PDF Workshop Manual 2020 Hino Truck XL Series - 23 MB
This workshop manual provides complete service and repair information for the 2020 Hino XL Series trucks.
It is the same manual used by dealership technicians, offering in-depth instructions for diagnostics, disassembly, and repair.
From the engine to the chassis and electrical systems, this guide covers every aspect of the vehicle in great detail.
Keep your Hino truck performing at its best with the professional-grade procedures outlined in this manual.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
FOREWORD 2
2020 XL Chassis 1_DT_ST_ABS 3
2020 XL Chassis 2_RA 498
2020 XL Chassis 3_EWD_SUSP_WT 1063
2020 XL ENGINE 1544
2020 XL Troubleshooting 1_ELEC_ENG 2110
2020 XL Troubleshooting 2_ENG 2742
2020 XL Troubleshooting 3_ENG 3267
2020 XL Troubleshooting 4_CAN_DEF_VCS_SUSP 3794
--- Page 3 ---
CL02–4 CLUTCH MAIN UNIT (EATON SOLO 1402)
Symptom Possible cause Remedy/Prevention
Noisy clutch. Release bearing worn or dried. Replace release bearing.
Pilot bearing worn or dried. Replace pilot bearing.
Clutch disc distorted or warped. Replace clutch disc.
Flywheel housing misalignment. Replace flywheel housing.
Transmission input shaft or clutch disc Clean and lubricate or replace.
spline worn.
Insufficient lubrication of pedal and its Lubricate.
accessories.
Insufficient lubrication of release shaft Lubricate.
and release bearing hub.
Transmission input shaft retainer Clean or replace if rusted.
rusted or soiled.
Clutch pedal free-play incorrectly Adjust free-Play.
adjusted.
Clutch pedal cannot be depressed. Clutch control incorrectly adjusted. Adjust clutch control.
Insufficient lubricant release shaft and Lubricate.
release bearing hub.
Change in clutch pedal give. Air trapped in clutch fluid. Bleed air.
--- Page 4 ---
TR06–2 TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION)
TRANSMISSION CONTROL UNIT
TROUBLESHOOTING
EN03Z0306F300001
1. MANUAL TRANSMISSION
Symptom Possible cause Remedy/Prevention
Unable to shift the gear or very diffi- Damaged shift lever assembly Replace shift lever.
cult to shift when the engine is Damaged or broken transmission Replace.
turned off. upper cover (lever, spring, etc.)
The looseness of tightening bolt and Inspect and tighten each bolt and nut.
nut
Gear disengages when driving on Loose control lever joint Tighten or replace.
bumpy roads.
The play of the lever is excessive. A joint is seriously worn Replace the joint.
The looseness of tightening bolt and Inspect and tighten each bolt and nut.
nut
--- Page 5 ---
BR02–6 SERVICE BRAKE
When the air pressure reaches approximately 106 psi, the four pressure protection valves will open and air will be supplied to
the primary reservoir, secondary reservoir and accessories. If the pressure protection valves are preset to different values the
valves will open—in order of lowest setting to highest setting—when charging a flat system.
The air dryer and reservoir system will remain in the charge cycle until the air brake system pressure builds to the governor
cut-out setting of approximately 130 p.s.i.
SAPH06Z080200003
PURGE CYCLE (Refer to Figure 3.)
When air brake system pressure reaches the cut-out setting of the governor, the governor unloads the compressor activating
the purge cycle of the air dryer and reservoir.
The governor unloads the compressor by allowing air pressure to fill the line leading to the compressor unloader mechanism.
This suspends the delivery of compressed air to the Bendix® AD-IS® air dryer and reservoir system.
Similarly, the governor also supplies air pressure to the air dryer. The pressure also moves the air dryer purge piston down,
opening the purge valve to atmosphere and closing off the compressor air supply to the turbo cut-off valve (covered in the
Turbo Cut-off Feature section of this document). Water and contaminants captured are expelled immediately when the purge
valve opens. In addition, air—which was flowing through the desiccant cartridge—changes direction and begins to flow toward
the open purge valve. Contaminants collected by the air dryer are removed by air flowing from the purge reservoir through the
desiccant drying bed to the open purge valve.
The initial purge and desiccant cartridge decompression lasts only a few seconds, evidenced by an audible burst of air at the
air dryer exhaust.
--- Page 6 ---
BR02–50 SERVICE BRAKE
SAPH06Z080200035
--- Page 7 ---
BR02–94 SERVICE BRAKE
SAPH06Z080200079
--- Page 8 ---
BR02–138 SERVICE BRAKE
SAPH06Z080200123
--- Page 9 ---
BR03–28 ABS (ASR, VSC)
MM1719-14
--- Page 10 ---
BR03–72 ABS (ASR, VSC)
MM1719-58
--- Page 11 ---
POWER STEERING SR03–11
ON-VEHICLE SERVICE
EN07Z0803C100003
1. FILLING AND AIR BLEEDING THE SYSTEM
! CAUTION
Make sure poppets are set correctly before beginning this procedure.
(1) Fill the reservoir nearly full. Do not steer. Start and run the engine for
10 seconds, then shut it off. Check and refill the reservoir. Repeat at
least three times, checking the reservoir each time.
! CAUTION
Do not allow the fluid level to drop significantly or run out of the reser-
voir. This may induce air into the system.
(2) Start the engine and let it idle for 2 minutes. Do not steer. Shut off the
engine and check the fluid level in the reservoir. Refill as required.
(3) Start the engine again. Steer the vehicle from full left to full right sev-
eral times. Add fluid, as necessary, to the full line on the dip stick.
Automatic bleed systems should now be free from trapped air.
Auto Bleed Plug
Do Not Remove
SAPH07Z080300008
2. INPUT SHAFT SEAL REPLACEMENT
This procedure uses the vehicle's power steering pump to force out
the input shaft seal. To use this procedure, the power steering pump
should have a minimum of 1,500 psi available.
(1) Disconnect return line from the steering gear and plug the line. Also
cap the return port of the gear with a high pressure fitting.
SAPH07Z080300009
--- Page 12 ---
POWER STEERING SR03–55
POWER STEERING PUMP
DATA AND SPECIFICATIONS
EN07Z0803I200002
Type Vane type
14.0-14.7 MPa
Relief pressure
{142.76-149.89 kgf/cm2, 2030.54-2132.05 lbf/in2}
Flow rate 15.4-18.4 L/min {4.07-4.86 U.S. gal/min}
DESCRIPTION
EN07Z0803C100004
1 2 3
10 8
9
4
14
6 13 11 12
5
7
SAPH07Z080300163
1 Flow control valve assembly 8 Ball bearing
2 Relief valve 9 Pump shaft
3 Spring 10 Oil seal
4 Pump body 11 Dowel
5 Rotor 12 Front plate
6 Cam ring 13 Rear plate
7 Vane 14 Pump cover
--- Page 14 ---
AX03–26 REAR AXLE (WITH DIFFERENTIAL CARRIER)
S21-140-25
--- Page 15 ---
AX03–70 REAR AXLE (WITH DIFFERENTIAL CARRIER)
S21-170,S23-170-28
--- Page 16 ---
AX03–114 REAR AXLE (WITH DIFFERENTIAL CARRIER)
S21-170,S23-170-72
--- Page 17 ---
AX03–158 REAR AXLE (WITH DIFFERENTIAL CARRIER)
23060SH-44
--- Page 18 ---
AX03–202 REAR AXLE (WITH DIFFERENTIAL CARRIER)
DSH-40-037
--- Page 19 ---
AX03–246 REAR AXLE (WITH DIFFERENTIAL CARRIER)
DSH-40-081
--- Page 20 ---
AX03–290 REAR AXLE (WITH DIFFERENTIAL CARRIER)
D40-156-15
--- Page 21 ---
AX03–334 REAR AXLE (WITH DIFFERENTIAL CARRIER)
D40-156-59
--- Page 22 ---
AX03–378 REAR AXLE (WITH DIFFERENTIAL CARRIER)
D170-12
--- Page 23 ---
AX03–422 REAR AXLE (WITH DIFFERENTIAL CARRIER)
D170-56
--- Page 24 ---
AX03–466 REAR AXLE (WITH DIFFERENTIAL CARRIER)
D40-145-05
--- Page 25 ---
AX03–510 REAR AXLE (WITH DIFFERENTIAL CARRIER)
D40-145-49
--- Page 26 ---
AX03–554 REAR AXLE (WITH DIFFERENTIAL CARRIER)
D40-145-93
--- Page 27 ---
SUSPENSION SU02–19
AIR SUSPENSION ASSEMBLY
DATA AND SPECIFICATIONS
EN09Z1002I200002
REAR SUSPENSION
(4 x 2 Model)
Model HINO NV1A, NH1A HINO NV1A, NH1A, TH1A
HENDRICSON COMFORT-AIR-SD
Type HENDRICSON COMFORT-AIR
(SD: SEVERE DUTY)
Option WITH HEIGHT CONTROL DEVICE
(6 x 4 Model)
Model HINO NM1A, TM1A HINO NM1A, NH1A, TM1A
HENDRICSON COMFORT-AIR HENDRICSON COMFORT-AIR
Type
40K LB 46K LB
Option WITH HEIGHT CONTROL DEVICE
--- Page 28 ---
SUSPENSION SU02–63
SAPH09Z100200091
--- Page 29 ---
COUPLER (5TH WHEEL) FC03–9
(2) Refer to Figure 18 for the following 4 steps:
21 Cylinder rod
centered in “V” a. Turn on the air supply to pressurize the air cylinder such that the
release handle is fully extended.
b. Position the loosely bolted air cylinder such that the release han-
dle is against the rib window of the fifth wheel and the air cylinder
rod is centered in the “V” of the air cylinder pickup (Item 19).
c. Keeping the air cylinder in place, tighten the two 1/2-20 x 3/4”
bolts (Item 21) to 40-50 ft.-lbs.
d. Release the pressure from the air cylinder and verify that the cyl-
Fully extended Handle against
cylinder rod rib window
inder rod retracts fully. Replace air cylinder if it is faulty.
Figure 18
SAPH10Z110300019
! WARNING
• Failure to replace a faulty air cylinder may result in tractor trailer
separation which, if not avoided, could result in death or serious
injury.
e. Verify that the release handle contacts the rib window when the
Handle against handle is in the locked position (Figure 19).
rib window
figure 19
SAPH10Z110300020
--- Page 30 ---
CAB CA02–31
1 Upper panel 14 Switch base
2 Instrument panel cross member 15 Card holder
3 Gusset 16 Instrument panel box No.1
4 Lower center cover 17 Instrument panel box plate
5 Lower right cover 18 Instrument lower panel No.3
6 Panel upper cover 19 Instrument lower center cover
7 Switch board panel 20 Instrument lower RH pad
8 Cluster finish panel 21 Instrument panel box No.2
9 Cluster housing 22 Instrument lower panel No.3
10 Cluster bezel 23 Instrument panel box No.1
11 Upper right cover 24 Instrument panel under cover No.2
12 Lower cover 25 Table
13 Cup holder (If so equipped)
Tightening torque Unit: Nm {kgfcm, lbfft}
A 2.1-3.9 {21-40, 1.6-2.9} C 7.5-16.5 {76-168, 5.5-12}
B 1.5-2.5 {15-25, 1.1-1.8}
--- Page 31 ---
ELECTRICAL EQUIPMENT EL01–11
RELAY (TYPE, NAME AND INSPECTION)
TYPE-1: Air suspension dump relay
Power relay No.1
Power relay No.2
Power relay No.3
Power relay No.4
Power accessory relay No.1
Mirror heater relay
Heater relay
TRANS stop dummy relay
TRANS back light relay
SAPH12Z080100011 Head light main relay
Head light dimmer relay
Daytime running light relay No.1
Daytime running light relay No.3
Clutch relay
Horn relay
Air horn relay
Tail light relay No.1
Daytime running light tail relay No.1
Daytime running light tail relay No.2
TRANS starter relay
Engine ECU main relay
Engine ECU actuator power relay
Urea tube heater relay
Fuel heater relay
TYPE-2: Vehicle control system relay
Air conditioner relay
TYPE-3: ABS stop light relay
Differential lock dummy relay No.1
TRANS stop NC relay
Daytime running light relay No.2
Starter cut relay
Stop light relay No.1
TYPE-4:
Stop light relay No.2
1. TYPE-1 AND TYPE-2 INSPECTION
(1) Apply voltage to terminals;
88630-E0040 12 V to terminal 1,
Ground to terminal 2.
88630-E0030 3 5
5 3 (2) Under normal condition, terminals 3 and 5 switch on.
2
1 2
1
SAPH12Z080100012
--- Page 32 ---
ELECTRIC WIRE EL02–21
AD
1
1
CAB SIDE WIRING
MWL DPFI MHTC MTAB MGLO
(MCHG)
E88 ED2 ED8 ED9 ERY
E0D
MPAK MCHG
E0E E0D
0.35 W-
1
%AD
MAIN W/H
ENG MAIN W/H
2
%AD
BATTERY 1
A49 A48
(-(1)) (+(1))
3
%36
(+)
CHASSIS SIDE WIRING
STA
4
%35
(B)
0.50 Y-G
40 B-
20.0 B-L
A43
(L)
A40
(B)
A40 2
(B)
SAPH12Z080200032
AD CHARGING CIRCUIT
1 Combination meter (Charge light)
2 Alternator
3 Mega fuse 350A
4 Starter
--- Page 33 ---
ELECTRIC WIRE EL02–65
EI
MENG PCO4 PCO2 PCO+
TAIL TAIL TAIL TAIL TAIL J/C J/C J/C J/C E0M E7F E78 E1D
$M4 $C1 $C2 $KC $P6 $P8 $RS $NR $NS
B SPK+ SPK– MSL– MSL+ SPME SPMP PCI+ MTM
B
ILL+ ILL+ ILL+ ILL+ ILL+ ILL+ J/C J/C J/C J/C E71 E72 EUL EUK E1M E1N E1F E0A
$KD $MZ $N0 $MD $RB $L1 $MM $RP $C6 $ML
1 5
SPR2 SPL2 ACC +
I0F I0H I0C I09
LH+ SPR1 SPL1 GND SPD ILLM KILL
H5Z I0E I0G I0B IAC I0A I0L
LH+ LH-
H9Q H9R 6
2
FLE FL+ FRLE FRL+
I04 I03 I8K I8J
+
EC7
IG MET GND LAMP
GR 7
EKU EKV EC9 EC8
3
FRE FR+ FRRE FRR+
I02 I01 I8H I8G
+24V CAN- TC DSW
8
K9G KS4 KS2 KPZ
B
ISOK CAN+ SGND CGFR +
K9E KS3 K9H L30 KE4
4
CANH CANH CANH CANH CANH CANH ILL+ ILL+ ILL+ ILL+ ILL+
%JA %JB %JC %JM %JR %JN %GQ %GR %GS %GT %GU
B
CANL CANL CANL CANL CANL CANL ACC ACC ACC ACC ACC
%JE %JF %JG %JJ %JW %JK %AA %AB %AC %AD %AE
9
SAPH12Z080200074
--- Page 35 ---
ELECTRIC WIRE EL02–153
KI
BATT ACC ENCH VECH
DMY3 STOP STA SIG PIG1 DMY2 DMY1 PAC1 T21 T22 T23 T24
A6Q T20 AT6 SL5 AGM A6P A6N AGK
B
I/UP FOG+ H ETCO CCRM CCST CCSW SSD GND ON ENCL VECL
ANZ T1Z T1Y SY7 SY6 SY0 SX9 I0M T25 T26 T2Y T2Z
1 4
SPR2 SPL2 ACC + CANH CANH CANH CANH CANH CANH ILL+ ILL+ ILL+ ILL+ ILL+
I0F I0H I0C I09 %JA %JB %JC %JM %JR %JN %GQ %GR %GS %GT %GU
B
SPR1 SPL1 GND SPD ILLM KILL CANL CANL CANL CANL CANL CANL ACC ACC ACC ACC ACC
I0E I0G I0B IAC I0A I0L %JE %JF %JG %JJ %JW %JK %AA %AB %AC %AD %AE
2 5
+24V CAN- TC DSW
K9G KS4 KS2 KPZ
B
ISOK CAN+ SGND CGFR +
K9E KS3 K9H L30 KE4
3
SAPH12Z080200159
--- Page 36 ---
OTHERS DN06–3
SAPH11Z080600002
--- Page 37 ---
OTHERS DN06–47
SAPH11Z080600046
--- Page 38 ---
3–2 ENGINE MECHANICAL (A09C)
Removal, Replacement and Instructions
HEAD COVER
COMPONENT LOCATOR
EN01F01105020H01009001
A
A
5
3
4
2
1
SAPH011050200001
1 Semicircle plugs 4 Head cover
2 Head cover gasket * 5 Cushion
3 Spacer
*: Nonreusable part
Tightening torque Unit: Nm {kgfcm, lbfft}
A 28.5 {291, 21}
HEAD COVER
EN01F01105020H01009002
GREASE AND OTHERS
Name Remarks
Liquid gasket (ThreeBond TB1207B: Black or equivalent) Apply to the mating area of the half-round plug.
--- Page 39 ---
3–46 ENGINE MECHANICAL (A09C)
MOUNTING THE CYLINDER HEAD ASSEMBLY
1. MOUNTING THE HEAD GASKET
(1) Clean the upper surface of cylinder block.
Upper surface of cylinder block NOTICE
Before working, remove dirt, water or oil on the cylinder head and
cylinder block.
SAPH011050200104
(2) Set a new head gasket to the dowel pin and place the gasket
Head gasket on the upper surface of cylinder block.
NOTICE
• Never reuse the gasket, or the engine will be broken.
• Before mounting the head gasket, check the seal ring for falling
or damage.
(3) Apply liquid gasket (ThreeBond TB1211: White or equivalent)
to the mating area of the flywheel housing head gasket and
cylinder block upper surface rear end (2 locations).
NOTICE
SAPH011050200105 • Apply liquid gasket so that it hangs over the upper surface of
the head gasket.
• Mount the case within 20 minutes after applying the liquid gas-
ket.
Application
Incorrect
A A No gap
Too low
Gap Incorrect
Application
Too low
Liquid gasket
Head gasket Some gap
Cylinder head Correct
Cylinder Flywheel
block housing Appropriate
Section A-A Heap up liquid gasket over the top surface