Hino A860E User Manual

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Automatic transmission A860E

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Table of contents

1. Outline

2. Specification

3. Power train

4. Shift pattern

5. Electric control

6. Maintenance

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1. Outline

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1. Outline

1) Automatic transnission

① As the engine power is transmitted via a fluid, the shock during acceleration and

deceleration is significantly reduced, and smooth starting, acceleration, and deceleration
can be performed.

② As the driving force at low velocities is large, uphill starting becomes easier.
③ The possibility of engine overruns is reduced.
④ As a fluid is used, vibrations of the drive system are absorbed and the shocks to all parts

are small.

⑤ There is little probability of an engine stall resulting from operation errors.

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1) Automatic transmission

Transmission is separate the 3 groups. (torque converter, Gear mechanism, Control system)

1. Outline

Output shaft
of engine

Control
system

Gear
mechanism

Output shaft

Torque
converter

1

2

3

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2. Specification

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2. Specification

1) System & gear ratio

Transmission

type

A860E

Converter type

3

-Element, 1-step, 2-Phase, with Lock-up

mechanism

Stall torque ratio

1.95

Shift

position

Gear ratio

1

st

gear

3.742

2

nd

gear

2.003

3

rd

gear

1.343

4

th

gear

1.000

5

th

gear

0.773

6

th

gear

0.634
Reverse

3.539

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3. Power train

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3. Power train

1) Torque converter

The torque ratio shows a maximum when the turbine runner is stopped and the speed ratio is

zero. This is called the torque ratio, and it is 1.95 for the A860.
With increasing speed ratio, the torque ratio decreases, and in the coupling range the torque
ratio becomes 1. The output is proportional to the torque and the rotation speed, and the
transmission efficiency increases in the converter range, but when the oil from the turbine
runner hits the rear of the stator blades, the transmission efficiency starts to drop. However,

afterwards, in the coupling range, it rises proportional to the speed ratio.

Turbine runner

Pump impeller

Stator

One-way

clutch

Converter

front cover

Lock-up piston

Lock up clutch

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Un lock up: The operation pressure is not supplied between the converter front cover and the

lock-up piston, the lock-up clutch and the plate are separated, and the free-wheeling state is
reached.
Lock up: The operation pressure is supplied between the converter front cover and the lock­up piston, the lock-up clutch and the plate are engaged, and the normal operating state is
reached.

3. Power train

2) Torque converter rock up function

When lock-up is not operating

When lock-up is operating

: ATF flow

:Power train

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3) Operation system diagram

3. Power train

Input shaft

Sun Gear shaft

Front planetary

Muddle planetary

Rear planetary

Output shaft

Component Operation

Clutch No. 1 C1 Input shaft and Sun gear shaft are connected
Clutch No. 2 C2 Input shaft and Middle planetary shaft are connected
Clutch No. 3 C3 Front planetary ring gear and Middle planetary ring gear are connected

Brake No. 1 B1 Middle planetary gear rotation is lock

Brake No. 2 B2 Middle & Rear planetary ring gear are rotation is lock
One way Clutch No.1 F1 Left rotation of Middle planetary carrier to case is lock

C1 C2 C3 B1 B2 F1 Gear ratio

P

● －

R

● ●

3.539

N

● －

D

1 st

● ●

3.742

2 nd

● ●

2.003

3 rd

● ●

1.343

4 th

● ●

1.000

5 th

● ●

0.773

6 th

● ●

0.634

Component & Operation condition

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3) Operation system diagram

3. Power train

(1) 1st (D range･ L-3 range)

(2) 2nd (D range・L - 3 range)

Input shaft

Sun Gear shaft

Front planetary Muddle planetary Rear planetary

Output shaft

Operation

Input shaft

Sun Gear shaft

Front planetary Muddle planetary Rear planetary

Output shaft

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3) Operation system diagram

3. Power train

Input shaft

Sun Gear shaft

Front planetary Muddle planetary Rear planetary

Output shaft

Input shaft

Sun Gear shaft

Front planetary

Muddle planetary

Rear planetary

Output shaft

(3) 3rd (D range･ L-3 range)

(4) 4th (D range・4 range)

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3) Operation system diagram

3. Power train

Input shaft

Sun Gear shaft

Front planetary Muddle planetary Rear planetary

Output shaft

Input shaft

Sun Gear shaft

Front planetary

Muddle planetary

Rear planetary

Output shaft

(5) 5th (D range)

(6) 6th (D range)

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3) Operation system diagram

3. Power train

Input shaft

Sun Gear shaft

Front planetary Muddle planetary

Rear planetary

Output shaft

(7) R (R range)

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4. Shift pattern

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1) Shift pattern

The gear change pattern of the shift position indicator is shown in the table of image.

4. Shift pattern

４

Ｒ

Ｄ

Ｎ

P

L-3

Range Gear change, lock-up pattern

D 1st ⇔ 2nd* ⇔ 3rd* ⇔ 4th* ⇔ 5th* ⇔ 6th*
4 1st ⇔ 2nd* ⇔ 3rd* ⇔ 4th*

L-3 1st ⇔ 2nd ⇔ 3rd

Overdrive button

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2) Shift lock release lever

New vehicle have the Shift lock release lever.

This information for the distributor only, Prohibition the share to the customer

4. Shift pattern

Shift lock release lever

Old model no equippedNew model

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5. Electric control

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1) System diagram for AT

5. Electric control

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2) Sensors

5. Electric control

Overall transmission control, gear change, lock-up, and clutch hydraulic control are performed

based on the sensors shown in the above figure.

Turbine sensor

Speed sensor

Neutral start
switch

Transmission
wire connector

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3) ECU & Switch

AT-related sensor positions in the cab

5. Electric control

DLC 3

ENGINE CONTROL
COMPUTER

AT ECU &

Shift rock controller

O/D switch

Component parts Function

Shift position indicator Shift position in use is displayed

Transmission ECU Receiver the signal from each sensor, Transmission controlled.

When trouble of system, It has Diagnosis mode and Fail safe.

DCL 3 Displayed to DTC and computer data by Hino DX

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4) Shift lock controller

New vehicle has the shift lock function.

Shift lock function is control by the shift lock controller.

5. Electric control

Shift rock
controller

Shift rock controller connector

No Pin

1

ACC

2

Ignition

3

Solenoid (shift lock side)

4

Stop

signal

5

Solenoid

(key lock side)

6 -

7

AT lock switch

8

AT free

switch

9 -

10

Earth

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5) System diagram for shift lock controller

Shift lock controller is receive brake signal, ACC signal, IG signal, shift lever lock

position, and shift lever free position for control the shift lever lock and free.

5. Electric control

4

Solenoid (Shift rock
side)

Solenoid (Key rock side)

1

2

8

7

10

3

5

Stop light

IG S/W

Brake S/W

Parking indicator

AT free S/W

AT lock S/W

ACC

IG

Shift lock
controller

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6) Component parts and their functions

The electronic components and the functions of the A860 are as shown in the table.

5. Electric control

Component parts Function

Transmission solenoid No. 1 Switches the clutch and brake connections of line pressure and control pressure.

Transmission solenoid No. 2 Switches the clutch and brake connections of line pressure and control pressure.
Transmission solenoid No. 3 Switches the clutch and brake connections of line pressure and control pressure.
Transmission solenoid No. 4 Switches the clutch and brake connections of line pressure and control pressure.
Linear solenoid No. 1 Controls the clutch hydraulic pressure.
Linear solenoid No. 2 Controls the clutch and brake hydraulic pressure.
Linear solenoid No. 3 Controls the clutch and brake hydraulic pressure and the lock-up pressure.
Linear solenoid PL Controls the line hydraulic pressure.
Output speed sensor Detects the transmission output speed.

A/T oil temperature sensor Detects the oil temperature in the transmission hydraulic pressure control circuit.

Stop lamp switch Detects the ON/OFF status of the brake pedal.
Neutral start switch Detects the transmission shift range.

O/D switch Detects the ON/OFF status of the O/D switch.

Engine speed sensor Detects the engine speed.
Turbine speed sensor Detects the turbine speed of the torque converter.
Exhaust brake switch Detects the ON/OFF status of the exhaust brake switch.

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7) Combination meter indicator

Use 3 Indicator lights for the Automatic transmission.

5. Electric control

＜O/D OFF lamp＞

＜Oil temperature warning lamp＞

＜AT check lamp＞

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8) DTC and combination of check lamp lighting

○ ： Lit ◎ ：Flashing ×：Not lit －：Not applicable

5. Electric control

SAE

CODE

TCCS

CODE

Warning lamp

Detection item

O/D OFF

CHECK ＡＴ

Ｐ0500

42

◎ ○※1

Vehicle speed sensor system 1

Ｐ0720

61

◎ ○※1

Vehicle speed sensor system 2

Ｐ0715

12

◎ ○

Turbine speed sensor

Ｐ0725

86

◎ ○

Engine rotation sensor

Ｐ0710

38

× ×

Oil temperature sensor (ATF)

Ｐ0740

17

◎ ×

Oil temperature sensor (TC)

Ｐ0705

43

◎ ○

Shift position switch

Ｐ0706

44

◎ ○

D range pressure abnormal

Ｐ0748

25

◎ ○

Linear solenoid 1

Ｐ0778

26

◎ ○

Linear solenoid 2

Ｐ2759

27

◎ ○

Linear solenoid 3

Ｐ2716

28

◎ ○

Linear solenoid 4

Ｐ0974

62

◎ ○

Shift solenoid 1 (ignition short-circuit/wire break)

Ｐ0973

62

◎ ○

Shift solenoid 1 (GND short-circuit)

Ｐ0977

63

◎ ○

Shift solenoid 2 (ignition short-circuit/wire break)

Ｐ0976

63

◎ ○

Shift solenoid 2 (GND short-circuit)

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8) DTC and combination of check lamp lighting

○ ： Lit ◎ ：Flashing ×：Not lit －：Not applicable

5. Electric control

SAE

CODE

TCCS

CODE

Warning lamp

Detection item

O/D OFF

CHECK ＡＴ

Ｐ0980

64

◎ ○

Shift solenoid 3 (ignition short-circuit/wire break)

Ｐ0979

64

◎ ○

Shift solenoid 3 (GND short-circuit)

Ｐ0986

65

◎ ×

Shift solenoid 4 (ignition short-circuit/wire break)

Ｐ0985

65

◎ ×

Shift solenoid 4 (GND short-circuit)

Ｐ1911

51

× ×

PTO solenoid

U0100 88

◎ ○

CAN communication suspension (engine ECU)

U110A 88

× ×

CAN communication suspension (vehicle control ECU) *2

P0562 11

◎ ○

Power supply system

P0746 31

◎ ○

Control valve 1

P0776 32

◎ ○

Control valve 2

P2557 33

◎ ○

Control valve 3

P0751 45

◎ ○

Shift valve 1

P0756 46

◎ ○

Shift valve 2

P0761 47

◎ ○

Shift valve 3

P0761 48

◎ ○

Shift valve 4

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8) DTC and combination of check lamp lighting

○ ： Lit ◎ ：Flashing ×：Not lit －：Not applicable

5. Electric control

SAE

CODE

TCCS

CODE

Warning lamp

Detection item

O/D OFF

CHECK ＡＴ

P0730 37

◎ ○

Gear ratio abnormal

P2764 36

× ×

Lock-up abnormal

Ｐ1604

24

◎ ×

CAN communication (accelerator opening abnormal)

Ｐ1604

54

◎ ×

CAN communication (exhaust brake operation signal abnormal)

※1 "CHECK A/T" lights up only when P0500 (vehicle speed sensor system1) and

P0720 (vehicle speed sensor system 2) both are established.

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6. Maintenance

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1) Supply part’s list

Shift lever and cable for A860E.

6. Maintenance

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Torque converter for A860E.

1) Supply part’s list

6. Maintenance

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Transmission front and rear bearing and speed sensor for A860E.

1) Supply part’s list

6. Maintenance

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Housing and oil pan for A860E.

1) Supply part’s list

6. Maintenance

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Control system for A860E.(under the transmission)

1) Supply part’s list

6. Maintenance

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Harness and shift lever for A860E.

1) Supply part’s list

6. Maintenance

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Oil cooler hose and bracket for A860E.

1) Supply part’s list

6. Maintenance

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Speed sensor and neutral S/W for A860E.

1) Supply part’s list

6. Maintenance

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AT ECU, shift lock controller and DC-DC converter for A860E.

1) Supply part’s list

6. Maintenance

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Have to do the initial learning for A860E when replacing AT assembly or replacing the AT ECU.

If you work the Initial learning by DLC connector shorting,
Engine ECU will lost the pump learning value, have to do the Difference learning again.

2) Initial learning

6. Maintenance

If you change the ECU or AT assembly, you have to do the initial learning.

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The ECU performs control of the AT and learns the oil pressure characteristic of the AT.

3) Initial learning flow(Dealer adjustment flow)

6. Maintenance

Learning mode IN by special operation
(Diagnostic terminals short-circuit or combination
of accelerator, brake, and shift operation)

Indication of mode IN by lamp

Learning start operation

(switch or shift operation)

Learning program implementation
(automatic operation of the AT by the ECU)

Indication of learning completion by lamp

Learning
program
implementation

Maintain an engine

speed of 1000 to

1500 rpm for
stabilization of the
AT oil pressure
during learning

Engine idling speed
increase

Initial learning flow

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3) Perform AT initial learning(step 1 to step 2)

6. Maintenance

Perform AT initial learning 1 (11)

Perform AT initial learning 2 (1)

AT initial learning (4)

TC

CG

Lit

No Lit

0.2 sec

0.2 sec

AT initial learning

During execution of

AT initial learning 1

During execution of

AT initial learning 2

0.2 sec 0.5 sec

0.2 sec

0.5 sec

Lit

No Lit

AT initial learning mode

0.2 sec 0.5 sec

0.2 sec

Lit

No Lit

0.2 sec

0.5 sec

0.2 sec

Perform AT initial learning 1 (7)

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6. Maintenance

3) Perform AT initial learning(step 3 to step 4)

Perform AT initial learning 3 (4)

Perform AT initial learning 4 (2)

Perform AT initial learning 4 (3)

During execution of AT initial learning 3

0.2 sec

0.5 sec

0.2 sec

Lit

No Lit

0.2 sec

0.5 sec

0.2 sec

During execution of
AT initial learning 3

During execution of
AT initial learning 4

0.2 sec 0.5 sec

Lit

No Lit

0.2 sec

2 sec

1 sec

Lit

No Lit

2 sec

1 sec

Ignition switch OFF

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Perform with the oil temperature for normal driving conditions (50 to 80 C).

Perform with the air conditioning switched OFF. The test details are as shown in the figure.

4) Running test after the initial learning

6. Maintenance

Inspection item Inspection and confirmation outline

D range shift function Inspect gear 1 ⇔ gear 2 ⇔ gear 3 ⇔ gear 4 ⇔ gear 5 ⇔ gear 6 shifting with normal driving

(driving on general city streets).
Shift shock level while running in D range Check the shock level each time the gear is shifted up during normal driving.
Operation of the transmission control switch In the range of gear 6, move the transmission control switch between ON and OFF and check

shifting between gear 6and gear 5.
Kick-down function • Perform kick-sown for each gear and check that down-shifting is performed.

• Check the shock level at the time of kick-down.

Engine brake operation • While driving with gear 5 in the D range (approximately 55 to 65 km/h), shift from D range to

range 4 and check the engine brake operation with rear 4.

• While driving with gear 4 in the range 4 (approximately 30 to 40 km/h), shift from D range to

L-3 range and check the engine brake operation with rear 3.

Shifting point with fully open accelerator pedal Start driving in D range with fully depressed accelerator pedal and check that the up-shift

speed from gear 1 to gear 2 is suitable for the shifting point.
Lock-up function While driving on a level road at a constant speed in the lock-up speed range, confirm that the

engine speed does not change much when the accelerator pedal is depressed lightly.
P range operation Stop the vehicle on a slope (approximately 5 (or more), shift to P range, and confirm that the

vehicle does not move when the parking brake is released.
Abnormal noise, vibrations Inspect for abnormal noise and vibrations while driving and shifting.
Oil leakage After the running test, inspect all parts for oil leakage.

Running test with D range mode

Running test with the manual mode

Shift lever position Position

D range gear 3
Range 4 gear 3

L-3 range gear 3

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DTC check method

1. Set the ignition switch to OFF.

2. Use the SST and short-circuit between 13 (CG) and 4 (TC) of DLC3.

3. Set the ignition switch to ON and read the fault code from the flashing pattern of Check AT .

5) DTC check method by the DLC connector

6. Maintenance

abnormal

Normal

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Diagnostic code deletion method

1. Short-circuit between 13 (CG) and 4 (TC) of DLC3 and wait for 3 seconds.

2. Set the O/D switch of the shift lever to OFF for O/D OFF status, and wait for 3 seconds.

3. Open between 13 (CG) and 4 (TC) of DLC3.

6. Maintenance

TC

CG

6) DTC delete method by the DLC connector

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Caution of ATF level check

1. Too much or too little oil can cause trouble.

2. Inspect after confirming the idle speed.

3. Stop the vehicle on a level surface.

4. Inspect after complete warm-up of the engine (70 to 80 C)

5. Use the specified fluid.

7) ATF maintenance interval

6. Maintenance

Specified

(recommended) brand

Genuine Toyota Auto Fluid type

T-IV

Inspection, replenishing For a new vehicle after 1,000 km

* Afterwards, every 3 months in
case of commercial use and
every 6 months in case off
private use

* Severe conditions

Replacement 2 years or 40,000 km

1 year or 20,000 km when driving

on rough roads or with frequent
starts and stops

Capacity Approximately 12.0 L

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8) Drain plug and fill plug position

6. Maintenance

Drain plug Fill plug