This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. It contains safety instructions and identifies relevant manuals for vehicle components and systems. Sections cover the engine, hybrid system, transmission, and other vehicle systems, with repair and inspection procedures, component locations, and specifications. Tightening torques and precautions are included to ensure safe and proper repair work.
2015 hino 155h series truck service repair manualfusjejfjskekme
This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h series equipped with a J05E engine. It contains safety instructions and identifies vehicle types by model, engine, dimensions, suspension type, and other specifications. Additional reference manuals are listed for components and systems.
2013 hino 195h series truck service repair manualfujsjekfkkseme
This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. General safety precautions for working on vehicles include wearing protective equipment, applying the parking brake and blocking wheels before starting work. The manual also outlines identification information for vehicles and safety instructions for tilting and lowering the cab.
2012 hino 195h series truck service repair manualfujsjefjskekmme
This document provides safety instructions and readiness guidelines for working on Hino trucks. It advises wearing protective equipment like safety glasses and removing loose clothing and jewelry before starting work. Additional guidelines include setting the parking brake and blocking the wheels, turning off the engine, and taking caution around hot or electrical components. Read and follow all warnings, cautions and instructions in the manuals carefully to prevent injury or damage.
2002 hino sg series truck service repair manualjfdjjskekksemm
This document is a workshop manual for 2002 Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these trucks. The manual covers the chassis, body, electrical systems, engine, transmission, brakes and other components. It aims to help owners and technicians service the trucks properly to ensure safe, smooth and economical operation over many years. Cautions are provided regarding safety when working on the vehicles.
2015 hino 195 series truck service repair manualfjjskeknjufksemm
This workshop manual provides repair and maintenance procedures for Hino Trucks models 155, 155h, 195, 195h equipped with the J05E engine, with safety warnings and instructions. It includes an introduction, lubricant recommendations, and sections covering the engine, hybrid system, transmission, and other vehicle systems, with specifications, troubleshooting and repair guides. Additional workshop manuals are referenced for vehicle components and electrical systems.
2015 hino 155h series truck service repair manualfjjskeknjufksemm
This document provides safety instructions and an overview of vehicle identification for working on Hino trucks. It warns technicians to take precautions like wearing protective equipment, parking securely, and avoiding hot components. The vehicle model is identified by codes for items like the engine, cab dimensions, suspension, and destination. Technicians are advised to reference specific chapter warnings and carefully tilt or lower the cab with assistance if needed.
2015 hino 155 series truck service repair manualfjjksekksemm
This document provides safety instructions and an overview of vehicle identification for working on Hino trucks. It outlines general precautions like wearing protective equipment and blocking wheels when working under a vehicle. It also describes how to identify a vehicle's model and specifications based on its vehicle identification number. Proper procedures are outlined for tilting and lowering the cab to perform maintenance.
2015 hino 195h series truck service repair manualfjjskekskem
This document provides safety instructions and an overview of vehicle identification for working on Hino trucks. It warns technicians to take precautions like wearing protective equipment, parking securely, and avoiding hot components. Identification information includes how to read vehicle identification numbers and model codes. Technicians should follow all warnings, cautions and notices in the manuals.
2015 hino 155h series truck service repair manualfusjejfjskekme
This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h series equipped with a J05E engine. It contains safety instructions and identifies vehicle types by model, engine, dimensions, suspension type, and other specifications. Additional reference manuals are listed for components and systems.
2013 hino 195h series truck service repair manualfujsjekfkkseme
This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. General safety precautions for working on vehicles include wearing protective equipment, applying the parking brake and blocking wheels before starting work. The manual also outlines identification information for vehicles and safety instructions for tilting and lowering the cab.
2012 hino 195h series truck service repair manualfujsjefjskekmme
This document provides safety instructions and readiness guidelines for working on Hino trucks. It advises wearing protective equipment like safety glasses and removing loose clothing and jewelry before starting work. Additional guidelines include setting the parking brake and blocking the wheels, turning off the engine, and taking caution around hot or electrical components. Read and follow all warnings, cautions and instructions in the manuals carefully to prevent injury or damage.
2002 hino sg series truck service repair manualjfdjjskekksemm
This document is a workshop manual for 2002 Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these trucks. The manual covers the chassis, body, electrical systems, engine, transmission, brakes and other components. It aims to help owners and technicians service the trucks properly to ensure safe, smooth and economical operation over many years. Cautions are provided regarding safety when working on the vehicles.
2015 hino 195 series truck service repair manualfjjskeknjufksemm
This workshop manual provides repair and maintenance procedures for Hino Trucks models 155, 155h, 195, 195h equipped with the J05E engine, with safety warnings and instructions. It includes an introduction, lubricant recommendations, and sections covering the engine, hybrid system, transmission, and other vehicle systems, with specifications, troubleshooting and repair guides. Additional workshop manuals are referenced for vehicle components and electrical systems.
2015 hino 155h series truck service repair manualfjjskeknjufksemm
This document provides safety instructions and an overview of vehicle identification for working on Hino trucks. It warns technicians to take precautions like wearing protective equipment, parking securely, and avoiding hot components. The vehicle model is identified by codes for items like the engine, cab dimensions, suspension, and destination. Technicians are advised to reference specific chapter warnings and carefully tilt or lower the cab with assistance if needed.
2015 hino 155 series truck service repair manualfjjksekksemm
This document provides safety instructions and an overview of vehicle identification for working on Hino trucks. It outlines general precautions like wearing protective equipment and blocking wheels when working under a vehicle. It also describes how to identify a vehicle's model and specifications based on its vehicle identification number. Proper procedures are outlined for tilting and lowering the cab to perform maintenance.
2015 hino 195h series truck service repair manualfjjskekskem
This document provides safety instructions and an overview of vehicle identification for working on Hino trucks. It warns technicians to take precautions like wearing protective equipment, parking securely, and avoiding hot components. Identification information includes how to read vehicle identification numbers and model codes. Technicians should follow all warnings, cautions and notices in the manuals.
2013 hino 155h series truck service repair manualufjjsjefkkekmme
This document provides safety instructions for working on Hino trucks. It warns technicians to take precautions like wearing protective equipment, removing jewelry, and securing long hair. It also instructs them to engage the parking brake and block the wheels when working under the vehicle. Technicians are advised to avoid hot surfaces on the engine and exhaust, and take care when working around batteries, as they contain acid. The document emphasizes the importance of carefully reading jack instructions and using safety stands whenever working under a raised vehicle.
2013 hino 155h series truck service repair manualfjjsjefkskemme
This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. General safety precautions for working on vehicles include wearing protective equipment, applying the parking brake and blocking wheels before starting work. The manual also outlines vehicle identification methods and provides lubrication recommendations.
2013 hino 155 series truck service repair manualfjjsjefkskemme
This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. General safety precautions for working on vehicles include wearing protective equipment, blocking wheels, and avoiding moving parts when the engine is running. The document also outlines vehicle identification methods and cautions for tilting and lowering the cab.
2013 hino 195 series truck service repair manualufjjsjefkkekmme
This document provides safety instructions for working on Hino trucks. It warns technicians to take precautions like wearing protective equipment, removing jewelry, securing long hair, applying the parking brake and chocking the wheels when working under the vehicle. Technicians are advised to avoid hot parts on the engine, not smoke while refueling, use caution when working on the battery due to sulfuric acid, and always support the vehicle with safety stands in addition to a jack. Proper maintenance following the instructions in this manual is recommended to prevent injury and vehicle malfunctions.
2013 hino 155 series truck service repair manualfujsjefjskekmme
This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. General safety precautions for working on vehicles include wearing protective equipment, applying the parking brake and blocking wheels before starting work. The manual also outlines vehicle identification methods and introduces terminology used in the workshop manuals.
2013 hino 155 series truck service repair manualfujsekfkksemm
This workshop manual provides information for repairing Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. It contains safety instructions, vehicle identification information, and references to other relevant manuals. Technicians are advised to take precautions to avoid injury when working and carefully follow instructions.
2013 hino 155h series truck service repair manualfhsjejfksemm
This workshop manual provides information for repairing Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. It contains safety instructions, vehicle identification information, and references to other relevant manuals. Technicians are advised to take precautions to avoid injury when working and carefully follow instructions.
2013 hino 195h series truck service repair manualfujsefkskemm
This workshop manual provides information for repairing Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. It contains safety instructions, vehicle identification information, and references to other relevant manuals. Technicians are advised to take precautions to avoid injury when working and carefully follow instructions for any repairs.
2013 hino 195 series truck service repair manualfhsjejfksemm
This workshop manual provides repair procedures for Hino Trucks models 155, 155h, 195, 195h equipped with a J05E engine. It contains safety instructions for working on vehicles and identifies vehicle types by model, engine, specifications and other details. Tables list applicable chapter sections for different vehicle components and systems.
2012 hino 155 series truck service repair manualfjjskksekmemm
This document provides safety instructions and readiness information for working on Hino trucks. It warns technicians to take necessary precautions like wearing protective gear, parking the vehicle properly, and avoiding hot or moving parts. Specific cautions are given for tilting and lowering the cab, including ensuring ample space, no obstacles, and that locking mechanisms are fully engaged. Standard terms are defined to indicate hazard levels and provide additional information.
2012 hino 195 series truck service repair manualjfjskeksemm
This document provides safety instructions and guidelines for working on Hino trucks. It warns technicians to take necessary precautions like wearing protective gear, parking the vehicle properly, and avoiding hot or moving parts. Specific cautions are given for tilting and lowering the cab, including ensuring ample space, no obstacles, and that locking mechanisms are securely engaged. Standard terms are defined to indicate hazard levels and importance of following proper procedures.
2012 hino 155h series truck service repair manualjfdjjskfkksmemm
This document provides safety instructions and readiness guidelines for working on Hino trucks. It advises wearing protective equipment like safety glasses and removing loose clothing and jewelry before starting work. Additional guidelines include setting the parking brake and blocking the wheels, turning off the engine, and taking caution around hot or electrical components. Read and follow all warnings, cautions and instructions in the manuals carefully to prevent injury or damage.
2012 hino 195h series truck service repair manualjfdjjskekksemm
This document provides safety instructions and readiness guidelines for working on Hino trucks. It advises wearing protective equipment like safety glasses and removing loose clothing and jewelry before starting work. Additional guidelines include setting the parking brake and blocking the wheels, turning off the engine, and taking caution around hot or electrical components. Read and follow all warnings, cautions and instructions in the manuals carefully to prevent injury or damage.
2012 hino 155h series truck service repair manualfjsjekksemm
This document provides safety instructions for working on Hino trucks. It advises wearing protective equipment like safety glasses and removing loose clothing and jewelry. When working on a vehicle, the parking brake should be applied and the wheels blocked. Smoking and open flames should be avoided when working with flammable fluids. Batteries contain acid and high current flows, so precautions are needed. Jacks and safety stands should also be used carefully per instructions.
2012 hino 195h series truck service repair manualfujsekfkksemm
This document provides safety instructions and guidelines for working on Hino trucks. It emphasizes wearing protective equipment, applying parking brakes, blocking wheels, and taking precautions around hot or moving parts. Specific warnings are given for tilting and lowering the cab, including ensuring adequate space, cooling of parts, keeping others away, and securely locking the cab in position. Readers are advised to consult the owner's manual and follow all warnings and cautions to avoid injury or damage.
2012 hino 155 series truck service repair manualfjsjekksemm
This document provides safety instructions and guidelines for working on Hino trucks. It warns technicians to take necessary precautions like wearing protective gear, applying parking brakes, and avoiding hot or moving components. Specific dangers of tilting and lowering the cab are also outlined, such as ensuring adequate space and that no objects are left underneath. Technicians are advised to consult owners manuals and ask for help if needed to prevent injury while performing maintenance.
2012 hino 155h series truck service repair manualfjskekmsemmwe
This document provides safety instructions and guidelines for working on Hino trucks. It emphasizes wearing protective equipment, applying parking brakes, blocking wheels, and taking precautions around hot or electrical components. Specific warnings are given for tilting and lowering the cab, including ensuring adequate space, cooling of components, and checking for objects underneath. Readers are advised to consult the owner's manual and follow all warnings to avoid injury or damage.
2012 hino 195 series truck service repair manualfjskefksemer
This document provides safety instructions for working on Hino trucks. It advises wearing protective equipment like safety glasses and removing loose clothing and jewelry before starting work. When servicing a vehicle, the parking brake should be applied, the transmission shifted to neutral, and the wheels chocked. Hot components like the engine and exhaust should be avoided to prevent burns. Smoking and improper battery handling are warned against as well. Proper jack usage and safety stands are also recommended.
2002 hino fe series truck service repair manualfjsjekksemm
This document provides information on identifying Hino trucks models FD, FE, FF and SG from 2002. It discusses identifying the vehicle using the vehicle identification number (VIN), which is a 17-digit code providing information on the manufacturer, model, engine, assembly plant and more. It also provides the engine and chassis numbers' locations to further identify the specific vehicle. The document aims to clearly identify Hino truck models and components for maintenance and repair work.
2002 hino fe series truck service repair manualfjskekmsemmwe
This document provides information on identifying Hino trucks models FD, FE, FF, and SG from 2002. It discusses identifying the vehicle using the vehicle identification number (VIN), which is a 17-digit code providing information on the manufacturer, model, engine, assembly plant, and other details. It also provides the engine identification number and chassis number locations to further identify components.
2004 nissan frontier service repair manualfuhsejskekmmm
This document contains a quick reference chart for the 2004 Nissan Frontier equipped with a KA24DE engine. It includes sections with information on engine specifications, tune-up data, transmission specifications, suspension specifications, brake specifications, refill capacities, and more. The document aims to provide technicians with essential technical specifications and repair limit values for servicing the vehicle in an efficient and safe manner.
2003 toyota tundra service repair manualfuhsejskekmmm
This document provides instructions on how to use the service manual for the 2003 Toyota Tundra. It discusses the manual's organization including the index, precautions, troubleshooting tables, preparation sections, repair procedures, references, specifications, cautions, and units of measurement. The repair procedures use a standardized format with illustrations, task headings, and detailed text. The document also provides general repair instructions and identifies vehicle and engine identification locations.
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Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
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1. 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
2. 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
4. 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
6. 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
7. 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
8. GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE1–2
HOW TO IDENTIFY VEHICLE TYPE
HOW TO IDENTIFY VEHICLE TYPE
VEHICLE MODEL
EN01E01ZZZ010102001001
X J C 7 0 0 L H K T Q M A 3
CLASSIFICATIONREPORTED MODEL
J05E-UG (HV)X
X
F
J05E-TP (Diesel)J
ENGINE MODEL
C
VEHICLE MODEL
HEAVY DUTY TRACK
CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE
7 0
7 1
7 2
7 3
CAB WIDTH DRIVE WHEEL BASE
FRAME ASSEMBLY WIDTH
FRAME
FORM
WIDE 2WD MEDIUMOPEN
WIDE 2WD LONGOPEN
WIDE 2WD SUPER LONGOPEN
WIDE 2WD SUPER LONGOPEN
840 mm {33 in.}
2,900 mm {114 in.}
3,500 mm {138 in.}
3,800 mm {150 in.}
4,100 mm {161 in.}
0
TYPE OF SUSPENSION
FRONT RIGID, REAR RIGID
CAB FORM BRAKE TYPE
CAB FORM, BRAKE TYPE
STEERING WHEEL POSITION
L LEFT HAND DRIVE
H
Q
SINGLE CAB VACUUM
CREW CAB VACUUM
C
D
SINGLE CAB HYDRAULIC
CREW CAB HYDRAULIC
DECK HEIGHT
K HIGH FLOOR CAB
TRANSMISSION
T 6AT
DECK FORM
3 CHASSIS WITH CAB
ENGINE HORSEPOWER, FUEL
FUEL HORSEPOWER EXHAUST
VERY HIGH US13 (13OBD)DIESEL OILM
LOADING CAPACITY, GVW, REAR TIRES
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 LONGOPEN 4,400 mm {173 in.}
REAR DOUBLE
REAR DOUBLE
SHTS01ZZZ0100001
9. GENERAL INTRODUCTION/APPEARANCE OF VEHICLE1–4
APPEARANCE OF VEHICLE
APPEARANCE
APPEARANCE OF VEHICLE
EN01E01ZZZ020102003001
SHTS01ZZZ0200001
10. 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. If you have any question about per-
forming maintenance, please consult your Hino dealer.
WARNING
When working on your vehicle, observe the following general precautions to prevent death, personal injury and/
or property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chap-
ter.
• Always wear safety glasses or goggles to protect your eyes.
• Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.
• Bind long hair securely behind the head.
• When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and
block the wheels.
• Always turn off the starter switch to stop the engine, unless the operation requires the engine running.
Removing the key from the switch is recommended.
• To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radia-
tor, muffler, exhaust pipe and tail pipe.
• Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.
• Take utmost care when working on the battery. It contains corrosive sulfuric acid.
• Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which
can result in personal injury and/or property damage.
• Read carefully and observe the instructions specified on the jack before using it.
• Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a
vehicle supported only by a jack.
• If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly
applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.
• Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.
• Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when
the engine is running.
• Be careful not to damage lines and hoses by stepping or holding your feet on them.
• Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can
cause personal injury.
11. GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–6
PRECAUTIONS IN TILTING AND LOWERING THE CAB
! WARNING
Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may
result in death, serious injury and/or property damage.
• Park the vehicle on a level place and ensure ample space around the cab before tilting the cab.
• Apply the parking brake firmly and place the gearshift lever in “N” position (“P” position if your vehicle is
equipped with automatic transmission).
• Stop the engine and block the wheels.
• Remove any articles in or over the cab and close the doors firmly.
• Make sure there is no one in or around the cab and there are no obstacles in front of the vehicle or above the
cab.
• The catch (E), stopper (F), stay (G) and other parts such as the engine, radiator, and exhaust pipe can be very
hot while your vehicle is operated. Be sure to confirm they have been cooled down before you start working
under the cab.
• Never raise or lower the cab only by yourself if your cab is equipped with heavy component such as a roof rack.
• Never put your body under the cab while raising or lowering the cab.
• Make sure the cab stopper stay is securely locked by the catch (E) and raise the stopper (F) to lock the catch (E)
completely after raising the cab.
• Before lowering the cab, make sure that any object such as hand tools, gloves or cloth are not left under the
cab.
• Make sure the handle (B) is caught by the catch after lowering the cab.
Read the Owner’s manual for details.
DEFINITION OF SAFETY TERMS
Indicates an extremely hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a potential hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a hazardous situation if proper procedures are not followed and could result
in serious injury or damage to parts/equipment.
Indicates the need to follow proper procedures and to pay attention to precautions so
that efficient service is provided.
Provides additional information to help you to perform the repair efficiently.
B
F
E
G
SHTS01ZZZ0300001
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. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with
the bumper.
1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle
shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle
lubricant and entry of dirt or foreign matter.
(2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the
frame.
(3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and ver-
tical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in
towing a vehicle trapped in a gutter.
(4) Keep the gear shift lever in Neutral.
(5) Make sure that the starter switch is kept in the "ON" position, if the engine is not running.
(6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vac-
uum will be available for the brake. This is dangerous, as the brake system does not function if the engine is not
running.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually
hard to turn, making it impossible to control the vehicle.
(7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
(8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.
2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck
designed for that purpose.
(1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect
the transmission and differential gears from being damaged. The hub openings should be covered to prevent the
loss of axle lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed
for vehicles equipped with either manual or automatic transmission, and for even short distance towing. After
being towed, check and refill the rear axle housing with lubricant if necessary.
(2) Rear end towing
When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight-
ahead position.
13. HYBRID/HYBRID SYSTEM 3–11
SERVICE PLUG
COMPONENT LOCATOR
EN01E03ZZZ040402007001
Tightening torque Unit: Nm {kgfcm, lbfft}
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
14. HYBRID/HYBRID SYSTEM3–12
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
15. 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
19. HYBRID/HYBRID SYSTEM 3–17
Tightening torque Unit: Nm {kgfcm, lbfft}
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
20. HYBRID/HYBRID SYSTEM3–18
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
21. 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
22. HYBRID/HYBRID SYSTEM3–20
5. REMOVING THE PCU.
(1) Set the engine lifter on the PCU.
(2) Remove the nuts (6 pcs.) to remove the PCU.
SHTS03ZZZ0400017
23. 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
24. HYBRID/HYBRID SYSTEM3–22
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
25. HYBRID/HYBRID SYSTEM 3–23
HV BATTERY
COMPONENT LOCATOR
EN01E03ZZZ040402003001
*: Nonreusable part
Tightening torque Unit: Nm {kgfcm, lbfft}
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
26. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
28. 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
29. HYBRID/HYBRID SYSTEM3–26
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
30. 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
31. HYBRID/HYBRID SYSTEM3–28
(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