1 page

INDEX1
Model FA ANTI LOCK BRAKE SYSTEM 77-1

77-05E-03

CHAPTER 77
ANTI LOCK BRAKE SYSTEM
(ABS)
1 Model FB

ABS OVERVIEW .........................................................................77- 4

ABS COMPOSITION, BASIC PRINCIPLE, AND OPERATION .. 77- 6

NON-ABS BRAKE OPERATION FUNCTION ............................. 77- 9

EXHAUST BRAKE CONTROL FUNCTION ................................ 77- 9

PRECAUTIONS WHEN DRIVING VEHICLES

EQUIPPED WITH ABS ............................................................... 77-10

OVERVIEW OF COMPONENTS AND THEIR FUNCTIONS ...... 77-11

ABS COMPUTER ....................................................................... 77-12

ABS ACTUATOR ........................................................................ 77-13

WHEEL SENSOR ....................................................................... 77-18

SENSOR RING ........................................................................... 77-18

CLAMPING BUSHING ............................................................... 77-18

WHEEL SENSOR WIRE HARNESS .......................................... 77-19

DEDICATED ABS FUSIBLE LINK ............................................. 77-19

WARNING LAMP ....................................................................... 77-20

RELAYS ..................................................................................... 77-21

77
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77-2 ANTI LOCK BRAKE SYSTEM Model FA

ABS OPERATION INSPECTION AND

MALFUNCTION DIAGNOSTICS ................................................ 77-22

YEARLY ABS INSPECTION ...................................................... 77-22

OPERATION STATUS INSPECTION ......................................... 77-22

MALFUNCTION DIAGNOSTICS BASED ON

ILLUMINATION OF WARNING LAMPS ..................................... 77-23

MALFUNCTION DIAGNOSTICS BASED ON ILLUMINATION

OF WARNING LAMPS UPON ENGINE STARTUP,
WHEN STARTING TO DRIVE, AND WHILE DRIVING
AND BRAKING .......................................................................... 77-24

READING THE MALFUNCTION CODES GENERATED

BY THE ABS COMPUTER MALFUNCTION DIAGNOSTICS ... 77-27

PRECAUTIONS WHEN PERFORMING CIRCUIT CHECKS

USING A CIRCUIT TESTER....................................................... 77-32

ABS COMPUTER HARNESS CONNECTOR

INSPECTION ITEMS .................................................................. 77-34

MAINTENANCE OF COMPONENTS ......................................... 77-35

ABS COMPUTER ....................................................................... 77-35

ABS ACTUATOR ........................................................................ 77-36

WHEEL SENSOR, SENSOR RING,

AND CLAMPING BUSHING ...................................................... 77-37

WARNING LAMP ....................................................................... 77-38

RELAYS ...................................................................................... 77-38

ABS WIRE HARNESSES ........................................................... 77-40

 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-3

HANDLING THE WIRE HARNESSES ....................................... 77-42

ADDITIONAL PRECAUTIONS ................................................... 77-42

CABLING DIAGRAM ................................................................. 77-44

 1 page 1
77-4 ANTI LOCK BRAKE SYSTEM Model FA

ABS OVERVIEW

ABS is a system that makes effective use of the friction between the tires and the road surface to maintain
vehicle stability while the brakes are being applied in order to retard the motion of the vehicle.
Applying the brakes forcefully while on a slippery road surface can cause the wheels to lock, due to exces-
sive braking force. This causes the vehicle to lose stability because the locked wheels lose resistance in the
lateral direction. More specifically, if the front wheels are locked it becomes impossible to steer the vehicle,
and if the rear wheels are locked, the rear of the vehicle may fishtail from side to side.
Also, when wheel locking occurs, it is not possible to make effective use of the friction between the tires and
the road surface. This causes the braking distance to increase.
ABS uses wheel sensors mounted on the axles to constantly monitor the rotation of the wheels. If any of the
wheels begins to lock up, the ABS computer sends signals to the ABS actuator and immediately adjusts the
brake pressure to prevent wheel locking.
In this way, ABS maintains the stability of the vehicle and enables the vehicle to be brought to a stop by
making effective use of the friction between the tires and the road surface.

VACUUM BOOSTER

ABS ACTUATOR

ABS COMPUTER

ABS WARNING LAMP

ABS WHEEL
SENSOR

SENSOR RING

WHEEL CYLINDER

OIL CIRCUIT
ELECTRICAL CIRCUIT
ABS WHEEL SENSOR
MASTER CYLINDER
SENSOR RING

WHEEL CYLINDER
ABS INSTALLATION DIAGRAM
SM77-45
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-5

1. BRAKING ON CURVES WITH SLIPPERY ROAD SURFACES

If the wheels lock when braking on a curve with a slippery road surface, the vehicle may lose its
directionality and skid off course even if the driver attempts to maintain control using the steering
wheel.

VEHICLE NOT EQUIPPED

WITH ABS

VEHICLE EQUIPPED
WITH ABS

VEHICLE POSITION - 1

2. BRAKING ON ROAD SURFACES WHERE THE LEFT AND RIGHT FRICTION COEFFICIENTS DIFFER
(ROAD SURFACES CONSISTING OF ONE SLIPPERY SIDE AND ONE NON- SLIPPERY SIDE)
When the brakes are applied, the wheels on the slippery side of the road surface lock before the
wheels on the non-slippery side. The locked wheels slip and their braking effectiveness is reduced,
resulting in a situation analogous to one in which the brakes fail on one side of the vehicle. This can
cause the steering wheel to no longer provide control and possibly result in a spinout.

VEHICLE NOT EQUIPPED WITH ABS

SLIPPERY ROAD SURFACE
(FROZEN ROAD SURFACE, ETC.)

NON-SLIPPERY ROAD SURFACE

(DRY ROAD SURFACE, ETC.)

VEHICLE EQUIPPED WITH ABS

SLIPPERY ROAD SURFACE

(FROZEN ROAD SURFACE, ETC.)

NON-SLIPPERY ROAD SURFACE

(DRY ROAD SURFACE, ETC.)
VEHICLE POSITION - 2
 1 page 1
77-6 ANTI LOCK BRAKE SYSTEM Model FA

ABS COMPOSITION, BASIC PRINCIPAL, AND OPERATION

The ABS comprises sensor rings mounted on the wheels, the ABS computer which receives signals from
wheel sensors that monitor the rotational speed of the wheels and sends out control signals to maintain the
appropriate braking force, the ABS actuator which increase or decrease the braking force based on the
control signals, the warning lamp which provides an alarm if the system malfunctions, and the piping, wire
harnesses, etc. that link together the various units that make up the system.
Pulse signals generated by the sensor rings mounted on the wheel hubs that rotate with the wheels and the
wheel sensors mounted near them on the axles are sent to the ABS computer. The ABS computer then
calculates the wheels’ rotational speed, acceleration, deceleration, amount of slippage, etc. based on these
signals. If the vehicle’s acceleration, deceleration, or slippage ratio limits are exceeded, the ABS computer
immediately sends signals to the ABS actuator to adjust any excess braking force.
This ABS controls braking as shown on the following chart.

FRONT AXLE REAR AXLE

CONTROL INDEPENDENTLY CONTROL INDEPENDENTLY CONTROL

METHOD RIGHT AND LEFT WHEELS RIGHT AND LEFT WHEELS

1. SYSTEM COMPOSITION DIAGRAM

5 2
1 3

2 5
3

2 5
4 6
5 2

OIL CIRCUIT
ELECTRICAL CIRCUIT

1. MASTER CYLINDER 5. ABS WHEEL SENSOR

2. WHEEL CYLINDER 6. ABS WARNING LAMP
3. VACUUM BOOSTER 7. ABS ACTUATOR
4. ABS COMPUTER
SM77-12
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-7

2. ABS CONTROL FLOWCHART

INPUT SIGNALS ABS COMPUTER OUTPUT SIGNALS

FRONT RIGHT FRONT RIGHT PRES-

WHEEL SENSOR SURE MAINTENANCE
SOLENOID VALVE

FRONT LEFT FRONT RIGHT PRES-

SURE REDUCTION
WHEEL SENSOR SOLENOID VALVE

REAR RIGHT FRONT LEFT PRES-

ABS COMPUTER SURE MAINTENANCE
WHEEL SENSOR SOLENOID VALVE

REAR LEFT FRONT LEFT PRES-

SURE REDUCTION
WHEEL SENSOR SOLENOID VALVE

REAR RIGHT PRES-

STOP LAMP SURE MAINTENANCE
SWITCH SOLENOID VALVE

REAR RIGHT PRES-

SURE REDUCTION
SOLENOID VALVE

REAR LEFT PRESSURE

MAINTENANCE SOLE-
NOID VALVE

REAR LEFT PRESSURE

REDUCTION SOLE-
NOID VALVE

EXHAUST BRAKE CUT

RELAY
SUB
RELAY
ABS MOTOR RELAY

ABS SOLENOID RELAY

ABS WARNING LAMP

DIAGNOSTIC
CONNECTOR
 1 page 1
77-8 ANTI LOCK BRAKE SYSTEM Model FA

3. BASIC PRINCIPLE

Based on its relationship with the slip ratio, which is obtained from the wheels’ rotational speed and the
vehicle’s speed, ABS controls the brake force so that it will be most effective.
When the driver applies the brakes, the rotation of the wheels is impeded and the speed of the vehicle
drops. However, the momentum of the vehicle attempts to push it forward further even though the
rotation of the wheels is being impeded. At this point, slipping will occur if there is a difference between
the wheels’ rotational speed and the vehicle’s speed. The slip ration is a value that expresses the rate
of slippage.
Vehicle’s speed - Wheel’s rotational speed
Slip ratio= × 100%
Vehicle’s speed

Slip ratio 0% : No slipping between the wheels and road surface

100% : Wheels locked

The graph shown at left shows the relationship between

FRICTION COEFFICIENT
BETWEEN TIRES AND

1 NON-SLIPPERY ROAD SURFACE

the friction coefficient of the tires and the road surface and
the slip ratio.
ROAD SURFACE

In an ABS-equipped vehicle, the brake force is controlled

SLIPPERY ROAD to ensure that it is within the range where the friction coef-
SURFACE ficient is high (shaded portion of graph) and no wheel lock-
ing occurs. This ensures efficient braking performance.
0 50 100
SLIP RATIO

WHEEL SPEED 4. OPERATION

HIGH VEHICLE BODY SPEED
The ABS computer calculates the wheel speed and wheel
SPEED

acceleration speed for each of the 4 wheels, from 4 speed

sensor signals, and determines the wheel slip conditions.
LOW
And depending on these conditions, control signals are
output to the ABS actuator solenoid valves in 3 modes
ACCELERATION

+ (pressure increase, pressure maintenance, and pressure

reduction). Control signals are output independently to the
0
WHEEL

SPEED

front and rear wheels and to the left and right wheels.
–
CONTROL SIGNAL

PRESSURE
REDUCTION
PRESSURE
MAINTENANCE
PRESSURE
INCREASE
WHEEL CYLINDER
FLUID PRESSURE

HIGH

0
TIME SM77-13
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-9

NON-ABS BRAKE OPERATION FUNCTION

When the ABS warning lamp comes on while the vehicle is being driven, there could be a problem with the
ABS. Your regular service will, however, work normally, but you should be careful and drive the vehicle in
the same way that you would drive a vehicle without ABS. Have your vehicle inspected and serviced
immediately at your nearest Hino service center.

EXHAUST BRAKE CONTROL FUNCTION

The ABS of this vehicle is equipped with a function that controls the exhaust brake while ABS is operating.
If the exhaust brake is applied independently or in conjunction with the service brake on a road surface with
an abnormally low friction coefficient, the drive wheels may lock. This ABS prevents the drive wheels from
locking in such situations by automatically releasing the exhaust brake, if necessary, during ABS operation.

Only vehicles with manual

CLUTCH ACCELERATOR EXHAUST BRAKE transmission
SWITCH SWITCH SWITCH

;;
+12V
EXHAUST BRAKE

;;
MAGNETIC VALVE

+12V

;;
EXHAUST BRAKE CUT SUB RELAY
ABS COMPUTER
RELAY

ABS MOTOR RELAY

EXHAUST BRAKE CONTROL

;; SM77-14
 1 page 1
77-10 ANTI LOCK BRAKE SYSTEM Model FA

PRECAUTIONS WHEN DRIVING MODELS EQUIPPED WITH ABS

Electronically, ABS uses the coefficient of friction (the amount of traction) between the tires and the road
surface to monitor the speed of each wheel. If one or more wheels indicates the possibility of locking,
resulting in fishtailing or other loss of stability, ABS enables the vehicle to be brought to a stop. Even with
ABS, however, a driver must operate the vehicle in a safe manner and recognize the following points with
respect to the operation of ABS.
CHECK POINTS REMEDIAL ACTIONS

• Even with ABS, the braking distance on a wet or slippery

road will be longer than on a dry road, and if the road
surface is covered with ice, snow or gravel, the braking
distance will be even greater.
• ABS does not operate when the vehicle is starting, ac-
celerating or turning, and will not assist in maintaining
directional stability or steerability or in shortening the brak-
ing distance.
• Even if the ABS is operational, where the coefficient of
friction is very low, such as on an icy roadway, skidding,
inability to steer, and instability may occur because of
insufficient traction by the tires.
• Where engine braking, as a result of downshifting, oc-
curs on a surface with a low coefficient of friction, such
as ice, the drive wheels may lock, causing fishtailing or
vehicle instability. ABS does not operate unless the brake
pedal is applied.
• Even with ABS, always drive safely, tak-
ing into consideration the road and traffic
conditions and the condition of your tires,
including tire type and tire wear. Always
keep a safe distance from any vehicle
being driven in front of you.
• If engine braking causes instability or fish-
tailing, the clutch should be engaged or
the transmission shifted to neutral, to pre-
vent the application of the engine brak-
ing to the drive wheels.
• Vibrations and noise during the operation
of ABS are not malfunctions. Remain calm
and continue to steer the vehicle in an
appropriate manner.

• When ABS is activated, the driver may experience a small
amount of vibration (especially if the road surface be-
tween the left and right tires is different) and difficulty in
steering. Also, the operation of the ABS may generate
some noise.
• The ABS warning light will come on when you turn the
starter switch to the "on" position. It stays on briefly and
then turns off automatically. If the light does not come
on, have your vehicle inspected and serviced immedi-
ately at your nearest Hino service dealer.
• If the warning lamp lights again when you
reach a speed of about 10 km/h (6.25
mile/h), the ABS system may not be func-
tioning properly. Have it inspected and re-
paired if necessary. * The warning lamp
can be reset by turning off the engine
while the vehicle is at rest. If the warning
lamp fails to go out after the engine is re-
started and the speed indicated above is
reached, or if it lights frequency while the
vehicle is being driven, the ABS must be
inspected.

• OTHER CHECKPOINTS REGARDING HANDLING

1. When washing the vehicle, take care not to direct high-pressure streams of water at the ABS actuator, harnesses, or
connectors. Also, under no circumstances should the ABS computer or electrical relays be exposed to water.
2. Be very careful not to damage the ABS wire harness when removing snow, ice, mud or other material from the outside or
underside of the vehicle.
3. All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS computer and wire
harness as possible. Installation of certain electronic and radio equipment can also cause the ABS computer to malfunction.
All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment,
please contact your Hino service representative.
LAYOUT OF COMPONENTS

G. WHEEL SENSOR
SENSOR RING
G
F

C E SM77-5

B F. ABS ACTUATOR
Model FA
1 page 1

SM77-15 SM77-19

A. ABS COMPUTER B. ABS WARNING LAMP C. FUSE BLOCK D. WHEEL SENSOR E. FUSIBLE LINK
DIAGNOSTIC CONNECTOR SENSOR RING
RELAYS
OVERVIEW OF COMPONENTS AND THEIR FUNCTIONS

SM77-17 SM77-1 SM77-16 SM77-42 SM77-18

ANTI LOCK BRAKE SYSTEM 77-11
 1 page 1
77-12 ANTI LOCK BRAKE SYSTEM Model FA

ABS COMPUTER
The ABS micro-computer calculates and evaluates the slip ratio, deceleration and acceleration based upon
signals received from the wheel sensors. The micro-computer then sends signals to the ABS actuator, as
necessary, causing them to operate and apply the brakes to maintain the slippage of the wheels within the
optimal range.
Regardless of whether the vehicle is stopped or being driven, and whether or not the brakes are being
applied, ABS circuitry constantly checks the ABS wheel sensors, actuator, micro-computer and wiring har-
nesses. If a malfunction occurs, this circuitry activates the ABS warning lamp to alert the driver. At the same
time, the ABS is disabled and the service brakes are restored to normal (non-ABS) operation.

INDICATION
PLATE

SM77-20

NOTE: The ABS computer is exclusively specified at 12V. For indication purposes, an indication
plate such as the one shown in the above diagram is attached. Pay close attention to pre-
vent misuse when replacing.
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-13

ABS ACTUATOR
1. OVERVIEW
The ABS actuator is mounted between the vacuum booster
and wheel cylinder. It controls the fluid pressure to the wheel
cylinder, regulating the pressure according to signals from
the computer in three modes: pressure maintenance, pres-
sure reduction, and pressure increase.

SM77-19

VACUUM BOOSTER

PRESSURE MAINTENANCE PRESSURE MAINTENANCE

SOLENOID VALVE SOLENOID VALVE

PUMP

PRESSURE REDUCTION PRESSURE REDUCTION

SOLENOID VALVE SOLENOID VALVE

RESERVOIR RESERVOIR

WHEEL WHEEL WHEEL WHEEL

CYLINDER CYLINDER CYLINDER CYLINDER

ABS ACTUATOR
SM77-21
 1 page 1
77-14 ANTI LOCK BRAKE SYSTEM Model FA

2. OPERATION
1) During Normal Braking (ABS is not operating)
Since there is no control signal input from the ABS computer, the pressure maintenance solenoid
valve port A is open, and the pressure reduction solenoid valve port B is closed. Accordingly,
when the fluid pressure generated by the vacuum booster rises according to the fluid pressure
from the master cylinder produced when the brake pedal is depressed, brake fluid is fed through
port A to the wheel cylinder. Brake fluid is not sent to the pump side at this time because of the
check valve 2 installed on that side. Then, when the brake pedal is released, the wheel cylinder
brake fluid is returned to the master cylinder via two routes: through the pressure maintenance
solenoid valve port A to the vacuum booster and from the wheel cylinder to check valve 1 to the
vacuum booster.

Each Port Status

ABS computer signal Port status
Pressure maintenance
OFF Port A: Open
solenoid valve
Pressure reduction
OFF Port B: Closed
solenoid valve

ABS ACTUATOR

VACUUM BOOSTER
PORT A
(OPEN) ORIFICE a

CHECK VALVE 1

PRESSURE MAINTENANCE
SOLENOID VALVE [OFF]

CHECK VALVE 2

PORT B ORIFICE b
PUMP
(CLOSE)

PRESSURE REDUCTION ABS

SOLENOID VALVE [OFF] CHECK VALVE 3 COMPUTER

RESERVOIR

WHEEL
CYLINDER
WHEEL SENSOR

BRAKE FLUID FLOW (DURING NORMAL BRAKING)

SM77-22
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-15

2) During ABS Braking

(1) Pressure Reduction Mode
When the wheels are about to lock, the pressure maintenance solenoid valve port A closes and
the pressure reduction solenoid valve port B opens according to control signals from the ABS
computer. Accordingly, the wheel cylinder brake fluid is fed through the pressure reduction solenoid
valve port B to the reservoir, reducing the wheel cylinder fluid pressure. While the ABS is in
operation, the ABS computer outputs a normal operating signal to the pump, which pumps out the
brake fluid that accumulates in the reservoir and returns it to the vacuum booster.

Each Port Status

ABS computer signal Port status

Pressure maintenance
ON Port A: Closed
solenoid valve
Pressure reduction
ON Port B: Open
solenoid valve

ABS ACTUATOR

VACUUM BOOSTER
PORT A

;;
(CLOSE)
ORIFICE a

CHECK VALVE 1

;;
PRESSURE MAINTENANCE
SOLENOID VALVE [ON]

CHECK VALVE 2

ORIFICE b
PUMP

;;
PORT B
(OPEN)

;;
PRESSURE REDUCTION ABS
CHECK VALVE 3 COMPUTER
SOLENOID VALVE [ON]

;RESERVOIR

WHEEL
CYLINDER
WHEEL SENSOR

BRAKE FLUID FLOW (DURING PRESSURE REDUCTION)

SM77-23
 1 page 1
77-16 ANTI LOCK BRAKE SYSTEM Model FA

(2) During Pressure Maintenance

When the wheel cylinder fluid pressure is reduced or increased to the required fluid pressure, the
pressure maintenance solenoid valve port A and the pressure reduction solenoid valve port B
simultaneously close according to control signals from the ABS computer. This closes both the
vacuum booster side and reservoir side oil routes, maintaining the wheel cylinder fluid pressure.

Each Port Status

ABS computer signal Port status

Pressure maintenance
ON Port A: Closed
solenoid valve
Pressure reduction
OFF Port B: Closed
solenoid valve

ABS ACTUATOR

VACUUM BOOSTER

ORIFICE a

;;
PORT A
(CLOSE)
CHECK VALVE 1

;;
PRESSURE MAINTENANCE
SOLENOID VALVE [ON]

CHECK VALVE 2

PORT B ORIFICE b
(CLOSE) PUMP

;;
ABS
PRESSURE REDUCTION
CHECK VALVE 3 COMPUTER
SOLENOID VALVE [OFF]

;; RESERVOIR

WHEEL
CYLINDER
WHEEL SENSOR

BRAKE FLUID FLOW (DURING PRESSURE MAINTENANCE)

SM77-24
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-17

(3) During Pressure Increase

When the wheel cylinder fluid pressure needs to increase rapidly, the pressure maintenance
solenoid valve port A opens and the pressure reduction solenoid valve port B closes according to
control signals from the ABS computer. This condition is the same as the normal condition, and
vacuum booster brake fluid is fed to the wheel cylinder, causing the wheel cylinder fluid pressure
to rise. If there is any brake fluid remaining in the reservoir at this time, it is pumped out by the
pump and sent to the wheel cylinder. The speed of the pressure increase is controlled by
combination of the pressure increase and the pressure maintenance.

Each Port Status

ABS computer signal Port status

Pressure maintenance
OFF Port A: Open
solenoid valve
Pressure reduction
OFF Port B: Closed
solenoid valve

ABS ACTUATOR

VACUUM BOOSTER
PORT A
(OPEN)

;;
ORIFICE a

CHECK VALVE 1

;;
PRESSURE MAINTENANCE
SOLENOID VALVE [OFF]

CHECK VALVE 2

PORT B ORIFICE b
(CLOSE) PUMP

;; PRESSURE REDUCTION
SOLENOID VALVE [OFF] CHECK VALVE 3
ABS
COMPUTER

; RESERVOIR

WHEEL
CYLINDER
WHEEL SENSOR

BRAKE FLUID FLOW (DURING PRESSURE INCREASE)

SM77-25
 1 page 1
77-18 ANTI LOCK BRAKE SYSTEM Model FA

WHEEL SENSOR
These sensors are mounted facing the sensor rings on each wheel on the front and rear axles.
The wheel sensors are electromagnetic sensors consisting of a permanent magnet core with a coil of wire
wrapped around it. The frequency of the pulse signals generated by magnetic inductance between the
sensors and the sensor rings they face is proportional to the rotational speed of the wheels. These pulse
signals are sent to the ABS computer and are used to determine the wheels’ rotational status.

SENSOR BRACKET SENSOR BODY

CLAMPING SLEEVE SENSOR RING
WHEEL HUB

AXLE HOUSING

SENSOR RING
The sensor rings are press-fitted into the insides of the wheel
FRONT REAR
hubs of each wheel on the front and rear axles, and they face
the wheel sensors described in the preceding section. The sen-
sor rings are made of a magnetic material, and teeth are cut
into the surface which faces the wheel sensor at regular inter-
vals. Also, when the sensor ring performs one complete rota-
tion, the sensor generates pulse signals corresponding to the
number of teeth.

CLAMPING BUSHING
The wheel sensors are held in place through friction by clamp-
ing bushings that are inserted into the mounting brackets. If
they are assembled properly (the clamping bushings should be
pushed in to place so that the stoppers on the clamping bush-
ings come in contact with the holder), the clamping bushings
serve to eliminate the need to adjust the clearance between
the wheel sensors and sensor rings.
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-19

WHEEL SENSOR WIRE HARNESSES

Each wheel sensor wire harness employs a two-conduc-
tor twisted wire cable. Its function is to protect the wheel
sensor signals, which are vital to the proper operation of
the ABS, from electromagnetic interference. Under no cir-
cumstances should any part of the wheel sensor wire har-
ness be cut or connected to any other wire. In the event
CONDUCTOR that the wire harness should become cut, have it replaced
OUTER COVER by an authorized Hino dealer.

DEDICATED ABS FUSIBLE LINK

ABS FUSIBLE LINK The dedicated ABS fusible link is located by the fusible
CASE COLOR: PINK
link block to protect the circuit.

FL-5 FL-1

FL-10 FL-2
FL-12

FL-7

FL-11 FL-6

FL-9

FL-8 FL-3

FL-13 FL-4

ASM77-001
 1 page 1
77-20 ANTI LOCK BRAKE SYSTEM Model FA

WARNING LAMP
The ABS is equipped with the following warning lamp.

ABS WARNING LAMP

SM77-1

1. ABS WARNING LAMP

This lamp indicates the status of the ABS. It lights once
when the starter switch is turned on and automatically goes
off if the ABS is functioning normally. If a malfunction oc-
curs in the ABS while the vehicle is being driven, the lamp
lights to alert the driver.
Also used as the diagnostic display lamp.
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-21

RELAYS
Several relays are located near the ABS computer.

ABS SUB RELAY

ABS MOTOR RELAY

ABS SOLENOID RELAY

EXHAUST BRAKE CUT RELAY
SM77-44

1. ABS Solenoid Relay

When this relay is excited according to a command from the ABS computer, the relay contact closes,
supplying current to the solenoid valve inside the actuator.

2. Sub Relay
When this relay is excited according to a command from the ABS computer, the relay contact closes,
supplying exciting current to the exhaust brake cut relay and ABS motor relay.

3. Exhaust Brake Cut Relay

When this relay is excited by the current supplied from the sub relay during ABS operation, the relay
contact opens, cutting off the current to the exhaust brake solenoid valve and thereby releasing the
exhaust brake.

4. ABS Motor Relay

When this relay is excited by the current supplied from the sub relay during ABS operation, the relay
contact closes, supplying current to the actuator motor and operating the pump inside the actuator.
 1 page 1
77-22 ANTI LOCK BRAKE SYSTEM Model FA

ABS OPERATION INSPECTION AND MALFUNCTION DIAGNOSTICS

YEARLY ABS INSPECTION
Inspect the operation of the ABS once per year using the following procedure.
1. Operation status inspection
If this inspection reveals any malfunctions, be sure to carry out the next inspection.

OPERATION STATUS INSPECTION

To perform an OPERATION STATUS INSPECTION, utilize the following procedure:
1. Inspection using brake tester
Check the braking force of each wheel using a brake tester. If any malfunction is discovered, inspect
the wheel brakes, service brake system and ABS actuator.
NOTE: The same procedure for checking the braking force on vehicles not equipped with ABS
may also be used for vehicles equipped with ABS.

2. ABS operation status inspection using test drive

NOTE: ● Use a large, safe area for the test drive.
● Conduct the test drive with the vehicle unloaded.
● Apply white tape, or make other markings, to the sides of the front wheels and rear
wheels so that a determination can be made as to the status of the rotation of the
wheels.
● If a vehicle is equipped with a load sensing device, adjust the lever to set the vehicle
as if it were loaded.

1) Turn the starter switch of the vehicle off, and then on. Confirm that the ABS warning lamp lights
once and then goes off.
2) Start driving the vehicle and confirm that the ABS warning lamp does not light again when a speed
of about 10 km/h (6.25 mile/h) is reached.
3) Accelerate to a speed of 20 - 30 km/h (12.5 - 18.75 mile/h) , then apply the brakes hard. Confirm
that none of the wheels lock.

If any malfunction is discovered in the above inspections, be sure to inspect and adjust the components of
the ABS and the ABS circuit.
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-23

MALFUNCTION DIAGNOSTICS BASED ON ILLUMINATION OF WARNING

LAMPS

LIT LAMP CAUSE OF MALFUNCTION RESULT OF MALFUNCTION

ABS warning lamp POWER SUPPLY RELATED The entire ABS becomes nonfunctional.
* Lamp is continuously * Fuse burned out (The brakes of all wheels operate in nor-
lit after turning the * Wire harness connector disconnected mal braking)
starter switch on or * Bad contact with wire harness
while driving vehicle * Broken wire in wire harness
* Low battery voltage

WHEEL SENSOR RELATED ABS becomes non-functional on the

* Sensor clearance too wide
* Bad sensor unit
* Broken wire in wire harness
* Wire harness connector disconnected
or bad contact
wheel in the system where the sensor
malfunctioned and the wheels operate
in normal braking.

ABS ACTUATOR RELATED ABS becomes non-functional on the

* Broken wire or short circuit in solenoid wheel in the system where the ABS ac-
controller tuator malfunctioned and the wheels
* Broken wire in wire harness of ABS operate in normal braking.
actuator
* Wire harness connector disconnected
or bad contact
* Bad ABS solenoid relay and ABS motor
reray

COMPUTER The entire ABS becomes nonfunctional.

* Internal malfunction in computer (The brakes of all wheels operate in nor-
mal braking)

NOTE: The ABS warning lamp may remain lit if the ABS experiences a temporary malfunction
and then recovers. Should this occur, reset it by switching off the engine temporarily
while the vehicle is stopped. Turn the starter switch of the vehicle on and after the ABS
warning lamp lights, check that it goes off, and then restart the engine. If the lamp does
not light, even though a speed of about 10 km/h (6.25 mile/h) is reached, ABS is work-
ing normally.
 1 page 1
77-24 ANTI LOCK BRAKE SYSTEM Model FA

MALFUNCTION DIAGNOSTICS BASED ON ILLUMINATION OF WARNING LAMPS UPON

ENGINE STARTUP, WHEN STARTING TO DRIVE, AND WHILE DRIVING AND BRAKING
1. ABS warning lamp illuminates.

* Remove the diagnostic connector short connector.

* Short between the diagnostic connector TC terminal
and E terminal.

Does the ABS warning lamp display a diagnostics code YES

Malfunction Diagnostics Code Table
(malfunction code) when the IG switch is ON?
NO
YES * Check the solenoid relay.
Is a normal code displayed? * Wire harness body short (between the diagnostic con-
nector WB terminal and the solenoid relay W terminal)
NO
YES * Faulty computer connector connection
Is the ABS warning lamp extinguished? * Faulty wire harness [between the fuse (ECU-IG) and the
computer IG terminal]
NO

Turn the IG switch OFF.

Remove the diagnostic connector short connector and

the computer connector.

YES
Is the ABS warning lamp OFF when the IG switch is ON? Computer malfunction

NO

Wire harness body short (between the meter and the com-
puter or between the meter and the diagnostic WA terminal)

2. The ABS warning lamp does not illuminate for 3 seconds after the ignition switch has been turned ON.

Remove the diagnostic connector short connector, short

between the diagnostic connector WA and E terminals,
and then turn the IG switch ON.

NO
* Check the combination meter.
Does the ABS warning lamp illuminate?
* Faulty wire harness [between the fuse (gauge) and meter]
YES

Check the current flow between the solenoid relay W

terminal and the GND terminal.
There is cur-
rent flow on
both sides.
Try changing the polarity of the tester probes. Is there cur- Solenoid valve internal malfunction
rent flow on one side only?
YES

When the IG switch is OFF, remove the diagnostic con-

nector short connector and the computer connector, and
ground the computer connector WA terminal on the vehicle
side to the vehicle body. Then turn the IG switch ON.

NO
Does the ABS warning lamp illuminate? Faulty wire harness (between the meter and the computer)
YES

Computer malfunction
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-25

3. Malfunctions when ABS is operating

* Remove the diagnostic connector short connector.

* Short between the diagnostic connector TC terminal
and E terminal.

Does the ABS warning lamp display a normal code when NO

Malfunction Diagnostics Code Table
the IG switch is ON?

Is the installation condition of each speed sensor normal NO

when the IG switch is OFF? Are there any loose installa- Faulty speed sensor installation
tion bolts?
YES
Disconnect the computer connector and check the cur-
rent flow between all sensor terminals on the harness side.

NO
There is no change in current flow when the wire harness
and connector part are moved. Faulty wire harness connection

YES

Connect the computer and then turn the IG switch ON.

Execute a speed sensor functional check or confirm the

speed sensor signal waveform with an oscilloscope.

NO
Is the speed sensor signal output voltage level normal? Faulty speed sensor

YES
NO
Does the speed sensor signal output voltage fluctuate? Check the brake actuator.
YES

Remove the speed sensor that disturbs the signal.

Are there any iron fragments or other foreign matters stuck NO Remove foreign matters stuck to the speed sensor and
to the tip of the speed sensor? then change the grease.
YES

Deformation of front axle hub sensor rotor or speed sen-

sor rotor
 1 page 1
77-26 ANTI LOCK BRAKE SYSTEM Model FA

4. ABS does not operate smoothly.

* Remove the diagnostic connector short connector.

* Short between the diagnostic connector TC terminal
and E terminal.

Does the ABS warning lamp display a normal code when NO

the IG switch is ON? Malfunction Diagnostics Code Table

YES

Is the voltage between the computer STP terminal and NO * Check the Stop lamp switch.
the GND terminal 8 - 14V when the brake pedal is * Faulty wire harness (between the Stop lamp switch
depressed? and the computer)

YES

Check the brake actuator operation.

 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-27

READING THE MALFUNCTION CODES GENERATED BY THE ABS COMPUTER

MALFUNCTION DIAGNOSTICS
The ABS stores data on all the malfunctions that have occurred in the past in the computer. It also has a
readout function for displaying this information, and indicating them as malfunction codes.
The display of malfunction data as malfunction codes allows inspection, maintenance, and remedial action
to be accomplished more accurately and quickly.

1. MALFUNCTION CODES READOUT PROCEDURE

A diagnostic connector (malfunction codes readout) is
ABS COMPUTER
located near the ABS computer, and a malfunction code
display lamp (diagnostic display lamp) is built into the ABS
DIAGNOSTIC warning lamp.
CONNECTOR
Malfunction codes can be read, using the starter switch
and diagnostic connector, by following the steps described
below.

SM77-17

(1) Check the ABS warning lamp.

1) Turn the ignition switch ON.
Standard: The ABS warning lamp will be illumi-
nated for about 3 seconds and then
go out.

SM77-1

(2) Check the diagnostics.

1) Make sure that the ignition switch is turned OFF,
and then remove the diagnostic connector short
connector.

SM77-26

2) Short between the diagnostic connector TC ter-

minal (wiring color: pink) and E terminal (wiring
color: black).
NOTE: Shorting between the wrong terminals will
cause equipment damage; therefore, make
sure that the connector short-circuit location
is correct.

SM77-27
 1 page 1
77-28 ANTI LOCK BRAKE SYSTEM Model FA

3) Turn the ignition switch ON and read the number of flashes of the ABS warning lamp.
A) Output code under normal conditions
If conditions are normal, the warning lamp will alternately flash ON and OFF for 0.25
seconds each.

NORMAL CODE 0.25S

Light on
Warning lamp
Light off

2.0S
0.25S
SM77-28

B) Output code when a malfunction occurs

q Malfunction code display

CODE DISPLAY 1 0.5S CODE DISPLAY 10 0.5S

Light on Light on
Warning lamp Warning lamp
Light off Light off

0.5S 1.5S
SM77-28

w If there is one malfunction code, the same code will be output at intervals of 4 seconds;
if there are two or more malfunction codes, different codes will be output at intervals of
2.5 seconds, and each cycle of codes is repeated, with a 4-second delay between
cycles.
e When two or more malfunction codes are output, their code numbers are displayed in
numerical order.

EXAMPLE: MALFUNCTION CODES 11 AND 23

0.5S 0.5S 0.5S 0.5S 0.5S 0.5S 0.5S 0.5S 0.5S 0.5S

Light on
Warning lamp
Light off
4.0S 1.5S 2.5S 1.5S Repeat

11 23

SM77-28
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-29

(3) Erasing a malfunction code

1) Make sure that the ignition switch is OFF and then
short between the diagnostic connector TC terminal
(wiring color: pink) and E terminal (wiring color: black).
NOTE: Shorting between the wrong terminals will
cause equipment damage; therefore, make
sure that the connector short-circuit location
is correct.
SM77-27

2) Turn the ignition switch ON.

SM77-30

3) Depress the brake pedal so that the stop lamp switch

is turned ON and OFF 8 times or more for 5 seconds.

SM77-29

4) Confirm that the normal code is output after the mal-

function code has been erased.
NOTE: If the malfunction code was not erased, repeat
step 3) above.

SM77-1
 1 page 1
77-30 ANTI LOCK BRAKE SYSTEM Model FA

4) Malfunction Diagnostics Code Table

Code Diagnostic system Check location

number (terminal symbols)

ABS solenoid relay system disconnection • ABS solenoid relay (contacts, coil)
11 (SR, R+, AST) • ABS solenoid relay system wire harness
• ABS actuator system (AST) wire harness

ABS solenoid relay system short (SR, AST) • ABS solenoid relay (contacts)
• ABS solenoid relay system wire harness
12 • ABS actuator system (AST) wire harness
• Connector

ABS motor relay system disconnection • ABS motor relay (contacts, coil)
(MR, R+, MT) • ABS motor relay system wire harness
13
• ABS actuator system (MT) wire harness
• Connector

ABS motor relay system short • ABS motor relay (contacts)

14 (MR, MT) • ABS motor relay system wire harness
• ABS actuator system (MT) wire harness
• Connector

Actuator right solenoid system malfunction • All solenoid system wire harnesses and
21
(SFRH, SFRR) connectors
• All solenoid valves
Actuator left solenoid system malfunction
22
(SFLH, SFLR)

Actuator right solenoid system malfunction

23
(SRRH, SRRR)

Actuator left solenoid system malfunction

24 (SRLH, SRLR)
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-31

Code Diagnostic system

Check location
number (terminal symbols)

Front right speed sensor system signal • All speed sensor system wire
31
malfunction (FR+, FR-) harnesses and connectors
• All speed sensors
Front left speed sensor system signal mal- • All speed sensor rotors
32
function (FL+, FL-) • ABS computer

Rear right speed sensor system signal mal-

33
function (RR+, RR-)

Rear left speed sensor system signal mal-

34
function (RL+, RL-)

Power supply voltage malfunction (IG1) • Battery

41
• IC regulator

49 Stop lamp switch disconnection (STP) • Stop lamp wire harness

ABS actuator motor does not rotate (MT) • ABS actuator motor wire harness and con-
nector
51
• Motor relay
• Battery

• Computer malfunction • Battery

* • High Power supply voltage

malfunction
• IC regulator

: Warning lamp lights up.

*
 1 page 1
77-32 ANTI LOCK BRAKE SYSTEM Model FA

ABS COMPUTER PRECAUTIONS WHEN PERFORMING CIRCUIT

HARNESS
CONNECTOR CHECKS USING A CIRCUIT TESTER
STRANDED
WIRE WARNING
● When using a conventional circuit tester to check
the ABS circuits, be very careful and follow these
precautions:
TEST PROBE OF ● Do not insert the test probe of the circuit tester
CIRCUIT TESTER SM77-7 directly into the pin holes of the harness con-
nector which is attached to the ABS computer.
Insertion will cause the holes to widen, result-
ing in poor contacts when the connector is
reattached to the ABS computer.
● Always wrap narrow stranded wire around the
tip of the test probe. Then insert one end of the
narrow stranded wire into the pin hole to test
the circuit.
● Always refer to the ELECTRICAL WIRING DIA-
GRAM when performing circuit inspections.

26-PIN CONNECTOR

E1 E2 E5 E8 E9 E10 E11 E12 E13

E14 E15 E21 E22 E23 E25 E26

[ABS COMPUTER HARNESS CONNECTOR PIN NUMBERS]

12-PIN CONNECTOR

E27 E28 E29 E31 E32

E33 E34 E35 E36 E37 E38

[ABS COMPUTER HARNESS CONNECTOR PIN NUMBERS]

SM77-7
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-33

Connector terminal name

Connector Pin No. Symbol Contents
E1 SFRR FR pressure reduction solenoid output
E2 SFRH FR pressure maintenance solenoid output
E3 Blank
E4 Blank
E5 STP Stop lamp switch input
E6 Blank
E7 Blank
E8 TC Diagnostics start-up input
E9 RL– Rear left wheel speed sensor (–) input
E10 RR+ Rear right wheel speed sensor (+) input
E11 WA ABS warning lamp output
26-pin connector

E12 GND Ground

E13 IG1 IG1 power source
E14 SRLR RL pressure reduction solenoid output
E15 SRLH RL pressure maintenance solenoid output
E16 Blank
E17 GND (Connection to vehicle prohibited)
E18 Blank
E19 Blank
E20 Blank
E21 TS Sensor check start-up input
E22 RL+ Rear left wheel speed sensor (+) input
E23 RR– Rear right wheel speed sensor (–) input
E24 D/G (Connection to vehicle prohibited)
E25 GND Ground
E26 R+ Relay power source

Connector Pin No. Symbol Contents

E27 MR ABS motor relay output
E28 FL– Front left wheel speed sensor (–) input
E29 FR+ Front right wheel speed sensor (+) input
E30 Blank
12-pin connector

E31 SFLH FL pressure maintenance solenoid output

E32 SFLR FL pressure reduction solenoid output
E33 SR ABS solenoid relay output
E34 FL+ Front left wheel speed sensor (+) input
E35 FR– Front right wheel speed sensor (–) input
E36 MT ABS motor relay test input
E37 SRRH RR pressure maintenance solenoid output
E38 SRRR RR pressure reduction solenoid output
 1 page 1
77-34 ANTI LOCK BRAKE SYSTEM Model FA

ABS COMPUTER HARNESS CONNECTOR INSPECTION ITEMS

STANDARD
No. INSPECTION ITEM PIN NO. NOTES
VALUE
Inspect with starter switch in the ON position
1. Test of solenoid relay coils and E26-E33 100-300 (mA) Confirm relay operation
associated wiring sound
2. Test of sub relay coil and its wiring E26-E27 100-300 (mA) Confirm relay operation
sound
Inspect with starter switch in the OFF position
1. Resistance of wheel sensor Front left E34 - E28
coil and its wiring Front right E29 - E35
1.20-3.00(kΩ)
Rear left E22 - E9
Rear right E10 - E23
2. Wheel sensor output voltage Front left E34 - E28 1. Wheels should make one
rotation every five seconds.
Front right E29 - E35 2. The ratio of the output volt-
150-1999(mV)
Rear left E22 - E9 ages for the left and right
wheels should be approxi-
Rear right E10 - E23 mately 200%.

NOTE: ● Pin no.: Indicates pin number of ABS computer harness connector.
● Front left: Front left wheels, Front right: Front right wheels, Rear left: Rear left wheels,
Rear right: Rear right wheels
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-35

MAINTENANCE OF COMPONENTS
ABS COMPUTER
REMOVAL
1. Turn off the starter switch.
(This will prevent damage to the ABS computer.)
2. Remove the passenger seat.
3. Unplug the harness connector from the ABS computer.
NOTE: Grasp the harness connector by the base and
unplug it slowly.

SM77-17
4. Remove the bolts that secure the ABS computer in place.
WARNING
NEVER disassemble the ABS computer. If the ABS
computer malfunctions, replace the entire ABS com-
puter assembly.

MOUNTING
1. Mount the ABS computer by reversing the removal proce-
dure.
NOTE: ● Grasp the harness connector by the base
when handling it.
● Do not exert excessive force on the pin
when fitting them together.
● Confirm that the harness connector and
harness connector lock are securely locked
together.
 1 page 1
77-36 ANTI LOCK BRAKE SYSTEM Model FA

ABS ACTUATOR
INSPECTION
1. Inspecting the solenoid coil of the ABS actuator.
1) Switch off the starter switch.
2) Remove the harness connector from the ABS actua-
tor.
SRLR SFLR SFRR 3) Apply the test probe of the circuit tester to the pins of
the harness connector of the ABS actuator to mea-
SFRH
sure the solenoid coil resistance.
SFLH STANDARD VALUES
SRLH Between BS and SFRH : 8.8 ± 0.5 Ω
Between BS and SFLH : 8.8 ± 0.5 Ω
SRRH
Between BS and SRLH : 8.8 ± 0.5 Ω
BS SRRR Between BS and SRRH : 8.8 ± 0.5 Ω
Between BS and SRRR : 4.3 ± 0.3 Ω
Between BS and SRLR : 4.3 ± 0.3 Ω
Between BS and SFLR : 4.3 ± 0.3 Ω
Between BS and SFRR : 4.3 ± 0.3 Ω

4) If the measured values are outside the 8.8 ± 0.5 Ω,

4.3 ± 0.3 Ω range, there may be a broken wire or a
short in the solenoid coil. Replace the ABS actuator.

WARNING
NEVER disassemble any ABS actuator. If an ABS
actuator malfunctions, replace the entire ABS ac-
tuator assembly.

ACTUATOR
SM77-31

FOR FRONT REMOVAL AND MOUNTING

Tighten the oil pipe flare nuts using the rated torque val-
ues.
kg·cm (lb·ft)

PIPE SIZE FLARE NUT TORQUE

200 – 300
ø6.35 M12
(14 – 21)
SM77-19
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-37

WHEEL SENSOR, SENSOR RING AND CLAMPING BUSHING

REMOVAL AND MOUNTING OF EACH PARTS
The removal and mounting of the wheel sensor, sensor
ring and clamping bushing, requires removal of the wheel
hub.
Make sure to read CHAPTER 10, REAR AXLE and CHAP-
TER 11, FRONT AXLE before removal and mounting.

INSPECTION
WHEEL SENSOR
1. Wheel sensor resistance check
1) Turn off the starter switch.
2) Remove the harness connector from the wheel sen-
sor.
CONNECTOR 3) Apply the test probe of the circuit tester to the pins of
SENSOR
the harness connector to measure the wheel sensor
SM77-8 resistance.

STANDARD VALUE: 1.2 – 3.0 kΩ

4) If the measured values are outside the standard value

range, the wheel sensor may have malfunctioned. Re-
place the wheel sensor.

SENSOR RING
1. Make a visual inspection to check for damage or malfunc-
tion of the sensor ring, and also to make sure that it is not
coming loose from the wheel hub.
2. If any damage or malfunction is discovered, replace the
sensor ring.
3. If the sensor ring is coming loose from the wheel hub, use
a dolly block and a press to pressure mount it again.
SM77-42

CLAMPING BUSHING
1. Confirm that the wheel sensor is securely fixed in place.
2. If the wheel sensor comes off easily, or if it can be pushed
in easily, replace the clamping bushing.
 1 page 1
77-38 ANTI LOCK BRAKE SYSTEM Model FA

WARNING LAMP
ABS WARNING LAMP CHECK
1. Turn on the starter switch and confirm that the ABS warn-
ing lamp lights once and goes off.
2. If the ABS warning lamp does not light and go out nor-
mally, inspect the warning lamp relay.

SM77-1

RELAY
INSPECTION
1. Turn off the starter switch.
2. Remove the relay.
3. Use a battery (12V) and a circuit tester to inspect current
flow and insulation between the pins in the relay harness
connector.
4. If the current flow and insulation status of the relay differs
EXHAUST BRAKE ABS MOTOR from what’s indicated below, replace the relay.
CUT RELAY RELAY

SUB RELAY ABS SOLENOID

RELAY
SM77-32

EXHAUST BRAKE CUT RELAY

PIN NO. TO BE TESTED
BETWEEN BETWEEN
CURRENT FLOW STATUS
30 - 87 30 - 87a

12V FLOWING CURRENT

INSULATED
BETWEEN 85 AND 86 FLOW

NO CURRENT FLOWING CURRENT

INSULATED
BETWEEN 85 AND 86 FLOW

1 ABS MOTOR RELAY

3
PIN NO. TO BE TESTED
BETWEEN
CURRENT FLOW STATUS
1-2

12V FLOWING CURRENT

BETWEEN 3 AND 4 FLOW

NO CURRENT FLOWING
INSULATED
BETWEEN 3 AND 4
2 4 SM77-33
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-39

2 1 SUB RELAY
PIN NO. TO BE TESTED
BETWEEN
CURRENT FLOW STATUS
1-2

12V FLOWING CURRENT

BETWEEN 3 AND 4 FLOW

4 NO CURRENT FLOWING
3 INSULATED
BETWEEN 3 AND 4
SM77-33

1 4 ABS SOLENOID RELAY

NOTE: When measuring parts marked with an asterisk ( ),
5
alternate the tester probes and designate which-
*
ever terminal is conductive as the current flow.
CURRENT FLOW
STATUS 12V FLOWING NO CURRENT
BETWEEN FLOWING
PIN NO.
TO BE TESTED
4 AND 6 BETWEEN 4 AND 6
2
6
3 BETWEEN CURRENT
SM77-33 INSULATED
1-3 FLOW

BETWEEN CURRENT
INSULATED
* 1-5 FLOW

BETWEEN CURRENT
INSULATED
2-3 FLOW

BETWEEN CURRENT
INSULATED
* 2-5 FLOW

BETWEEN CURRENT CURRENT

* 3-5 FLOW FLOW
 1 page 1
77-40 ANTI LOCK BRAKE SYSTEM Model FA

ABS WIRE HARNESSES

FRONT AXLE ABS WIRE HARNESS

The wire harness that runs from the side frame to the front
axle wheel sensor must absorb the steering angle of the
front wheel and the movement of the chassis springs. It is
therefore necessary to always maintain an optimal spac-
ing between the clips.

ASM13-949

The optimal spacing between the clips is achieved when the wheel sensor connectors are attached in the
regular locations shown in the diagram such that the sensor cabling within the frame is not loose.
When disassembling and reassembling, confirm that the connector and sensor cable layout is appropriate.

FRONT AXLE WHEEL SENSOR WIRE HARNESS ARRANGEMENT

ASM77-10
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-41

REAR AXLE ABS WIRE HARNESS

The wheel sensor wire harness is arranged so that the left and right wheel sensor wire harnesses are
near each other. Therefore, special care should be taken not to make incorrect connections if the
harnesses have been removed for inspection or repairs. If incorrect connections are made, it will
interfere with the functioning of the ABS. For this reason, caution plates indicating “LEFT” and “RIGHT”
are affixed to the wire harnesses. Be sure to check when connecting the harnesses. The wheel sensor
wire harnesses, just like the front axle harnesses, must absorb the movement of the chassis springs.
It is therefore necessary to always maintain an optimal spacing between the clips.

When disassembling and re-assembling, confirm that the connector is secured in its proper place as
shown in the diagram and that the sensor cables in the frame and over the axle are not hanging
loosely.

SM77-11
 1 page 1
77-42 ANTI LOCK BRAKE SYSTEM Model FA

HANDLING WIRE HARNESSES

The various sensors, valves, relays and wire harness connections to the ABS computer employ multi-
polar harness connectors suitable for use with the weak currents used by electronic circuitry. Be very
careful when handling them.
1. Place the starter switch on “LOCK” before unplugging the harness connectors.
2. When unplugging the harness connectors, release the lock, hold the housing and unplug it straight
as much as possible.
3. Do not pull holding the wire harness or pull with excessive force. Doing so can cause the pins of
the harness connectors to be deformed.
4. Remove unnecessary connectors and do not plug them.
5. When inspecting using a circuit tester, insert the test probe from the wire harness side.
Never insert the test probe from the pins of harness connectors as this can cause bad contacts.

HOW TO INSERT TEST PROBE

6. When unplugging the harness connectors, do not allow water, oil, dust, or any other liquid or
substance to get on the terminals as they can cause bad contacts.
7. Be careful not to allow water, oil, dust, or any other liquid or substance to get on any component.
8. When plugging the harness connector, insert it completely and confirm that the harness connec-
tor lock is engaged.

ADDITIONAL PRECAUTIONS
1. Make sure the model’s starter switch is in the OFF position before unplugging the harness con-
nector from the ABS computer.
2. Make sure to unplug all the harness connectors from the ABS computer before performing weld-
ing on the chassis or body of the vehicle. Also be careful that welding sputter does not get onto
the harnesses.
3. When cleaning the interior of the model, make sure water does not get onto the ABS computer,
various relays, connectors, or any other component.
 1 page 1
Model FA ANTI LOCK BRAKE SYSTEM 77-43

4. USE OF A CIRCUIT TESTER

If a circuit tester is being used, always use one with an internal resistance greater than 100 kΩ
inside the voltage measurement range.
5. INSTALLATION OF A RADIO OR OTHER ELECTRONIC EQUIPMENT
All electronic and radio equipment installed on the vehicle must be mounted as far away from the
ABS computer and wire harness as possible. Installation of certain electronic and radio equip-
ment can also cause the ABS computer to malfunction. All such equipment must also conform to
all applicable laws. If you wish to install a radio or other electronic equipment, please contact your
Hino service representative.
6. QUICK BATTERY CHARGE
When charging batteries using a quick charger, do it with both battery terminals removed.
7. INSTALLATION OF ELECTRICAL EQUIPMENT INSIDE OF THE CAB
When installing an air conditioner or other electrical equipment inside of the cab, be careful not to
damage the engine, chassis, and wire harnesses inside the cab. Moreover, do not forget to plug
the harness connectors unplugged during the installation.
 1 page 1
77-44 ANTI LOCK BRAKE SYSTEM

CABLING DIAGRAM
MODEL FA
1 page 1
ANTI LOCK BRAKE SYSTEM 77-45

ASM77-50