Package Include
Hino J05D-TI, J05E-TI, J08E-TI, A09C, P11C Engines Workshop Repair Manual

Language
English

Format
PDF

Total Number of pages
723

Compatible
All windows and mac systems

Additional Requirement
User needs to Install PDF Reader Software

Shipping Policy
Download link by high speed web server Total Download size 20 mb

This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.

Applicable for :  FC6J, FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM1A, FM2P, SG8J, FT8J, GT8J series,
Equipped with : J05D-TI, J05E-TI, J08E-TI, A09C, P11C engine

CONTENTS OF THIS PDF MANUAL

GENERAL INTRODUCTION

WARNING
HOW TO USE THIS MANUAL
PRECAUTIONS FOR WORK
TIGHTENING OF BOLTS
AND NUTS FOR ENGINE
TIGHTENING OF BOLTS
AND NUTS FOR CHASSIS
TIGHTENING OF FLARE NUTS AND HOSES
SEALANT ON THE TAPERED SCREW
FOR PIPING
NYLON TUBE
ASSEMBLY OF JOINT/GASKET
FOR PIPING
HANDLING OF LIQUID GASKET
TROUBLESHOOTING USING
THE TROUBLE LIST
TROUBLESHOOTING USING
A DIAGNOSIS MONITOR
DIAGNOSIS USING THE PC
(PERSONAL COMPUTER)
DIAGNOSIS TOOL WITH INTERFACE
CHASSIS SERIAL NUMBER, VEHICLE
IDENTIFICATION NUMBER
AND ENGINE SERIAL NUMBER
RECOMMENDED LUBRICANTS

CLUTCH MAIN UNIT

CLUTCH ASSEMBLY
DATA AND SPECIFICATIONS
DESCRIPTION
TROUBLESHOOTING
SPECIAL TOOL
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

CLUTCH CONTROL

CLUTCH CONTROL UNIT
DATA AND SPECIFICATIONS
DESCRIPTION
SPECIAL TOOL
INSPECTION AND ADJUSTMENT

CLUTCH PEDAL AND RELEASE UNIT
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR
CLUTCH MASTER CYLINDER

COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

CLUTCH BOOSTER
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

TRANSMISSION MAIN UNIT

TRANSMISSION ASSEMBLY
DATA AND SPECIFICATIONS
DESCRIPTION
TROUBLESHOOTING
SPECIAL TOOL
PROPOSAL TOOL
(TRANSMISSION CASE ASSEMBLY)
DISMOUNTING AND MOUNTING

GEAR SHIFT HOUSING
COMPONENT LOCATOR
OVERHAUL

CASE AND MAIN UNIT
COMPONENT LOCATOR

TRANSMISSION CASE ASSEMBLY
OVERHAUL
INSPECTION AND REPAIR

INPUT SHAFT ASSEMBLY
OVERHAUL
INSPECTION AND REPAIR

OUTPUT SHAFT ASSEMBLY
OVERHAUL
INSPECTION AND REPAIR

COUNTER SHAFT ASSEMBLY
OVERHAUL
INSPECTION AND REPAIR

TRANSFER MAIN UNIT

TRANSFER ASSEMBLY
DATA AND SPECIFICATIONS
DESCRIPTION
TROUBLESHOOTING
PROPOSAL TOOL
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

AUTOMATIC TRANSMISSION

ASSEMBLY
TROUBLESHOOTING
SPECIAL TOOL
DISMOUNTING AND MOUNTING

P.T.O. (POWER TAKE-OFF)

POWER TAKE-OFF ASSEMBLY
DATA AND SPECIFICATIONS
DESCRIPTION
TROUBLESHOOTING

POWER TAKE-OFF UNIT
COMPOMENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

TRANSMISSION / TRANSFER CONTROL

TRANSMISSION CONTROL UNIT
TROUBLESHOOTING

TRANSMISSION CONTROL LINKAGE
COMPONENT LOCATOR
DISMOUNTING AND MOUNTING
ADJUSTMENT

POWER SHIFT
(TRANSMISSION SERIES:
LX06S, LJ06S)
DESCRIPTION
PROPOSAL TOOL
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

POWER SHIFT
(TRANSMISSION SERIES:
MF06S, HK06S)
DESCRIPTION
SPECIAL TOOL
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

TRANSFER SHIFT CONTROL
(TRANSFER SERIES: MA12C)
DIAGRAM
TROUBLESHOOTING

PROPELLER SHAFT

PROPELLER SHAFT ASSEMBLY
DATA AND SPECIFICATIONS
DESCRIPTION
TROUBLESHOOTING
SPECIAL TOOL
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

DIFFERENTIAL EQUIPMENT

LOCKING TYPE DIFFERENTIAL GEAR (NO SPIN)
DATA AND SPECIFICATIONS
DESCRIPTION
PROPOSAL TOOL
INSPECTION
TROUBLESHOOTING
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

DIFFERENTIAL CARRIER

DIFFERENTIAL CARRIER (SH13)
DATA AND SPECIFICATIONS
DESCRIPTION
TROUBLESHOOTING
SPECIAL TOOL
COMPONENT LOCATOR
OVERHAUL
INSPECTION AND REPAIR

HOW TO USE THIS MANUAL

1. REPAIR WORK
(1) The repair work is roughly classified into the three processes: “diagnosis”, “mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work” and “final inspection”.
(2) This manual describes the first process “diagnosis” and the second process “mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work”. Description on the third process “final inspection” is omitted.
(3) While this manual does not describe the following element work, the work is to be performed in practical cases:
a. Jack work and lift work
b. Cleaning of removed parts as required
c. Visual inspection

2. TROUBLESHOOTING IN THIS MANUAL
(1) This manual describes the following steps 2 and 3.

(1) Interview “Step 1” Thoroughly listen to the conditions and environment for the trouble and confirm the fact.
(2) Pre-inspection
(3) Replication method “Step 2”
Perform diagnostic inspection, checkup of the symptom, function
inspection and basic inspection to confirm the trouble. If the trouble hardly recurs, use the replication method.
(4) Troubleshooting by diagnosis code
(5) Troubleshooting by trouble “Step 3”
Classify the inspection results obtained in step 2 to systematically
perform inspection accordance with the troubleshooting procedure by diagnosis code or trouble.
(6) Checkup test “Step 4”
Check for the trouble after the trouble is removed. In case the
trouble is hardly replicated, conduct a checkup test under the conditions and environment for the trouble

3. Pre-inspection

• Execute the following steps to perform pre-inspection.
Diagnostic inspection  diagnosis code erasure  trouble check (If the trouble does not recur,
use the replication method.)  Diagnosis code re-check

• Assume the faulty system before the replication test. Connect a tester and determine a probable cause of trouble together with checkup of the trouble. For a probable cause of trouble, refer
to the troubleshooting chart.

• In case the trouble is momentary or in case an error code is displayed but no special trouble
takes place, execute related troubleshooting procedures while using the replication method.

• Trouble checkup
In case the trouble recurs, follow steps 2, 3 and 4 in this order.
Otherwise, use the replication method, that is, reproduce the external conditions, and inspect
each wire harness and connector parts.