Toyota HINO 155 2017 Workshop Manual
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Toyota HINO 155 2017 Workshop Manual

Toyota HINO 155 2017 Workshop Manual

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A
Toyota
Group Company
2017
WORKSHOP MANUAL
GENERAL INTRODUCTION, HYBRID SYSTEM, TRANSMISSION, PROPELLER SHAFT, AXLE,
DIFFERENTIAL , BRAKE, STEERING, SUSPENSION, FRAME AND FRAME ACCESSORY, CAB
MOUNTING AND CAB SUSPENSION, BODY INSIDE ACCESSORY, BODY OUTSIDE
ACCESSORY, AIR BAG AND SEAT BELT, ELECTRICAL, CONTROL SYSTEM, WIRING
DIAGRAM ACCORDING TO SYSTEM
Hino Motors Sales U.S.A. , Inc.
HINO 155, 155h, 195, 195h

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  • Page 1 Toyota Group Company 2017 WORKSHOP MANUAL HINO 155, 155h, 195, 195h GENERAL INTRODUCTION, HYBRID SYSTEM, TRANSMISSION, PROPELLER SHAFT, AXLE, DIFFERENTIAL , BRAKE, STEERING, SUSPENSION, FRAME AND FRAME ACCESSORY, CAB MOUNTING AND CAB SUSPENSION, BODY INSIDE ACCESSORY, BODY OUTSIDE ACCESSORY, AIR BAG AND SEAT BELT, ELECTRICAL, CONTROL SYSTEM, WIRING DIAGRAM ACCORDING TO SYSTEM Hino Motors Sales U.S.A.

  • Page 2: Workshop Manual

    INDEX: CHASSIS GROUP 1/2 GENERAL INTRODUCTION ENGINE HYBRID SYSTEM WORKSHOP TRANSMISSION MANUAL CLUTCH PROPELLER SHAFT HINO 155, 155h, 195, AXLE 195h series truck DIFFERENTIAL 2017 MY BRAKE equipped with J05E engine STEERING SUSPENSION FRAME AND FRAME ACCESSORY CAB MOUNTING AND CAB SUSPENSION BODY CONSTRUCTION BODY INSIDE ACCESSORY BODY OUTSIDE ACCESSORY...
  • Page 3 INDEX: CHASSIS GROUP 2/2 ELECTRICAL CONTROL SYSTEM Find manuals at https://best-manuals.com...
  • Page 4 FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks. Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner s Manual.
  • Page 5 CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. MANUAL No. S1-LXJE05A (U.S.A.), S1-LXJE06A (CANADA) MODELS HINO 155, 155h, 195, 195h CHAPTER XFC710, XFC720, XFC730, XFC740, Production Code XJC700, XJC710, XJC720, XJC730, XJC740 GENERAL INTRODUCTION 1-001 HYBRID...

  • Page 6: Table Of Contents

    GENERAL INTRODUCTION 1–1 GENERAL INTRODUCTION 1-001 HOW TO IDENTIFY VEHICLE TYPE ....1-2 LUBRICANTS ..........1-35 HOW TO IDENTIFY VEHICLE TYPE ......1-2 LUBRICANTS.............1-35 VEHICLE MODEL ...........1-2 RECOMMENDED LUBRICANTS ......1-35 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE ............1-3 APPEARANCE OF VEHICLE ......1-4 APPEARANCE.............1-4 APPEARANCE OF VEHICLE .........1-4 SAFETY INSTRUCTIONS AND...

  • Page 7: How To Identify Vehicle Type

    1–2 GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE HOW TO IDENTIFY VEHICLE TYPE HOW TO IDENTIFY VEHICLE TYPE VEHICLE MODEL EN01E01ZZZ010102001001 REPORTED MODEL CLASSIFICATION ENGINE MODEL VEHICLE MODEL DECK HEIGHT HEAVY DUTY TRACK J05E-UG (HV) K HIGH FLOOR CAB J05E-TP (Diesel) CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE TRANSMISSION CAB WIDTH DRIVE...

  • Page 8: Vehicle Identification Number (Vin) Structure

    GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE 1–3 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE EN01E01ZZZ010102001002 SHTS01ZZZ0100002 Find manuals at https://best-manuals.com...

  • Page 9: Appearance Of Vehicle

    1–4 GENERAL INTRODUCTION/APPEARANCE OF VEHICLE APPEARANCE OF VEHICLE APPEARANCE APPEARANCE OF VEHICLE EN01E01ZZZ020102003001 SHTS01ZZZ0200001 Find manuals at https://best-manuals.com...

  • Page 10: Safety Instructions And Readiness To Work

    GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–5 SAFETY INSTRUCTIONS AND READINESS TO WORK WARNING GENERAL PRECAUTIONS EN01E01ZZZ030101001001 Some recommended and standard maintenance services for your vehicle are included in this section. When performing maintenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a mal- function of the vehicle which may result in personal injury and/or property damage.
  • Page 11 1–6 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK PRECAUTIONS IN TILTING AND LOWERING THE CAB ! WARNING Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may result in death, serious injury and/or property damage. •...
  • Page 12 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–7 TOWING • When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No.

  • Page 13: Clean Air Act

    1–8 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK CLEAN AIR ACT Heavy-duty engine rebuilding practices. § 86.004-40 • The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and are applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reas- sembly, and also may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine.

  • Page 14: Identification Information

    GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–9 IDENTIFICATION INFORMATION EN01E01ZZZ030101001002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number (VIN) is stamped on the right frame, as shown in the illustration. This number has also been stamped on the manufacture's label. A: Vehicle Identification Number (VIN) B: Manufacturer's Label See VEHICLE IDENTIFICATION NUMBER (VIN) STRUC-...

  • Page 15: Engine Serial Number

    1–10 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK VEHICLE NOISE EMISSION CONTROL INFORMATION • The Vehicle Noise Emission Control Information is affixed to the left pillar of the cab. The name of manufacturer, production year FOR ALL MODELS and month, and noise emission applicable to medium and heavy trucks in conformity with U.S.
  • Page 16 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–11 EXEMPTION LABEL FOR US GHG REGULATION • The Vehicle Emission Control Information is affixed to the side of the right door. The name of manufacturer, production year and month, and emission applicable to medium and heavy trucks in conformity with U.S.

  • Page 17: Safety Instructions For Work

    1–12 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK SAFETY INSTRUCTIONS FOR WORK PRECAUTIONS EN01E01ZZZ030101004001 SAFETY INSTRUCTIONS FOR HANDLING ELECTRICAL SYSTEMS Remove the battery cable ! WARNING • Be sure to wait for at least ten minutes after the starter key is turned to "LOCK" position before you disconnect the battery terminals from the battery, as the vehicle data is recorded on ECU and DCU starts working for the exhaust gas after treatment after the starter key is turned to "LOCK"...
  • Page 18 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–13 Handling of electronic parts Never give an impact to electronic parts of a computer or relay. Keep electronic parts away from high temperatures and humidity. Never splash water onto electronic parts in washing the vehicle. Do not remove the harness connector, electric component box, and cover except for repair and inspection.
  • Page 19 1–14 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK Handling of connectors When removing a connector, hold a connector (area shown in an arrow in the figure) and then pull it off. Do not pull wire harnesses. Pull off a lockable connector after unlocking. When connecting a lockable connector, make sure to insert a lockable connector until it makes a click sound.
  • Page 20 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–15 PRECAUTION FOR ELECTRIC WELDING Electrical components such as the alternator and tachograph are directly connected to the battery and one end is earthed to the chassis frame. Under these conditions, welding current will flow back along the earth circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, electrical components, etc.

  • Page 21: Introduction To Workshop Manual

    1–16 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK GENERAL INFORMATION INTRODUCTION TO WORKSHOP MANUAL GENERAL EN01E01ZZZ030102002001 SCOPE OF REPAIR DESCRIPTIONS There are three major processes in repair work: i.e. "troubleshooting", "removal/installation, replacement, over- haul, assembly, inspection and adjustment" and "final inspection". This document covers only the first process (troubleshooting) and the second process (removal/installation, replacement, overhaul, assembly, inspection and adjustment) and omits the third process (final inspection).

  • Page 22: Introduction To Descriptions

    GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–17 INTRODUCTION TO DESCRIPTIONS EN01E01ZZZ030102002002 COMPONENT LOCATOR Alphabetical mark indicating the tightening torque in the following tightening torque table Numerical order indicating the part name in the following part name table Numerical order Part name table Part name Tightening torque table...

  • Page 23: Work Steps

    1–18 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK WORK STEPS Indicating the work sequence Descriptive text: Indicating the work method which is gone into detail Indicating the part number of SST required for work SHTS01ZZZ0300020...

  • Page 24: Definition Of Term

    GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–19 DEFINITION OF TERM EN01E01ZZZ030102002003 Terms used in this document are defined as follows. DIRECTION CHASSIS RELATED Longitudinal direction The forward direction and the reverse direction of a vehicle are respectively defined as front and rear in the installed position in a vehicle.

  • Page 25: Tightening Of Bolts And Nuts

    1–20 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK TIGHTENING OF BOLTS AND NUTS BOLTS AND NUTS EN01E01ZZZ030602008001 More than hundreds of bolts/nuts are used in a vehicle and improper handling of them will cause damage and looseness. Because tightening torque varies depending on tightening condition, strength class, and surface treatment, etc., make sure to check the types and tightening torques of bolts/nuts and use them properly.

  • Page 26: Types And Identification

    GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–21 TYPES AND IDENTIFICATION EN01E01ZZZ030602008004 There are three types of bolts and nuts. Standard (w/o flange) • Bolts/nuts without flange SHTS01ZZZ0300021 With old flange (w/grooves) • Flange is small and has grooves on its back. GROOVE GROOVE FLANGE OUTER DIAMETER...
  • Page 27 1–22 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK Comparison of flange outer diameters Bolt With old flange With new flange With old flange With new flange Thread (w/grooves) (w/o grooves) (w/grooves) (w/o grooves) diameter Flange Flange Flange Flange Strength Strength Strength Strength outer...

  • Page 28: Strength Classes And Symbols

    GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–23 STRENGTH CLASSES AND SYMBOLS EN01E01ZZZ030602008006 With old flange (w/grooves) Bolt Symbols Strength Strength Symbols class class Carbon steel Boron steel — With new flange (w/o grooves) Bolt Symbols Strength Strength Symbols class class Carbon steel Boron steel...

  • Page 29: Part No

    1–24 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK PART No. EN01E01ZZZ030602008007 Standard (w/o flange) Bolt Thread Strength Surface Strength Surface diameter Part No. Part No. class treatment class treatment SH111-**** Plating SL113-00807 Plating SH112-**** Plating SH111-**** Plating SL113-01008 Plating SH112-**** Plating SH111-**** Plating...

  • Page 30: List Of Tightening Torque

    GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–25 With new flange (w/o grooves) Bolt Thread Strength Surface Strength Surface diameter Part No. Part No. class treatment class treatment 91551-808** Plating 94151-80800 Plating 10.9 91551-008** Plating 91552-E10** Neotorquer 94151-81001 Neotorquer 10.9 91552-F10** Neotorquer 91552-E12**...
  • Page 31 1–26 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK With old flange (w/grooves) Unit: Nm {kgfcm, lbfft} Thread diameter Strength classes Tightening Torque 18.0-26.0 {184-265, 14-19} 23.5-34.5 {240-351, 18-25} 41.5-61.5 {424-627, 31-45} 55.0-82.0 {561-836, 41-60} 73.0-109.0 {745-1,111, 54-80} 96.0-144.0 {979-1,468, 71-106} With new flange (w/o grooves) Unit: Nm {kgfcm, lbfft} Thread diameter...

  • Page 32: Tightening Of Flare Nuts And Hoses

    GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–27 TIGHTENING OF FLARE NUTS AND HOSES EN01E01ZZZ030602008009 TIGHTENING TORQUE FOR PIPE FLARE NUTS HINT Steel pipes and copper pipes (excluding power steering pipe). Unit: Nm {kgfcm, lbfft} Outer diameter 4.76 6.35 8 10 12 15...

  • Page 33: Handling Of Liquid Gasket

    1–28 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK HANDLING OF LIQUID GASKET LIQUID GASKET EN01E01ZZZ030602013001 PROCEDURES FOR APPLYING LIQUID GASKET AND ASSEMBLING PARTS Thoroughly remove old liquid gasket remaining on individual parts and mating parts. Use clean cloth to remove oil, moisture, dirt or other contaminants.

  • Page 34: Glossary

    GENERAL INTRODUCTION/GLOSSARY 1–29 GLOSSARY DEFINITION OF ABBREVIATION IN THIS MANUAL LIST OF ABBREVIATION EN01E01ZZZ060102001001 Abbreviations Meaning, or Official Name Air Conditioner Anti-lock Brake System Accessory Auto Clutch Unit Automated manual transmission Automatic Transmission After Turbo Catalyst Automatic Transmission Fluid Crank Angle Controller Area Network CD-ROM Compact Disc Read Only Memory...
  • Page 35 1–30 GENERAL INTRODUCTION/GLOSSARY Abbreviations Meaning, or Official Name Front Fiber Reinforced Plastic Front Underrun Protector Ground Gross Vehicle Weight High HINO DX HINO Diagnostic eXplorer HINO Signal Converter Hybrid Vehicle HVAC Heating, Ventilating and Air-Conditioning unit I.S.C. Idle Speed Control Integrated Circuits Identification Intelligent Power Device...
  • Page 36 GENERAL INTRODUCTION/GLOSSARY 1–31 Abbreviations Meaning, or Official Name Particulate Matter Glass-fiber-reinforced Polypropylene Parts Per Million Power Steering Power Take-Off Physical Vapor Deposit Power QR code Quick Response Code Rear Axle Right Hand Selective Catalytic Reduction Suction Control Valve Special Service Tool Switch Transmission Vehicle Control System...

  • Page 37: Glossary Of Sae And Hino Terms

    1–32 GENERAL INTRODUCTION/GLOSSARY GLOSSARY OF SAE AND HINO TERMS EN01E01ZZZ060102001002 This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as well as their HINO equivalents. SAE ABBREVIATIONS SAE TERMS HINO TERMS ( ) -- ABBREVIATIONS AUTOMATIC TRANSMISSION Automatic transmission AMBIENT AIR TEMPERATURE...
  • Page 38 GENERAL INTRODUCTION/GLOSSARY 1–33 SAE ABBREVIATIONS SAE TERMS HINO TERMS ( ) -- ABBREVIATIONS ENGINE CONTROL Engine control ENGINE COOLANT TEMPERATURE Coolant Temperature ENGINE COOLANT TEMPERATURE Water Temperature ENGINE FUEL TEMPERATURE Fuel temperature EFT Sensor ENGINE FUEL TEMPERATURE Sensor Fuel temperature sensor EXHAUST GAS RECIRCULATION EGR Valve EXHAUST GAS RECIRCULATION Valve...
  • Page 39 1–34 GENERAL INTRODUCTION/GLOSSARY SAE ABBREVIATIONS SAE TERMS HINO TERMS ( ) -- ABBREVIATIONS PCV Valve POSITIVE CRANKCASE VENT Valve PCV Valve PARK/NEUTRAL POSITION Neutral position PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch RAIL FUEL PRESSURE Common rail Pressure RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor SPARK PLUG...

  • Page 40: Recommended Lubricants

    LUBRICANTS VISCOSITY RECOMMENDATIONS (SAE) Cylinder block Engine oil (JASO: DH-2) (API: CJ-4) (ACEA: E-6, E-9) Transmission: Toyota genuine ATF Type T-IV A465 Automatic (ATF: JWS3309) Transmission Differential: SH13 HINO GENUINE SERIES Differential gear oil for Hypoid gear F (API: GL-5) C...
  • Page 41 HYBRID 3–1 HYBRID 3-001 STANDARD VALUE......... 3-2 SYSTEM MAIN RELAY JUNCTION BLOCK .....3-38 COMPONENT LOCATOR ........3-38 HYBRID SYSTEM ............3-2 REPLACEMENT ...........3-39 SERVICE PLUG............3-2 INVERTER..............3-41 PCU.................3-2 COMPONENT LOCATOR ........3-41 HV BATTERY ............3-3 REPLACEMENT ...........3-42 HV BATTERY COOLING FAN.........3-3 HV BATTERY ECU..........3-3 HV-ECU ..............3-46 SYSTEM MAIN RELAY JUNCTION BLOCK...3-3 COMPONENT LOCATOR ........3-46...

  • Page 42: Standard Value

    3–2 HYBRID/STANDARD VALUE STANDARD VALUE HYBRID SYSTEM SERVICE PLUG EN01E03ZZZ010701001001 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Usable limit Action Between service plug pins 1 or less Replace TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks —...

  • Page 43: Hv Battery

    HYBRID/STANDARD VALUE 3–3 HV BATTERY EN01E03ZZZ010701001003 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks — PCU mounting bolt 31 {316, 22.9} — Under cover mounting bolt 13 {133, 9.6} — Harness connecting nut 7.2-10.8 {73-110, 5.3-8.0} — Terminal cover mounting bolt 9 {92, 6.6} HV BATTERY COOLING FAN...

  • Page 44: Inverter

    3–4 HYBRID/STANDARD VALUE INVERTER EN01E03ZZZ010701001007 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks — Inverter bracket mounting bolt 19.0 {194, 14.0} — Main battery cable mounting bolt (terminal side) 7.2-10.8 {73-110, 5.3-8.0} — Harness mounting bolt 9 {92, 6.6} HV-ECU EN01E03ZZZ010701001008 TIGHTENING TORQUE...

  • Page 45: Water Pump

    HYBRID/STANDARD VALUE 3–5 WATER PUMP EN01E03ZZZ010701001010 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks — Water pump mounting bolt 12.5 {127, 9.2} — Water pump assembly mounting bolt 19 {194, 14.0} INVERTER RADIATOR EN01E03ZZZ010701001011 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks...

  • Page 46: Required Items

    3–6 HYBRID/REQUIRED ITEMS REQUIRED ITEMS HYBRID SYSTEM HYBRID SYSTEM EN01E03ZZZ020702001001 OIL AND GREASE, AND OTHERS Name Remarks Insulated gloves Protection against electric shock Insulation tape Protection against electric shock RECOMMEND SERVICE TOOL Part No. Name Remarks S0823-E0024 HINO HV service Insulation tool SERVICE PLUG EN01E03ZZZ020702001002...
  • Page 47 HYBRID/HYBRID SYSTEM 3–7 HYBRID SYSTEM HYBRID SYSTEM CAUTIONS EN01E03ZZZ040402009001 CAUTIONS AT THE TIME OF HYBRID SYSTEM INSPECTION AND MAINTENANCE. ! CAUTION The hybrid system has high-voltage circuits. As wrong handling can cause electric shock, current leakage, etc., perform the work correctly following the procedures of this manual.
  • Page 48 3–8 HYBRID/HYBRID SYSTEM Check the insulated gloves for damage such as cracks and break before use. Also, do not use wet insulated gloves. Do not carry on any metal product such as a pen and scale which may fall to cause short circuit while working. Be sure to wear insulated gloves when it is necessary to INCORRECT touch any high-voltage terminal without insulating coating.
  • Page 49 HYBRID/HYBRID SYSTEM 3–9 HIGH-VOLTAGE WORK DO NOT TOUCH! In charge: Make a copy, fold it, and place it onto the roof of the vehicle. SHTS03ZZZ0400002...
  • Page 50 3–10 HYBRID/HYBRID SYSTEM (11) After working on high-voltage components, check for any component or tool left, tightening condition of high-voltage terminals and connector conditions again before connecting the service plug. NOTICE Confirm that connectors are not half-connected, and connect them securely. (12) Do not confuse plus and minus when removing and installing the battery.
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

Hino 155h 2017Hino 195 2017Hino 195h 2017

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