INSPECTION....12327
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY....12328
INSPECTION BY WAY OF HINO DX II....12329
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL)....12333
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX II....12336
CHECKING THE DPR STATE....12336
REPLACEMENT OF DPR FILTER....12337
OVERALL OPERATION FLOW....12341
DIFFERENTIAL PRESSURE SENSOR....12349
COMPONENT LOCATOR....12349
DISMOUNTING AND MOUNTING....12350
INSPECTION AND REPAIR....12351
AFTERTREATMENT FUEL INJECTOR....12353
COMPONENT LOCATOR....12353
OVERHAUL....12354
EXHAUST CONTROL CYLINDER....12365
SYSTEM CONFIGURATION....12365
DPR INSPECTION CHECK SHEET....12366
EXHAUST GAS TEMPERATURE SENSOR 1....12369
COMPONENT LOCATOR....12369
OVERHAUL....12370
LUBRICATING SYSTEM (J08E)....12371
LUBRICATING SYSTEM....12372
DIAGRAM....12372
OIL PUMP AND OIL STRAINER....12374
COMPONENT LOCATOR....12374
OVERHAUL....12375
INSPECTION AND REPAIR....12376
OIL FILTER AND OIL COOLER....12378
COMPONENT LOCATOR....12378
SPECIAL TOOL....12379
DISMOUNTING AND MOUNTING....12380
INSPECTION AND REPAIR....12381
COOLING SYSTEM (J08E)....12382
COOLING SYSTEM....12383
DIAGRAM....12383
COOLANT PUMP....12384
COMPONENT LOCATOR....12384
THERMOSTAT....12385
COMPONENT LOCATOR....12385
OVERHAUL....12386
RADIATOR AND INTERCOOLER....12388
COMPONENT LOCATOR....12388
OVERHAUL....12389
RADIATOR....12390
COMPONENT LOCATOR....12390
SPECIAL TOOL....12391
OVERHAUL....12392
INSPECTION AND REPAIR....12395
COOLING FAN....12396
COMPONENT LOCATOR....12396
INSPECTION AND REPAIR....12397
FUEL SYSTEM (J08E)....12398
FUEL SYSTEM....12399
DIAGRAM....12399
COMPONENT LOCATOR....12400
SUPPLY PUMP....12401
DESCRIPTION....12401
COMPONENT LOCATOR....12402
SPECIAL TOOL....12402
OVERHAUL....12403
COMMON RAIL....12412
DESCRIPTION....12412
INSPECTION....12413
REPLACEMENT....12414
INJECTOR....12418
DESCRIPTION....12418
REPLACEMENT....12419
PRE FUEL FILTER....12427
DESCRIPTION....12427
AIR BLEEDING....12428
FUEL FILTER....12430
DESCRIPTION....12430
OVERHAUL....12431
FUEL TANK....12434
COMPONENT LOCATOR....12434
FUEL CUTOFF VALVE....12436
COMPONENT LOCATOR....12436
OVERHAUL....12437
TURBOCHARGER (J08E)....12438
TURBOCHARGER....12439
DESCRIPTION....12439
TROUBLESHOOTING....12440
REPLACEMENT....12449
INSPECTION AFTER MOUNTING....12455
EMISSION CONTROL (J08E)....12456
EGR VALVE AND EGR PIPE....12457
COMPONENT LOCATOR....12457
EGR VALVE....12458
DESCRIPTION....12458
DISMOUNTING AND MOUNTING....12459
CLOSED VENTILATOR....12462
DESCRIPTION....12462
REPLACEMENT OF CLOSED VENTILATOR....12462
REPLACEMENT....12463
REPLACING THE ELEMENT....12463
SELECTIVE CATALYTIC REDUCTION (SCR)....12464
GENERAL DESCRIPTION....12464
COMPONENT LOCATOR....12466
INSPECTION....12467
SPECIAL TOOL....12468
DISMOUNTING AND MOUNTING....12469
INSPECTION AND REPAIR....12487
ALTERNATOR (J08E: REMY 12V-130A,135A,180A,200A)....12488
ALTERNATOR....12489
DATA AND SPECIFICATIONS....12489
TROUBLESHOOTING....12489
COMPONENT LOCATOR....12490
OVERHAUL....12491
INSPECTION AND REPAIR....12494
STARTER (J08E)....12495
STARTER....12496
DATA AND SPECIFICATIONS....12496
DESCRIPTION....12496
TROUBLESHOOTING....12497
COMPONENT LOCATOR....12498
OVERHAUL....12499
INSPECTION AND REPAIR....12503
AIR COMPRESSOR (J08E: 340 cm3)....12506
AIR COMPRESSOR....12507
DATA AND SPECIFICATIONS....12507
DESCRIPTION....12508
TROUBLESHOOTING....12509
COMPONENT LOCATOR....12510
SPECIAL TOOL....12511
OVERHAUL....12512
INSPECTION AND REPAIR....12521
ENGINE CONTROL (J08E)....12525
ACCELERATOR PEDAL....12526
DESCRIPTION....12526
ENGINE ECU....12527
COMPONENT LOCATOR....12527
REPLACEMENT....12528
S7-UNAE16A-1....12535
FOREWORD....12535
CHAPTER REFERENCES....12536
INDEX....12537
GENERAL INTRODUCTION....12538
GENERAL INTRODUCTION....12539
GENERAL PRECAUTIONS....12539
IDENTIFICATION INFORMATION....12542
HOW TO USE THIS WORKSHOP MANUAL....12550
INTRODUCTION TO DESCRIPTIONS....12550
PRECAUTIONS....12553
SEALANT ON THE TAPERED SCREW FOR PIPING....12556
METRIC INFORMATION....12557
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS....12559
SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS....12560
RECOMMENDED LUBRICANTS....12561
INFORMATION DISPLAY....12563
GLOSSARY....12568
GLOSSARY OF SAE AND HINO TERMS....12571
TROUBLE SHOOTING - COMPONENTS....12574
ENGINE BASIC....12575
ENGINE ASSEMBLY....12575
ENGINE ASSEMBLY (COMMON RAIL SYSTEM)....12582
TURBOCHARGER (J08E)....12583
TURBOCHARGER....12583
ALTERNATOR (J08E: REMY 12V-130A, 135A, 180A, 200A)....12592
ALTERNATOR....12592
STARTER (J08E)....12593
STARTER....12593
AIR COMPRESSOR (J08E: 340 cm3)....12594
AIR COMPRESSOR....12594
CLUTCH MAIN UNIT....12595
CLUTCH ASSEMBLY (EATON SAS1402)....12595
AUTOMATIC TRANSMISSION....12597
AUTOMATIC TRANSMISSION ASSEMBLY....12597
TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION) ....12598
TRANSMISSION CONTROL UNIT....12598
TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)....12599
TRANSMISSION CONTROL UNIT....12599
PROPELLER SHAFT (SPL 100, 140)....12599
PROPELLER SHAFT ASSEMBLY....12599
DIFFERENTIAL CARRIER (MERITOR MS-17, 19, 21 AND RS-23)....12600
DIFFERENTIAL CARRIER ASSEMBLY....12600
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)....12601
SERVICE BRAKE ASSEMBLY....12601
BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)....12606
SERVICE BRAKE ASSEMBLY....12606
SERVICE BRAKE (HYDRAULIC BRAKE)....12608
WHEEL BRAKE (TYPE: 4 PISTON)....12608
SERVICE BRAKE (FULL AIR BRAKE)....12610
AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS)....12610
EXHAUST BRAKE....12613
EXHAUST BRAKE SYSTEM....12613
PARKING BRAKE (BOSCH 12)....12614
PARKING BRAKE ASSEMBLY....12614
STEERING EQUIPMENT....12615
STEERING SYSTEM....12615
FRONT AXLE (MFS)....12619
FRONT AXLE (MFS)....12619
REAR AXLE....12621
REAR AXLE....12621
WHEEL AND TIRE....12622
WHEEL AND TIRE....12622
SUSPENSION....12624
LEAF SUSPENSION ASSEMBLY....12624
AIR SUSPENSION ASSEMBLY....12624
CHASSIS FRAME....12625
CHASSIS FRAME....12625
CAB....12626
AIR SUSPENSION DUMP SYSTEM....12626
CAB ASSEMBLY....12626
AIR CONDITIONING SYSTEM....12628
ELECTRICAL EQUIPMENT....12638
ELECTRICAL PARTS....12638
TROUBLE SHOOTING - ELECTRICAL CONTROL SYSTEM....12640
ABOUT HINO DX II....12641
About HINO DX II....12641
BASIC PROCEDURE FOR TROUBLESHOOTING....12643
BASIC PROCEDURE FOR TROUBLESHOOTING....12643
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....12645
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE....12645
SYMPTOM SIMULATION....12648
SYMPTOM SIMULATION....12648
TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART....12650
TROUBLE CODE DIAGNOSTIC INSPECTION FLOW CHART....12650
ELECTRONIC CIRCUIT INSPECTION PROCEDURE....12651
ELECTRONIC CIRCUIT INSPECTION PROCEDURE....12651
INSPECTION PROCEDURE FOR MULTIPLE DTCS....12656
INSPECTION PROCEDURE FOR MULTIPLE DTCS....12656
ENGINE CONTROL SYSTEM (J08E)....12657
ENGINE CONTROL SYSTEM....12660
PRECAUTIONS FOR DIAGNOSIS....12660
SYSTEM BLOCK DIAGRAM....12662
SYSTEM DIAGRAM....12663
PRECAUTIONS....12665
SENSOR LOCATION....12669
COMPUTER (ECU) PIN ASSIGNMENT....12678
ENGINE ECU CONNECTOR....12684
INSPECTION....12688
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....12689
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....12690
GROUP SHARING THE SENSOR POWER SUPPLY TERMINAL....12711
GROUP SHARING THE SENSOR GND TERMINAL....12712
ENGINE BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)....12713
NO DTC....12717
SIMULTANEOUS MALFUNCTION OF MULTIPLE ELECTRIC SYSTEMS....12720
MALFUNCTION OF STARTER....12724
MALFUNCTION OF ALTERNATOR....12731
DTC: P0005....12734
DTC: P0006 and P0007....12738
DTC: P0016....12743
DTC: P0027....12746
DTC: P003A....12751
DTC: P0045....12756
DTC: P0047....12761
DTC: P0048....12766
DTC: P006E....12771
DTC: P006F....12775
DTC: P007B....12779
DTC: P007C and P007D....12792
DTC: P0088....12800
DTC: P0096....12810
DTC: P0097 and P0098 ....12821
DTC: P0101....12829
DTC: P0104....12836
DTC: P0106....12842
DTC: P0107....12849
DTC: P0108....12856
DTC: P0111....12862
DTC: P0112 and P0113....12868
DTC: P0115....12875
DTC: P0117 and P0118....12884
DTC: P011A....12892
DTC: P0122 and P0123....12901
DTC: P0126....12910
DTC: P0128....12914
DTC: P0148 ....12919
DTC: P016E and P016F ....12930
DTC: P0182 and P0183 ....12941
DTC: P0191....12948
DTC: P0192 and P0193 ....12954
DTC: P01A5....12963
DTC: P01A6....12970
DTC: P0200....12977
DTC: P0201, P0202, P0203, P0204, P0205 and P0206....12979
DTC: P0217....12984
DTC: P0219....12989
DTC: P0222 and P0223....12996
DTC: P0234....13005
DTC: P0263, P0266, P0269, P0272, P0275 and P0278....13011
DTC: P026C and P026D....13022
DTC: P0299....13035
DTC: P0300....13041
DTC: P0301, P0302, P0303, P0304, P0305 and P0306....13049
DTC: P0335....13057
DTC: P0336....13063
DTC: P0340....13069
DTC: P0341....13074
DTC: P0381....13081
DTC: P0401....13086
DTC: P0402....13100
DTC: P0404....13110
DTC: P0405 and P0406....13115
DTC: P041B....13121
DTC: P041C and P041D....13129
DTC: P0420....13137
DTC: P0421....13139
DTC: P0422....13152
DTC: P0489 and P0490....13155
DTC: P049D....13161
DTC: P04D5 and P04D6....13166
DTC: P04DA....13174
DTC: P04DB....13184
DTC: P0500 and P0501....13192
DTC: P0504....13198
DTC: P0506 and P0507....13204
DTC: P0524....13207
DTC: P0545 and P0546....13212
DTC: P054E and P054F....13221
DTC: P0562 and P0563....13224
DTC: P0605....13230
DTC: P0606....13232
DTC: P0607....13234
DTC: P0610....13236
DTC: P0611....13239
DTC: P0617....13241
DTC: P0628 and P0629....13245
DTC: P062F....13252
DTC: P0630....13256
DTC: P0642....13260
DTC: P0643....13264
DTC: P064C....13269
DTC: P0652....13274
DTC: P0653....13279
DTC: P0671, P0672, P0675 and P0676 ....13285
DTC: P0683....13295
DTC: P0686....13300
DTC: P0698....13305
DTC: P0699....13307
DTC: P06A4....13309
DTC: P06A5....13311
DTC: P06D3 and P06D4....13313
DTC: P0704....13320
DTC: P073D....13324
DTC: P081A....13330
DTC: P081B....13334
DTC: P0850....13338
S7-UNAE16A-2....13344
FOREWORD....13344
CHAPTER REFERENCES....13345
INDEX....13346
ENGINE CONTROL SYSTEM....13347
ENGINE CONTROL SYSTEM....13350
DTC: P104E....13350
DTC: P104F....13354
DTC: P1133....13358
DTC: P119F....13364
DTC: P1426....13370
DTC: P1427....13377
DTC: P1428....13383
DTC: P1458....13389
DTC: P1459....13394
DTC: P146F....13399
DTC: P14B0....13404
DTC: P14B2....13408
DTC: P14B3 and P14B4....13412
DTC: P14B7 and P14B8....13418
DTC: P14BC and P14BD....13424
DTC: P14BF....13430
DTC: P1515....13435
DTC: P1530....13440
DTC: P2002....13444
DTC: P200C....13464
DTC: P2032 and P2033....13471
DTC: P203F....13479
DTC: P204F....13483
DTC: P206B....13485
DTC: P207F....13508
DTC: P2080....13532
DTC: P2084....13541
DTC: P20CD....13549
DTC: P20CE....13553
DTC: P20D8....13558
DTC: P20DE....13563
DTC: P20DF....13567
DTC: P20E0....13573
DTC: P20EE....13579
DTC: P20EF....13605
DTC: P2100....13607
DTC: P2101....13613
DTC: P2103....13619
DTC: P2120....13625
DTC: P2122 and P2123....13629
DTC: P2127 and P2128....13637
DTC: P2135....13646
DTC: P2138....13651
DTC: P2146....13656
DTC: P2147 and P2148....13663
DTC: P2149....13671
DTC: P2150 and P2151....13677
DTC: P2184 and P2185....13685
DTC: P2201....13693
DTC: P2227....13732
DTC: P2228 and P2229....13736
DTC: P2269....13741
DTC: P226C....13745
DTC: P229F....13753
DTC: P22D3....13793
DTC: P240F....13797
DTC: P2428....13806
DTC: P242B....13810
DTC: P242C and P242D....13818
DTC: P244A....13826
DTC: P244B....13843
DTC: P2457....13870
DTC: P2458....13884
DTC: P2459....13897
DTC: P2463....13899
DTC: P246F....13905
DTC: P2470 and P2471....13913
DTC: P2481 and P2482....13921
DTC: P2483....13929
DTC: P24A0....13937
DTC: P24A1....13940
DTC: P24A2....13942
DTC: P24AE....13952
DTC: P24AF....13961
DTC: P24B0....13966
DTC: P24B1....13971
DTC: P24B4....13974
DTC: P24B7....13986
DTC: P24C7....13989
DTC: P24D0....13993
DTC: P24D1....13998
DTC: P24DA....14003
DTC: P24FE....14008
DTC: P2563....14026
DTC: P2564 and P2565....14031
DTC: P259E....14038
DTC: P259F....14043
DTC: P2635....14048
DTC: P268A and P2696....14057
DTC: P2A00....14063
DTC: P2A01....14072
DTC: P2BA9....14081
DTC: U0073....14086
DTC: U010A....14089
DTC: U010C....14092
DTC: U010E....14095
DTC: U029D....14098
DTC: U029E....14101
DTC: U02A2....14104
DTC: U02A3 ....14107
DTC: U0301....14110
DTC: U1001....14113
DTC: U110A....14116
S7-UNAE16A-3....14120
FOREWORD....14120
CHAPTER REFERENCES....14121
INDEX....14122
DEF SCR SYSTEM (DCU)....14123
DEF SCR SYSTEM....14124
PRECAUTIONS FOR DIAGNOSIS....14124
SYSTEM BLOCK DIAGRAM....14126
SYSTEM DIAGRAM....14127
SENSOR LOCATION....14128
COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT....14131
SIGNAL CHECK HARNESS....14132
INSPECTION....14132
MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN....14133
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....14134
DIAGNOSTIC TROUBLE CODE (DTC) TABLE....14135
DTC: P0071....14141
DTC: P0072....14151
DTC: P0073....14159
DTC: P0562....14167
DTC: P0563....14170
DTC: P060B....14173
DTC: P060C....14175
DTC: P062F....14177
DTC: P0667....14179
DTC: P068A....14181
DTC: P06AD....14186
DTC: P06AE....14188
DTC: P142A....14190
DTC: P142B....14199
DTC: P14C1....14210
DTC: P14C2....14224
DTC: P14C3....14230
DTC: P202E....14237
DTC: P203C....14242
DTC: P203D....14245
DTC: P2044....14248
DTC: P2045....14251
DTC: P2047....14254
DTC: P2048....14258
DTC: P2049....14263
DTC: P204B....14269
DTC: P204C....14272
DTC: P204D....14278
DTC: P205B....14284
DTC: P205C....14293
DTC: P205D....14296
DTC: P206C....14299
DTC: P206D....14302
DTC: P208A....14305
DTC: P208B....14309
DTC: P208C....14312
DTC: P208D....14316
DTC: P20A0....14320
DTC: P20A1....14326
DTC: P20A2....14330
DTC: P20A3....14336
DTC: P20B1....14342
DTC: P20B2....14347
DTC: P20B3....14356
DTC: P20B4....14361
DTC: P20BD, P20B9 and P20C1....14366
DTC: P20C0, P20BC and P20C4....14374
DTC: P20E8....14380
DTC: P20E9....14391
DTC: P20F4....14396
DTC: P21C2....14400
DTC: P21C3....14405
DTC: P21C4....14410
DTC: P2202....14415
DTC: P2203....14418
DTC: P2204....14421
DTC: P2209....14428
DTC: P22A0....14436
DTC: P22A1....14439
DTC: P22A2....14442
DTC: P22A7....14450
DTC: P2510....14458
DTC: P2BAE....14463
DTC: U0029....14466
DTC: U0038....14469
DTC: U0100....14472
DTC: U029D....14476
DTC: U029E....14479
DTC: U02A2....14482
BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION))....14485
ABS....14486
TROUBLESHOOTING....14486
BRAKE CONTROL SYSTEM (ABS:FULL AIR)....14508
ABS....14509
TROUBLESHOOTING....14509
VEHICLE CONTROL SYSTEM (VCS)....14539
VEHICLE CONTROL SYSTEM....14540
PRECAUTIONS FOR DIAGNOSIS....14540
SYSTEM BLOCK DIAGRAM....14542
SIGNAL CHECK HARNESS....14543
DIAGNOSIS USING THE PC DIAGNOSIS TOOL....14551
VEHICLE CONTROL ECU INSPECTION....14552
DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE....14558
DTC: P0500....14559
DTC: P0501....14563
DTC: P0562....14567
DTC: P0563....14570
DTC: P0617....14573
DTC: P0704....14576
DTC: P0850....14582
DTC: P1565....14588
DTC: U0101....14594
DTC: U0105 ....14597
DTC: U0155....14600
NO ACTIVATION OF AUXILIARY BRAKE....14602
NO ACTIVATION/RELEASE OF ENGINE REVOLUTION CONTROL....14608
NO ACTIVATION/RELEASE OF CRUISE FUNCTION....14613
NO ACTIVATION/RELEASE OF ECO MODE....14621
CAN COMMUNICATION....14625
CAN COMMUNICATION TROUBLESHOOTING....14626
Outline....14626
Definition of Terms....14626
Troubleshooting Procedure....14627
Work Flow....14627
ECU individual code list....14628
CAN communication circuit diagram....14629
CAN communication relation connector location....14632
ENGINE CAN COMMUNICATION LINE....14636
ABNORMAL CAN COMMUNICATION DTC DETECTED....14636
CONNECTION DIAGRAM....14636
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE....14636
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE....14638
DISCONNECTION INSPECTION FOR ENGINE CAN_H/L_COMMUNICATION LINE....14641
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE....14647
INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE....14656
INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE....14665
INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE....14670
INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMUNICATION LINE)....14675
INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE....14680
INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE....14686
INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE....14692
INSPECTION FOR PM SENSOR CAN COMMUNICATION LINE....14698
DIAGNOSIS CAN COMMUNICATION LINE....14704
ABNORMAL CAN COMMUNICATION DTC DETECTED....14704
CONNECTION DIAGRAM....14704
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE....14704
PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE....14706
DISCONNECTION INSPECTION FOR DIAGNOSIS CAN_H/L_COMMUNICATION LINE....14709
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H-LINE....14713
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN L-LINE....14718
INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COMMUNICATION LINE)....14723
INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE....14727
CONTROL CAN COMMUNICATION LINE....14732
ABNORMAL CAN COMMUNICATION DTC DETECTED....14732
CONNECTION DIAGRAM (ALLISON AUTOMATIC TRANSMISSION)....14732
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ALLISON AUTOMATIC TRANSMISSION)....14732
CONNECTION DIAGRAM (MANUAL TRANSMISSION)....14733
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (MANUAL TRANSMISSION)....14733
PRE-INSPECTION FOR CAN COMMUNICATION LINE....14734
DISCONNECTION INSPECTION FOR CAN_H/L_COMMUNICATION LINE....14738
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE....14741
INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE....14743
INSPECTION FOR AUTOMATIC TRANSMISSION ECU CAN COMMUNICATION LINE....14745
Hino Trucks MY2017-MY2020 Repair Service Manual
