service repair manual

2. FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner's Manual.
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A. , Inc. reserves the right to make changes at any time without prior notice.
Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys-
tems in these vehicles.
Manual Name Pub. No.
Chassis Workshop Manual S1-LXJE05A EWD
J05E Engine Workshop Manual S5-LJ05E07A
Trouble shooting Workshop Manual
S7-LXJE05A 1/5
S7-LXJE05A 2/5
S7-LXJE05A 3/5
S7-LXJE05A 4/5
S7-LXJE05A 5/5
MENU

3. CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
CHAPTER
MANUAL No. S1-LXJE05A (U.S.A.), S1-LXJE06A (CANADA)
MODELS HINO 155, 155h, 195, 195h
Production Code
XFC710, XFC720, XFC730, XFC740,
XJC700, XJC710, XJC720, XJC730, XJC740
GENERAL INTRODUCTION 1-001
HYBRID 3-001
TRANSMISSION 4-001
PROPELLER SHAFT 6-001
AXLE 7-001
DIFFERENTIAL 8-001
BRAKE 9-001
STEERING 10-001
SUSPENSION 11-001
FRAME AND FRAME ACCESSORY 12-001
CAB MOUNTING AND CAB SUSPENSION 13-001
BODY INSIDE ACCESSORY 15-001
BODY OUTSIDE ACCESSORY 16-001
AIR BAG AND SEAT BELT 17-001
HEATER AND AIR CONDITIONER 18-001
ELECTRICAL 19-001
CONTROL SYSTEM 20-001

4. ENGINE
HYBRID SYSTEM
TRANSMISSION
CLUTCH
PROPELLER SHAFT
AXLE
DIFFERENTIAL
BRAKE
STEERING
FRAME AND FRAME ACCESSORY
CAB MOUNTING AND CAB SUSPENSION
BODY CONSTRUCTION
INDEX: CHASSIS GROUP 1/2
SUSPENSION
WORKSHOP
MANUAL
All rights reserved. This manual may not be
reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd.
BODY INSIDE ACCESSORY
BODY OUTSIDE ACCESSORY
AIR BAG AND SEAT BELT
HEATER AND AIR CONDITIONER
GENERAL INTRODUCTION

5. ELECTRICAL
INDEX: CHASSIS GROUP 2/2
CONTROL SYSTEM

6. WORKSHOP
MANUAL
All rights reserved. This manual may not be
reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd.
INDEX: ENGINE GROUP 1/2
STANDARD VALUE
REQUIRED ITEMS
TROUBLESHOOTING
MOUNTING AND DISMOUNTING THE ENGINE
ENGINE CONTROL
FUEL SYSTEM
EMISSION CONTROL
INTAKE
ENGINE MECHANICAL
COOLING
LUBRICATION
SPEED CONTROL SYSTEM
EXHAUST
IGNITION
STARTING/CHARGING
TURBOCHARGER
AIR COMPRESSOR
GENERAL INTRODUCTION

7. INDEX: ENGINE GROUP 2/2
ENGINE PTO
(POWER TAKE-OFF)

8. WIRING DIAGRAM ACCORDING TO SYSTEM
WIRE TO WIRE CONNECTOR
JUNCTION CONNECTOR
LOCATION
RELAY LOCATION/FUSE AND RELAY BLOCK
INDEX
INDEX: CHASSIS GROUP
WORKSHOP
MANUAL
All rights reserved. This manual may not be
reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd.
GENERAL INTRODUCTION

9. GENERAL INTRODUCTION 1–1
1
GENERAL INTRODUCTION
1-001
HOW TO IDENTIFY VEHICLE TYPE .............. 1-2
HOW TO IDENTIFY VEHICLE TYPE...........................1-2
VEHICLE MODEL...................................................1-2
VEHICLE IDENTIFICATION NUMBER (VIN)
STRUCTURE ..........................................................1-3
APPEARANCE OF VEHICLE ......................... 1-4
APPEARANCE.............................................................1-4
APPEARANCE OF VEHICLE .................................1-4
SAFETY INSTRUCTIONS AND
READINESS TO WORK .................................. 1-5
WARNING ....................................................................1-5
GENERAL PRECAUTIONS ....................................1-5
IDENTIFICATION INFORMATION ..........................1-9
SAFETY INSTRUCTIONS FOR WORK.....................1-12
PRECAUTIONS ....................................................1-12
INTRODUCTION TO WORKSHOP MANUAL............1-16
GENERAL.............................................................1-16
INTRODUCTION TO DESCRIPTIONS.................1-17
DEFINITION OF TERM.........................................1-19
TIGHTENING OF BOLTS AND NUTS .......................1-20
BOLTS AND NUTS ...............................................1-20
PURPOSES OF TIGHTENING TORQUE.............1-20
CAUTIONS TO PREVENT LOOSENESS.............1-20
TYPES AND IDENTIFICATION.............................1-21
COMPATIBILITY
(NO COMPATIBILITY IN BOLTS AND NUTS) ......1-22
STRENGTH CLASSES AND SYMBOLS..............1-23
PART No................................................................1-24
LIST OF TIGHTENING TORQUE .........................1-25
TIGHTENING OF FLARE NUTS AND HOSES ....1-27
HANDLING OF LIQUID GASKET..............................1-28
LIQUID GASKET...................................................1-28
GLOSSARY ................................................... 1-29
DEFINITION OF ABBREVIATION IN
THIS MANUAL ...........................................................1-29
LIST OF ABBREVIATION .....................................1-29
GLOSSARY OF SAE AND HINO TERMS ............1-32
LUBRICANTS................................................ 1-35
LUBRICANTS.............................................................1-35
RECOMMENDED LUBRICANTS .........................1-35

10. GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE
1–2
HOW TO IDENTIFY VEHICLE TYPE
HOW TO IDENTIFY VEHICLE TYPE
VEHICLE MODEL
EN01E01ZZZ010102001001
X
Ԙ
J
ԙ
C
Ԛ
7
ԛ
0
Ԝ
0
ԝ Ԟ
L ࡯
ԟ
H
Ԡ
K
ԡ
T
Ԣ
Q
ԣ
M
Ԥ
A
ԥ
3
Ԧ
CLASSIFICATION
REPORTED MODEL
Ԙ
J05E-UG (HV)
X
X
ԙ
F
J05E-TP (Diesel)
J
㧦ENGINE MODEL Ԛ
C
㧦VEHICLE MODEL
HEAVY DUTY TRACK
ԛ 㧦CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE
Ԝ
7 0
7 1
7 2
7 3
CAB WIDTH DRIVE WHEEL BASE
FRAME ASSEMBLY WIDTH
FRAME
FORM
WIDE 2WD MEDIUM
OPEN
WIDE 2WD LONG
OPEN
WIDE 2WD SUPER LONG
OPEN
WIDE 2WD SUPER LONG
OPEN
840 mm {33 in.}
2,900 mm {114 in.}
3,500 mm {138 in.}
3,800 mm {150 in.}
4,100 mm {161 in.}
ԝ
0
㧦TYPE OF SUSPENSION
FRONT RIGID, REAR RIGID
Ԡ
CAB FORM BRAKE TYPE
㧦CAB FORM, BRAKE TYPE
ԟ㧦STEERING WHEEL POSITION
L LEFT HAND DRIVE
H
Q
SINGLE CAB VACUUM
CREW CAB VACUUM
C
D
SINGLE CAB HYDRAULIC
CREW CAB HYDRAULIC
ԡ㧦DECK HEIGHT
K HIGH FLOOR CAB
Ԣ㧦TRANSMISSION
T 6AT
Ԧ㧦DECK FORM
3 CHASSIS WITH CAB
Ԥ㧦ENGINE HORSEPOWER, FUEL
FUEL HORSEPOWER EXHAUST
VERY HIGH US13 (13OBD)
DIESEL OIL
M
ԣ㧦LOADING CAPACITY, GVW, REAR TIRES
ԥ㧦DESTINATION
DESTINATION
A U.S., CANADA
6.58 t {14,500 lbs}
8.14 t {17,950 lbs},
8.85 t {19,500 lbs}
Q
T
7 4 WIDE 2WD SUPER LONG
OPEN 4,400 mm {173 in.}
REAR DOUBLE
REAR DOUBLE
SHTS01ZZZ0100001

11. GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE 1–3
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE
EN01E01ZZZ010102001002
WMI
VDS
CD
VIS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
J
H
H
K
D
L
2
H
X
C
K
0
0
1
0
0
(17)
1
MANUFACTURER
,TYPE
MODEL,
CAB
TYPE,
WHEEL
BASE,
BRAKE
SYSTEM
MODEL
YEAR
ENGINE
MODEL
ASSEMBLY
PLANT
SERIES
MAKE
CHECK
DIGIT
SEQUENTIAL
NUMBER
CODE
JHN
INCOMPLETE
VEHICLE
TYPE
MANUFACTURER
HINO
MOTORS,
LTD.
2AY
INCOMPLETE
VEHICLE
HINO
MOTORS
CANADA,
LTD.
CODE
CODE
YEAR
YEAR
K
2019
L
2020
M
2021
E
2014
F
2015
G
2016
CODE
PM
Hybrid
APPLICATION
ENGINE
MODEL
J05E-UG
DM
Diesel
J05E-TP
CODE
For
USA
For
Canada
1
2
ASSEMBLY
PLANT
CODE
CODE
H
MAKE
SERIES
GVWR
HINO
6,580
kg
{14,500
lbs.}
8,140
-
8,850
kg
{17,950
-
19,500
lbs.}
CODE
CLASS
MODEL
PRODUCTION
CODE
CAB
TYPE
WHEEL
BASE
BRAKE
SYSTEM
CODE
1
ASSEMBLY
PLANT
HINO
MOTORS,
LTD.
Hamura
Plant
in
Japan
K
HINO
MOTORS,
LTD.
Hamura
Plant
in
Japan
K
Canada
Plant
(COE)
N
2022
P
2023
H
2017
J
2018
R
S
T
U
V
W
X
Y
P
H
K
L
HINO
195h
HINO
195
HINO
195
HINO
195
HINO
155
HINO
155
HINO
155
HINO
155
HINO
195
HINO
195
HINO
155
HINO
155
5
5
5
5
4
4
5
5
4
4
4
4
XFC710
HINO
155h
XFC720
HINO
155h
XFC740
HINO
195h
XFC720
HINO
195h
XFC740
HINO
155h
XFC710
HINO
195h
XFC720
HINO
195h
XFC740
HINO
155h
XFC740
HINO
155h
XFC720
HINO
195
XJC710
COE
SINGLE
CAB
COE
SINGLE
CAB
COE
SINGLE
CAB
COE
SINGLE
CAB
COE
SINGLE
CAB
COE
SINGLE
CAB
COE
SINGLE
CAB
COE
SINGLE
CAB
COE
CREW
CAB
COE
CREW
CAB
COE
CREW
CAB
COE
CREW
CAB
3,500
mm
{138
in.}
3,500
mm
{138
in.}
2,900
mm
{114
in.}
2,900
mm
{114
in.}
3,800
mm
{150
in.}
3,800
mm
{150
in.}
3,800
mm
{150
in.}
3,800
mm
{150
in.}
4,400
mm
{173
in.}
4,400
mm
{173
in.}
4,400
mm
{173
in.}
4,400
mm
{173
in.}
XJC700
XJC700
XJC710
XJC720
XJC740
XJC740
XJC720
XJC720
XJC740
XJC720
XJC740
HYDRAULIC
G
HINO
195h
5
XFC730
HINO
195
XJC730
COE
SINGLE
CAB
4,100
mm
{161
in.}
HYDRAULIC
HYDRAULIC
HYDRAULIC
HYDRAULIC
HYDRAULIC
HYDRAULIC
VACUUM
VACUUM
VACUUM
VACUUM
VACUUM
VACUUM
SHTS01ZZZ0100002

12. HYBRID/HYBRID SYSTEM 3–11
SERVICE PLUG
COMPONENT LOCATOR
EN01E03ZZZ040402007001
Tightening torque Unit: Nm {kgfcm, lbfft}
UNIT CHECK
EN01E03ZZZ040402007002
INSPECTING THE SERVICE PLUG
1. INSPECTING THE SERVICE PLUG.
(1) Using a circuit tester, measure the resistance value between
service plug terminals.
1 Service plug 2 Service plug cover
A 9 {92, 6.6}
1
2
A
SHTS03ZZZ0400003
Inspection terminal Standard value
1-2 1 or less

13. HYBRID/HYBRID SYSTEM
3–12
REPLACEMENT
EN01E03ZZZ040402007003
REMOVING THE SERVICE PLUG
1. DISCONNECTING THE AUXILIARY BATTERY.
(1) Disconnect the auxiliary battery negative terminal.
2. REMOVING THE SERVICE PLUG COVER.
(1) Remove the bolts (4 pcs.) to remove the service plug cover.
3. REMOVING THE SERVICE PLUG.
(1) Wear insulated gloves to remove the service plug from the
HV battery assembly.
! CAUTION
To prevent another engineer from reconnecting the service plug
you disconnected, carry that plug around with you in your pocket.
SHTS03ZZZ0400004
1
2
3
SHTS03ZZZ0400005

14. HYBRID/HYBRID SYSTEM 3–13
MOUNTING THE SERVICE PLUG
1. MOUNTING THE SERVICE PLUG.
! CAUTION
Double check that you have not left any tools or parts inside
before connecting the service plug, and double check the status
of high-voltage connector tightening and the status of connector
connections.
(1) Wear insulated gloves to mount the service plug to the HV
battery assembly.
2. MOUNTING THE SERVICE PLUG COVER.
(1) Mount the service plug cover with the bolts (4 pcs.)
Tightening Torque:
9 N·m {92 kgf·cm, 6.6 lbf·ft}
3. CONNECTING THE AUXILIARY BATTERY.
(1) Connect the negative battery terminal of the auxiliary battery.
1
2
3
SHTS03ZZZ0400006
SHTS03ZZZ0400007

15. HYBRID/HYBRID SYSTEM
3–14
PCU
COMPONENT LOCATOR
EN01E03ZZZ040402004001
Tightening torque Unit: Nm {kgfcm, lbfft}
A 115 {1,173, 84.8}
A
A
SHTS03ZZZ0400008

16. HYBRID/HYBRID SYSTEM 3–15
1 Service hole cover 3 Front panel
2 Clip
1
2
3
SHTS03ZZZ0400009

17. HYBRID/HYBRID SYSTEM
3–16
Tightening torque Unit: Nm {kgfcm, lbfft}
1 Inverter terminal cover
A 9 {92, 6.6}
1
A
SHTS03ZZZ0400010

18. HYBRID/HYBRID SYSTEM 3–17
Tightening torque Unit: Nm {kgfcm, lbfft}
1 Motor cable
A 7.2-10.8 {73-110, 5.3-8.0} B 9 {92, 6.6}
A
A
B
B
1
SHTS03ZZZ0400011

19. HYBRID/HYBRID SYSTEM
3–18
REPLACEMENT
EN01E03ZZZ040402004002
REMOVING THE PCU
1. DISCONNECTING THE AUXILIARY BATTERY.
(1) Disconnect the auxiliary battery negative terminal.
2. REMOVING THE SERVICE PLUG.
Reference: HYBRID, HYBRID SYSTEM, SERVICE PLUG,
REPLACEMENT, REMOVING THE SERVICE PLUG (Page 3-12)
3. DISCONNECTING THE MOTOR CABLE AND 24V POWER
CABLE.
(1) Unfasten clips (4 pcs.) to remove the under cover service
hole cover.
(2) Remove the bolts (4 pcs.) and remove the inverter terminal
cover.
SHTS03ZZZ0400012
SHTS03ZZZ0400013

20. HYBRID/HYBRID SYSTEM 3–19
(3) Remove bolts (6 pcs.) and detach the motor cable.
4. DISCONNECTING THE CONNECTOR.
(1) Unfasten the clips (2 pcs.) and remove the front panel.
(2) Disconnect the connectors (2 locations).
TERMINAL SIDE
CABLE SIDE
SHTS03ZZZ0400014
SHTS03ZZZ0400015
SHTS03ZZZ0400016

21. HYBRID/HYBRID SYSTEM
3–20
5. REMOVING THE PCU.
(1) Set the engine lifter on the PCU.
(2) Remove the nuts (6 pcs.) to remove the PCU.
SHTS03ZZZ0400017

22. HYBRID/HYBRID SYSTEM 3–21
MOUNTING THE PCU
1. MOUNTING THE PCU.
(1) Set the engine lifter on the PCU.
(2) Mount the PCU using the nuts (6 pcs.).
Tightening Torque:
115 N·m {1,173 kgf·cm, 84.8 lbf·ft}
2. CONNECTING THE CONNECTOR.
(1) Connect the connectors (2 locations).
(2) Mount the front panel using the clips.
SHTS03ZZZ0400018
SHTS03ZZZ0400019
SHTS03ZZZ0400020

23. HYBRID/HYBRID SYSTEM
3–22
3. CONNECTING THE MOTOR CABLE AND 24V POWER CABLE.
(1) Connect the motor cable using bolts (6 pcs.).
Tightening Torque:
9 N·m {92 kgf·cm, 6.6 lbf·ft}
(Cable side)
7.2-10.8 N·m {73-110 kgf·cm, 5.3-8.0 lbf·ft}
(Terminal side)
(2) Mount the inverter terminal cover with the bolts (4 pcs.)
Tightening Torque:
9 N·m {92 kgf·cm, 6.6 lbf·ft}
(3) Fasten clips (4 pcs.) to mount the under cover service hole
cover.
4. MOUNTING THE SERVICE PLUG.
Reference: HYBRID, HYBRID SYSTEM, SERVICE PLUG,
REPLACEMENT, MOUNTING THE SERVICE PLUG (Page 3-13)
5. CONNECTING THE AUXILIARY BATTERY.
(1) Connect the negative battery terminal of the auxiliary battery.
TERMINAL SIDE
CABLE SIDE
SHTS03ZZZ0400021
SHTS03ZZZ0400022
SHTS03ZZZ0400023

24. HYBRID/HYBRID SYSTEM 3–23
HV BATTERY
COMPONENT LOCATOR
EN01E03ZZZ040402003001
*: Nonreusable part
Tightening torque Unit: Nm {kgfcm, lbfft}
1 HV battery 3 Under cover
2 Clip* 4 Clip
A 31 {316, 22.9} B 13 {133, 9.6}
1
2
2
2
3
4
4
A
A
A
A
B
SHTS03ZZZ0400024

25. HYBRID/HYBRID SYSTEM
3–24
Tightening torque Unit: Nm {kgfcm, lbfft}
1 Terminal cover
A 9 {92, 6.6}
1
A
SHTS03ZZZ0400025

26. Thank you very much for
your reading. Please Click
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MANUAL. NO WAITING
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27. HYBRID/HYBRID SYSTEM 3–25
REPLACEMENT
EN01E03ZZZ040402003002
REMOVING THE HV BATTERY ASSEMBLY
1. REMOVING THE PCU
Reference: HYBRID, HYBRID SYSTEM, PCU, REPLACEMENT,
REMOVING THE PCU (Page 3-18)
2. DISCONNECTING THE HARNESS.
(1) Disconnect the connector clamp and connector.
(2) Unfasten the nuts (4 pcs.) and remove the terminal cover.
(3) Unfasten the nuts (2 pcs.) to disconnect the harness.
(4) Disconnect the hose clamp of the snorkel hose.
(5) Disconnect the grommets (3 locations).
SHTS03ZZZ0400026
SHTS03ZZZ0400027
SHTS03ZZZ0400028

28. HYBRID/HYBRID SYSTEM
3–26
3. REMOVING THE UNDER COVER.
(1) Remove the bolts (3 pcs.) and clips (10 pcs.).
(2) Pull the under cover to the front, and remove the clips (5
pcs.) and under cover.
NOTICE
Clips (5 pcs.) inside the under cover are not reusable.
4. REMOVING THE BOTTOM OF PCU.
(1) Unfasten the bolts (10 pcs.) and remove the bottom of PCU.
5. REMOVING THE HV BATTERY COOLING FAN.
Reference: HYBRID, HYBRID SYSTEM, HV BATTERY COOL-
ING FAN, REPLACEMENT, REMOVING THE HV BATTERY
COOLING FAN (Page 3-31)
6. REMOVING THE HV BATTERY ECU.
Reference: HYBRID, HYBRID SYSTEM, HV BATTERY ECU,
REPLACEMENT, REMOVING THE HV BATTERY ECU (Page 3-
35)
7. REMOVING THE SYSTEM MAIN RELAY JUNCTION BLOCK.
Reference: HYBRID, HYBRID SYSTEM, SYSTEM MAIN RELAY
JUNCTION BLOCK, REPLACEMENT, REMOVING THE SYS-
TEM MAIN RELAY JUNCTION BLOCK (Page 3-39)
UNDER COVER
SHTS03ZZZ0400029
HV BATTERY
ASSEMBLY
PCU LOWER
SHTS03ZZZ0400030

29. HYBRID/HYBRID SYSTEM 3–27
MOUNTING THE HV BATTERY ASSEMBLY
1. MOUNTING THE SYSTEM MAIN RELAY JUNCTION BLOCK.
Reference: HYBRID, HYBRID SYSTEM, SYSTEM MAIN RELAY
JUNCTION BLOCK, REPLACEMENT, MOUNTING THE SYS-
TEM MAIN RELAY JUNCTION BLOCK (Page 3-40)
2. MOUNTING THE HV BATTERY ECU.
Reference: HYBRID, HYBRID SYSTEM, HV BATTERY ECU,
REPLACEMENT, MOUNTING THE HV BATTERY ECU (Page 3-
37)
3. MOUNTING THE HV BATTERY COOLING FAN.
Reference: HYBRID, HYBRID SYSTEM, HV BATTERY COOL-
ING FAN, REPLACEMENT, MOUNTING THE HV BATTERY
COOLING FAN (Page 3-32)
4. MOUNTING THE BOTTOM OF PCU.
(1) Mount the bottom of PCU with the bolts (10 pcs.).
Tightening Torque:
31 N·m {316 kgf·cm, 22.9 lbf·ft}
5. MOUNTING THE UNDER COVER.
(1) Mount the under cover using new clips (5 pcs.).
(2) Mount the bolts (3 pcs.) and clips (10 pcs.).
Tightening Torque:
13 N·m {133 kgf·cm, 9.6 lbf·ft}
6. CONNECTING THE HARNESS.
(1) Connect the grommets (3 locations).
(2) Connect the harness using the nuts (2 pcs.).
Tightening Torque:
7.2-10.8 N·m {73-110 kgf·cm, 5.3-8.0 lbf·ft}
(3) Connect the snorkel hose with clamps.
HV BATTERY
ASSEMBLY
PCU LOWER
SHTS03ZZZ0400031
UNDER COVER
SHTS03ZZZ0400032
SHTS03ZZZ0400033

30. HYBRID/HYBRID SYSTEM
3–28
(4) Mount the terminal cover with the nuts (4 pcs.).
Tightening Torque:
9 N·m {92 kgf·cm, 6.6 lbf·ft}
(5) Connect the connector clamp and connector.
7. MOUNTING THE PCU.
Reference: HYBRID, HYBRID SYSTEM, PCU, REPLACEMENT,
MOUNTING THE PCU (Page 3-21)
SHTS03ZZZ0400034
SHTS03ZZZ0400035