Hino S5-LJ05E04A Instruction manual

FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for 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.
FOREWORD.fm 1 ページ ２０１２年１１月２８日 水曜日 午後３時３５分
MENU

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular truck.
CHAPTER
MANUAL NO. S5-LJ05E04A (U.S.A.), S5-LJ05E05A (CANADA)
MODEL J05E
GENERAL INTRODUCTION 1-001
STANDARD VALUE 2-001
REQUIRED ITEMS 3-001
MOUNTING AND DISMOUNTING THE ENGINE 5-001
ENGINE CONTROL 6-001
FUEL SYSTEM 7-001
EMISSION CONTROL 8-001
INTAKE 9-001
ENGINE MECHANICAL 10-001
EXHAUST 11-001
COOLING 12-001
LUBRICATION 13-001
STARTING/CHARGING 16-001
TURBOCHARGER 17-001
FOREWORD.fm ページ ２０１２年１１月２８日 水曜日 午後３時３５分

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
INDEX_EN.fm 1 ページ ２０１２年１１月１９日 月曜日 午前９時４６分

INDEX: ENGINE GROUP 2/2
ENGINE PTO
(POWER TAKE-OFF)
INDEX_EN.fm ページ ２０１２年１１月１９日 月曜日 午前９時４６分

GENERAL INTRODUCTION 1–1
GENERAL INTRODUCTION
1-001
1
HOW TO IDENTIFY VEHICLE TYPE ...........................1-2
VEHICLE MODEL ...................................................1-2
VEHICLE IDENTIFICATION NUMBER (VIN)
STRUCTURE ..........................................................1-3
APPEARANCE OF VEHICLE ......................................1-4
APPEARANCE OF VEHICLE .................................1-4
SAFETY INSTRUCTIONS AND READINESS
TO WORK.....................................................................1-5
WARNING ...............................................................1-5
IDENTIFICATION INFORMATION ..........................1-9
SAFETY INSTRUCTIONS FOR WORK................1-12
INTRODUCTION TO WORKSHOP MANUAL.......1-15
TIGHTENING OF BOLTS AND NUTS ..................1-19
HANDLING OF LIQUID GASKET .........................1-29
GLOSSARY................................................................1-30
DEFINITION OF ABBREVIATION
IN THIS MANUAL..................................................1-30
LUBRICANTS ............................................................1-36
RECOMMENDED LUBRICANTS .........................1-36

GENERAL INTRODUCTION1–2
GENERAL INFORMATION
HOW TO IDENTIFY VEHICLE TYPE
VEHICLE MODEL
EN01F01ZZZ000102001001
X
Ԙ
J
ԙ
C
Ԛ
7
ԛ
0
Ԝ
0
ԝԞ
L࡯
ԟ
H
Ԡ
K
ԡ
T
Ԣ
Q
ԣ
M
Ԥ
A
ԥ
3
Ԧ
CLASSIFICATION
REPORTED MODEL
Ԙԙ
㧦ENGINE MODEL
Ԛ
C
㧦VEHICLE MODEL
HEAVY DUTY TRACK
ԛ
㧦CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE
Ԝ
70
71
72
74
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.}
4,400 mm {173 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
K
L
SINGLE CAB VACUUM
SINGLE CAB HYDRAULIC
ԡ
㧦DECK HEIGHT
K
HIGH FLOOR
Ԣ
㧦TRANSMISSION
T
6AT
Ԧ
㧦DECK FORM
3
CHASSIS WITH CAB
Ԥ
㧦ENGINE HORSEPOWER, FUEL
FUEL HORSEPOWER EXHAUST
VERY HIGH US10
DIESEL OIL
M
ԣ
㧦LOADING CAPACITY, GVW, REAR TIRES
ԥ
㧦DESTINATION
DESTINATION
AU.S., CANADA
6.58 t {14,500 lbs}
8.14 t {17,950 lbs}
8.85 t {19,500 lbs}
Q
T
REAR DOUBLE
REAR DOUBLE
J05E-UG (HV)
XF
J05E-TP (Diesel)
XJ
SHTS01ZZZ0000001

GENERAL INTRODUCTION 1–3
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE
EN01F01ZZZ000102001002
WMI VDS CD VIS
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)
JHH KDM2H 5 E K00100
(17)
1
MANUFACTURER ,TYPE
MODEL, CAB TYPE,
WHEEL BASE,
BRAKE SYSTEM
MODEL YEAR
ENGINE MODEL
ASSEMBLY PLANTSERIES
MAKE
CHECK DIGIT
SEQUENTIAL NUMBER
CODE
JHN INCOMPLETE VEHICLE
TYPEMANUFACTURER
HINO MOTORS, LTD.
2AY INCOMPLETE VEHICLE
HINO MOTORS CANADA, LTD.
CODE CODE YEARYEAR
H 2017
J 2018
K 2019
L 2020
M 2021
C 2012 D 2013
E 2014
F 2015
G 2016
CODE
PM Hybrid
APPLICATIONENGINE MODEL
J05E
DM DieselJ05E
CODE
1
1 2
ASSEMBLY PLANT
HINO MOTORS, LTD.
HINO PLANT IN JAPAN
HINO MOTORS, LTD.
Hamura Plant in Japan
3 Canada Plant 4
K
W.V 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
R
S
T
PRODUCTION
CODE CAB TYPE WHEEL BASE BRAKE
SYSTEM
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
3500mm{138 in.} 3500mm{138 in.} 2900mm{114 in.} 2900mm{114 in.} 3800mm{150 in.} 3800mm{150 in.} 3800mm{150 in.} 3800mm{150 in.} 4400mm{173 in.} 4400mm{173 in.} 4400mm{173 in.} 4400mm{173 in.}
XJC700 XJC700 XJC710 XJC720 XJC740 XJC740 XJC720 XJC720 XJC740 XJC720 XJC740
HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC HYDRAULIC
VACUUM VACUUM VACUUM VACUUM VACUUM VACUUM
SHTS01ZZZ0000002

GENERAL INTRODUCTION1–4
APPEARANCE OF VEHICLE
APPEARANCE OF VEHICLE
EN01F01ZZZ000102002001
SHTS01ZZZ0000003

GENERAL INTRODUCTION 1–5
SAFETY INSTRUCTIONS AND READINESS TO WORK
WARNING
EN01F01ZZZ000102003001
GENERAL PRECAUTIONS
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,
radiator, muffler, exhaust pipe and tail pipe.
•Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.
•Take utmost care when working on the battery. It contains corrosive sulfuric acid.
•Large electric current flows through the battery cable and starter cable. Be careful not to cause a short
which can result in personal injury and/or property damage.
•Read carefully and observe the instructions specified on the jack before using it.
•Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under
a vehicle supported only by a jack.
•If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is
firmly applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the
engine.
•Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.
•Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts
when the engine is running.
•Be careful not to damage lines and hoses by stepping or holding your feet on them.
•Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can
cause personal injury.

GENERAL INTRODUCTION1–6
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
SHTS01ZZZ0000004

GENERAL INTRODUCTION 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 con-
tact 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 vertical
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 vacuum 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.
CLEAN AIR ACT
1. 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 pro-
cess of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reassembly,
and also may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine.
Any deviation from the provisions contained in this section is a prohibited act under section 203(a) (3) of the Clean Air
Act (42 U.S.C. 7522(a) (3)).
(1) When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical basis
for knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configuration (i.e., tol-
erances, calibrations, specifications) and the model year(s) of the resulting engine configuration must be identified. A
reasonable basis would exist if:
a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and
function of motor vehicle engines would reasonably believe that the parts perform the same function with respect
to emissions control as the original parts; and
b. Any parameter adjustment or design element change is made only:
•In accordance with the original engine manufacturer's instructions; or
•Where data or other reasonable technical basis exists that such parameter adjustment or design element change,
when performed on the engine or similar engines, is not expected to adversely affect in-use emissions.
(2) When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a con-
figuration of the same or later model year as the original engine. When an engine is being replaced, the replacement
engine must be an engine of (or rebuilt to) a configuration of the same or later model year as the original engine.

GENERAL INTRODUCTION1–8
(3) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or reset
without diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are
installed to satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface. Diagnostic
systems must be free of all such codes when the rebuilt engine is returned to service. Such signals may not be ren-
dered inoperative during the rebuilding process.
(4) When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt engine,
all critical emissions-related components listed in § 86.004-25(2) not otherwise addressed by paragraphs (1) through
(3) of this section must be checked and cleaned, adjusted, repaired, or replaced as necessary, following manufac-
turer recommended practices.
(5) Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The
records shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the
engine and emissions-related control components including a listing of parts and components used, engine parame-
ter adjustments, emissions-related codes or signals responded to and reset, and work performed under paragraph
(4) of this section.
a. Parties may keep records in whatever format or system they choose as long as the records are understandable
to an EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an understandable
format when requested.
b. Parties are not required to keep records of information that is not reasonably available through normal business
practices including information on activities not conducted by themselves or information that they cannot reason-
ably access.
c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual engine
rebuilt in cases where those rebuild practices are followed routinely.
d. Records must be kept for a minimum of two years after the engine is rebuilt.
2. Maintenance instructions.
§ 86.010-38
(1) For each new diesel-fueled engine subject to the standards prescribed in § 86.007-11, as applicable, the manufac-
turer shall furnish or cause to be furnished to the ultimate purchaser a statement that
"This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for highway
diesel fuel, including a 15 ppm sulfur cap)."

GENERAL INTRODUCTION 1–9
IDENTIFICATION INFORMATION
EN01F01ZZZ000102003002
1. VEHICLE IDENTIFICATION NUMBER
(1) 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
(2) VIN
See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE
on the following page.
(3) PRODUCTION CODE AND VEHICLE COMPONENTS
A
B
SHTS01ZZZ0000010
MODEL (CLASS) HINO 155h (4) HINO 155 (4) HINO 195h (5) HINO 195 (5)
PRODUCTION CODE
XFC710
XFC720
XFC740
XJC700
XJC710
XJC720
XJC740
XFC710
XFC720
XFC740
XJC700
XJC710
XJC720
XJC740
TRANSMISSION SERIES A465
TRANSMISSION RATIO
1st 3.742
2nd 2.003
3rd 1.343
4th 1.000
5th 0.773
6th 0.634
REAR AXLE SERIES SH13
REAR AXLE RATIO 4.333 / 4.625 / 4.875 / 5.142 / 5.571 / 5.857
SERVICE BRAKE Vacuum Hydraulic
PARKING BRAKE ACTING ON DIFFERENTIAL OUTPUT SHAFT
SUSPENSION LEAF

GENERAL INTRODUCTION1–10
2. 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
and month, and noise emission applicable to medium and heavy
trucks in conformity with U.S. EPA Regulations are displayed.
3. ENGINE SERIAL NUMBER
(1) The engine serial number is stamped on the cylinder block, as
shown in the illustration.
A: J05E
4. TRANSMISSION SERIAL NUMBER
(1) The transmission serial number is stamped on the transmission,
as shown in the illustration.
A: A465
5. CLEAN IDLE CERTIFIED LABEL FOR U.S.
•Make sure that the following clean engine idling certified label is
affixed to the outside of the left door. By the CARB below, the
label must be affixed there to prove that the new vehicle with die-
sel engine manufactured from Jan., 2008 conforms to this low.
FOR ALL MODELS
SHTS01ZZZ0000011
A
SHTS01ZZZ0000012
A
SHTS01ZZZ0000013
SHTS01ZZZ0000014
CARB § 1956.8. Exhaust Emission Standard and Test
Procedure (a) (b) Heavy-Duty Diesel Engine Idling
Requirements

GENERAL INTRODUCTION 1–11
6. EXEMPTION LABEL FOR US GHG REGULATION
HINT
Exemption label fuel economy comes in paste right side of the
front passenger seat.
However, this label is limited to one year.
EXEMPTION LABEL
SHTS01ZZZ0000015

GENERAL INTRODUCTION1–12
SAFETY INSTRUCTIONS FOR WORK
EN01F01ZZZ000102003003
PRECAUTIONS
1. SAFETY INSTRUCTIONS FOR HANDLING ELECTRICAL SYSTEMS
(1) 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 discon-
nect 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" position. Otherwise, the vehicle
data will not be recorded on ECU properly and DCU will not complete working properly, which may result in
the malfunction of DPR system and DEF-SCR system.
•The MIL (malfunction indicator light) may come on when the starter key is turned to "ON" position again,
even if you wait for at least ten minutes before disconnecting the battery terminals from the battery after the
starter key is turned to "LOCK" position. In this case, use HINO-DX to clear the DTC (P204F and P068A), to
turn off the MIL and to conduct DPR regeneration manually.
a. Before electrical system work, remove the cable from the minus terminal of the battery in order to avoid burning
caused by short-circuiting.
b. To remove the battery cable, fully release the nut to avoid damage to the battery terminal. Never twist the termi-
nal.
(2) Handling of electronic parts
a. Never give an impact to electronic parts of a computer or relay.
b. Keep electronic parts away from high temperatures and humidity.
c. Never splash water onto electronic parts in washing the vehicle.
d. Do not remove the harness connector, electric component box, and cover except for repair and inspection.
If removal is necessary, pay attention that water and foreign matters do not attach or enter to the connector, ter-
minals, electric component box, and cover.
In restoration, make sure there is no attachment or entry of water and foreign matters and mount them properly,
because it causes degradation of waterproof function.
SHTS01ZZZ0000016
LOOSEN
INCORRECT
SHTS01ZZZ0000017

GENERAL INTRODUCTION 1–13
(3) Handling of wire harness
a. Perform marking on a clamp and a clip and secure then in original position so that the wire harness will not inter-
fere with the end and acute angle section of the body and a bolt.
b. To attach a part, take care not to bite the wire harness.
(4) Handling of connectors
a. 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.
b. Pull off a lockable connector after unlocking.
c. When connecting a lockable connector, make sure to insert a lockable connector until it makes a click sound.
d. When inserting a test lead, insert it from the back of a connector.
e. If it is difficult to insert a test lead from the back of a connector, make and use an inspection harness.
INCORRECT
INCORRECT
INCORRECT
SHTS01ZZZ0000018
INCORRECT
INCORRECT
CORRECT
SHTS01ZZZ0000019

GENERAL INTRODUCTION1–14
(5) Installation of battery disconnect switch
! WARNING
•Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF-
SCR (DCU) may damage or result in the malfunction of DEF-SCR system.
•Be sure to read and follow the procedures and instructions on the service bulletin before the installation of
the battery disconnect switch.
(6) Handling of battery disconnect switch
! WARNING
•Wait for at least ten minute before using the battery disconnect switch after the starter key is turned to
"LOCK" position.
Otherwise, the vehicle data will not be recorded on ECU properly, which may result in the malfunction of DPR
system.
2. 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. Consequently, the following precautions are always to be taken during welding.
(1) Disconnect the earth terminal of the battery at the frame fitment and earth the welding equipment securely to the
frame itself. (Do not fit the welding equipment earth to such things as the tire rims, brake pipes or fuel pipes and leaf
spring, etc.)
a. Turn the starter switch off.
b. Disconnect the battery’s negative terminal of the battery.
c. Earth welding equipment securely, near to the area to be welded.
d. Put back battery negative ground as original condition.
e. Finally check the functioning of all instruments.
(2) In order to prevent damage to ancillary equipment components from sparks during welding, take steps such as put-
ting fire-resistant covers over things like the engine, meters, steering wheel, hoses, leaf spring and tires.
SHTS01ZZZ0000020
Connect the ground of the ARC welding
machine near the place on the frame to be
welded but not connect it to plated parts such
as fuel pipes, brake pipes and leaf spring.
Disconnect the ground terminal for
battery at the connecting point on the
frame and disconnect the ground for
computer as well.
CHASSIS FRAME
CHASSIS FRAME
BATTERY
ALTERNATOR
ETC.
COMPUTER
ARC WELDING
MACHINE

GENERAL INTRODUCTION 1–15
INTRODUCTION TO WORKSHOP MANUAL
EN01F01ZZZ000102003004
GENERAL
1. SCOPE OF REPAIR DESCRIPTIONS
(1) There are three major processes in repair work: i.e. "troubleshooting," "removal/installation, replacement, overhaul,
assembly, inspection and adjustment" and "final inspection".
(2) This document covers only the first process (troubleshooting) and the second process (removal/installation, replace-
ment, overhaul, assembly, inspection and adjustment) and omits the third process (final inspection).
(3) The element tasks listed below are omitted from this document but must be done in actual repair work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual check
2. STANDARD VALUE
(1) Standard values, limits, required actions and tightening torques are tabulated in this document.
3. REQUIRED ITEMS
(1) Special tools, tools, instruments, oil and grease and other items to be prepared before starting work are listed in the
section titled "REQUIRED ITEMS". Note that general tools, jacks, rigid racks and other required items supposedly
available at a general service shop are omitted from the list.
4. REPRESENTATION OF SECTION AND TITLE
(1) Under a title containing a system name such as "ENGINE CONTROL SYSTEM", the descriptions cover "INSPEC-
TION", "ADJUSTMENT", "REPLACEMENT" and "OVERHAUL" of components.
(2) Under a title containing a part name such as "AIR COMPRESSOR ASSEMBLY", the descriptions cover "REPLACE-
MENT" and "OVERHAUL".

GENERAL INTRODUCTION1–16
INTRODUCTION TO DESCRIPTIONS
1. COMPONENT LOCATOR
☆: The ID number is given to required items for the purpose of preparing electronic data and is not needed
in repair work.
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
Part name table
Tightening torque table
Tightening torque
Alphabetical mark
SHTS01ZZZ0000021