Hino Series 155, Series 155h, Series 195, 195h Workshop Manual

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FOREWORD

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

Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine

When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.

Please note that the publications below have also been prepared as relevant workshop manuals for the components and sys­tems in these vehicles.

Chassis Workshop Manual

J05E Engine Workshop Manual S5-LJ05E04A

Trouble shooting Workshop Manual

's Manual.

Manual Name Pub. No.

S1-LXJE03A

S1-LXJE03A EWD

S7-LXJE03C 1/7
S7-LXJE03C 2/7
S7-LXJE03C 3/7
S7-LXJE03C 5/7
S7-LXJE03C 6/7
S7-LXJE03C 7/7

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.

MANUAL No. S7-LXJE03C 4/7 (U.S.A.), S7-LXJE04C 4/7 (CANADA)

CHAPTER

HYBRID 3-001

MODELS HINO 155, 155h, 195, 195h

Production Code XFC710, XFC720, XFC740, XJC700, XJC710, XJC720, XJC740

INDEX: TROUBLE SHOOTING GROUP 1/2

GENERAL INTRODUCTION

ENGINE

HYBRID

WORKSHOP
MANUAL

TRANSMISSION

CLUTCH

PROPELLER SHAFT

AXLE

DIFFERENTIAL

BRAKE

STEERING

SUSPENSION

All rights reserved. This manual may not be
reproduced or copied in whole in part, with­out the written consent of Hino Motors, Ltd.

FRAME AND FRAME ACCESSORY

CAB MOUNTING AND CAB SUSPENSION

BODY CONSTRUCTION

BODY INSIDE ACCESSORY

BODY OUTSIDE ACCESSORY

AIR BAG AND SEAT BELT

HEATER AND AIR CONDITIONER

INDEX: TROUBLE SHOOTING GROUP 2/2

ELECTRICAL

CONTROL SYSTEM

HYBRID 3–1

3

HYBRID

3-001

TROUBLE SHOOTING.................................... 3-4

HYBRID CONTROL SYSTEM......................................3-4

TROUBLE SHOOTING STEPS

FOR HYBRID SYSTEM ..........................................3-4

SAFETY MEASURES

FOR HIGH-VOLTAGE WORK ...............................3-12

LIST OF CONNECTOR SYMBOLS......................3-15

HV SYSTEM WIRING DIAGRAM ......................... 3-19

HEARING SHEET.................................................3-21

HYBRID ECU .............................................................3-22

DIAGNOSIS CODE TABLE...................................3-22

FREEZE FRAME DATA LIST ................................3-30

LIST OF DATA MONITOR ITEMS .........................3-33

COMMON INSPECTION CHART.........................3-36

DTC: P0500 (TC51) ..............................................3-41

DTC: P0501 (TC5B)..............................................3-51

DTC: P0562 (TC71) ..............................................3-57

DTC: P060B (TCB2) .............................................3-66

DTC: P0617 (TC59) ..............................................3-69

DTC: P062F (TCB3)..............................................3-78

DTC: P0810 (TC9C)..............................................3-81

DTC: P0810 (TC9D)..............................................3-85

DTC: P0A01 (TC7B) .............................................3-89

DTC: P0A02 (TC78)..............................................3-98

DTC: P0A03 (TC79)............................................3-106

DTC: P0A06 (TC7F)............................................3-113

DTC: P0A07 (TC7E) ...........................................3-125

DTC: P0A0F (TC31)............................................3-129

DTC: P0A1D (TC12) ...........................................3-133

DTC: P0A1D (TC17) ...........................................3-136

DTC: P0A78 (TC21)............................................3-139

DTC: P0A78 (TC22)............................................3-142

DTC: P0A7E (TC48) ...........................................3-145

DTC: P0A82 (TC67)............................................3-151

DTC: P0A84 (TC66)............................................3-164

DTC: P0A85 (TC65)............................................3-177

DTC: P0A90 (TC2A) ...........................................3-183

DTC: P0A92 (TC29)............................................3-195

DTC: P0A93 (TC7A) ...........................................3-210

DTC: P0AFD (TC6B)...........................................3-217

DTC: P0BCA (TC68)...........................................3-221

DTC: P0C73 (TC80)............................................3-227

DTC: P3000 (TC42) ............................................3-234

DTC: P3001 (TC41) ............................................3-243

DTC: P3001 (TC43) ............................................3-246

DTC: P3001 (TC44) ............................................3-249

DTC: P3001 (TC45) ............................................3-252

DTC: P3001 (TC46) ............................................3-255

DTC: P3001 (TC47) ............................................3-259

DTC: P3001 (TC4A)............................................3-263

DTC: P3001 (TC4B)............................................3-267

DTC: P3001 (TC4C)............................................3-270

DTC: P3009 (TC49) ............................................3-273

DTC: P3128 (TC7D)............................................3-289

DTC: P3129 (TC7C)............................................3-301

DTC: P314C (TC82)............................................3-306

DTC: P314D (TC81)............................................3-311

DTC: P324B (TC62)............................................3-323

DTC: P324C (TC61)............................................3-328

DTC: P33B1 (TC64)............................................3-334

DTC: P33B2 (TC63)............................................3-339

DTC: U0073 (TC11) ............................................3-345

DTC: U0074 (TC16) ............................................3-350

DTC: U0100 (TC13) ............................................3-354

DTC: U0101 (TC18) ............................................3-358

DTC: U0110 (TC14) ............................................3-365

DTC: U0111 (TC15) ............................................3-373

DTC: U0121 (TC24) ............................................3-381

DTC: U0155 (TC25) ............................................3-388

DTC: U110A (TC26)............................................3-395

DTC: U1136 (TC27) ............................................3-402

INVERTER................................................................3-409

DIAGNOSIS CODE TABLE .................................3-409

FREEZE FRAME DATA LIST ..............................3-415

DATA MONITOR ITEM LIST................................3-417

CONNECTION DIAGRAM ..................................3-420

INSULATION RESISTANCE MEASUREMENT
PROCEDURE FOR HYBRID MOTOR

[ROTATION MACHINE] .......................................3-421

DTC: P0562 (TC96) ............................................3-423

DTC: P0562 (TCA0)............................................3-433

DTC: P0604 (TC18) ............................................3-443

DTC: P0604 (TCD2)............................................3-445

DTC: P0605 (TC17) ............................................3-447

DTC: P0605 (TCD1)............................................3-449

DTC: P060B (TC1A) ...........................................3-451

DTC: P060C (TC1C) ...........................................3-454

DTC: P062F (TC41) ............................................3-456

DTC: P0A0D (TC20) ...........................................3-458

DTC: P0A1B (TC16) ...........................................3-465

HYBRID3–2

DTC: P0A1B (TC92)............................................3-472

DTC: P0A1B (TC97)............................................3-474

DTC: P0A1B (TC3F) ...........................................3-476

DTC: P0A1B (TCA1) ...........................................3-478

DTC: P0A1B (TCA2) ...........................................3-480

DTC: P0A1B (TCA3) ...........................................3-482

DTC: P0A1B (TCA4) ...........................................3-484

DTC: P0A1B (TCA5) ...........................................3-486

DTC: P0A1B (TCA6) ...........................................3-488

DTC: P0A1B (TCA7) ...........................................3-490

DTC: P0A1B (TCA8) ...........................................3-492

DTC: P0A1B (TCA9) ...........................................3-494

DTC: P0A1B (TCAA)...........................................3-496

DTC: P0A1B (TCBB)...........................................3-503

DTC: P0A1B (TCBC)...........................................3-505

DTC: P0A1B (TCBD)...........................................3-507

DTC: P0A1B (TCBE)...........................................3-509

DTC: P0A1B (TCBF) ...........................................3-511

DTC: P0A1B (TCD3) ...........................................3-513

DTC: P0A1B (TCD4) ...........................................3-515

DTC: P0A1B (TCD5) ...........................................3-517

DTC: P0A1D (TC21) ...........................................3-519

DTC: P0A2B (TCE9) ...........................................3-523

DTC: P0A2B (TCED)...........................................3-534

DTC: P0A2C (TCDA)...........................................3-545

DTC: P0A2D (TCDB) ..........................................3-555

DTC: P0A2F (TC33)............................................3-566

DTC: P0A3C (TC34) ...........................................3-573

DTC: P0A3F (TCB7) ...........................................3-593

DTC: P0A41 (TCC0) ...........................................3-602

DTC: P0A42 (TCC1) ...........................................3-614

DTC: P0A51 (TCD6) ...........................................3-626

DTC: P0A51 (TCD7) ...........................................3-629

DTC: P0A78 (TC13) ............................................3-632

DTC: P0A78 (TC14) ............................................3-645

DTC: P0A78 (TC15) ............................................3-664

DTC: P0AA1 (TCD8) ...........................................3-671

DTC: P0AA4 (TCD9) ...........................................3-678

DTC: P0ADB (TC1F)...........................................3-687

DTC: P0ADC (TC93)...........................................3-694

DTC: P0ADF (TC1E)...........................................3-702

DTC: P0AE0 (TC95)............................................3-709

DTC: P0AE6 (TC1D) ...........................................3-717

DTC: P0AE7 (TC94)............................................3-724

DTC: P0AEE (TC22) ...........................................3-732

DTC: P0AEE (TC23) ...........................................3-735

DTC: P0AEF (TC24) ...........................................3-738

DTC: P0AF0 (TC25)............................................3-742

DTC: P0BEA (TCB3)...........................................3-746

DTC: P0BEA (TCB4)...........................................3-749

DTC: P0BEB (TC9A)...........................................3-752

DTC: P0BEC (TC9B)...........................................3-755

DTC: P0BEE (TCB5)...........................................3-758

DTC: P0BEE (TCB6)...........................................3-761

DTC: P0BEF (TC9C)...........................................3-764

DTC: P0BF0 (TC9D) ...........................................3-767

DTC: P3126 (TC12) ............................................3-770

DTC: U0073 (TC91) ............................................3-783

DTC: U0074 (TC3E)............................................3-788

DTC: U0293 (TC31) ............................................3-792

BATTERY ECU .........................................................3-801

DIAGNOSIS CODE TABLE .................................3-801

LIST OF FREEZE FRAME DATA.........................3-804

LIST OF DATA MONITOR ITEMS .......................3-806

CONNECTION DIAGRAM...................................3-809

DTC: P0562.........................................................3-810

DTC: P0604.........................................................3-816

DTC: P0605.........................................................3-819

DTC: P060B ........................................................3-822

DTC: P062F ........................................................3-825

DTC: P0A1F ........................................................3-828

DTC: P0A7D........................................................3-831

DTC: P0A7F ........................................................3-835

DTC: P0A80 ........................................................3-840

DTC: P0A95 ........................................................3-845

DTC: P0A9D........................................................3-850

DTC: P0A9E........................................................3-854

DTC: P0AAE .......................................................3-858

DTC: P0AAF........................................................3-862

DTC: P0ABF........................................................3-866

DTC: P0AC0........................................................3-873

DTC: P0AC1........................................................3-880

DTC: P0AC2........................................................3-887

DTC: P0AC7........................................................3-894

DTC: P0AC8........................................................3-898

DTC: P0ACC .......................................................3-902

DTC: P0ACD .......................................................3-906

DTC: P0AEA .......................................................3-910

DTC: P0AEB .......................................................3-914

DTC: P0AFC .......................................................3-918

DTC: P0B25 ........................................................3-921

DTC: P0B3D........................................................3-925

DTC: P0B42 ........................................................3-930

DTC: P0B47 ........................................................3-935

DTC: P0B4C........................................................3-940

DTC: P0B51 ........................................................3-945

DTC: P0B56 ........................................................3-950

DTC: P0B5B........................................................3-955

DTC: P0B60 ........................................................3-960

DTC: P0B65 ........................................................3-965

DTC: P0B6A........................................................3-970

DTC: P0B6F ........................................................3-975

DTC: P0B74 ........................................................3-980

DTC: P0B79 ........................................................3-985

DTC: P0B7E........................................................3-990

DTC: P0B83 ........................................................3-995

DTC: P0B88 ......................................................3-1000

DTC: P0B8D......................................................3-1005

DTC: P0B92 ......................................................3-1010

DTC: P0B97 ......................................................3-1015

DTC: P0B9C .....................................................3-1020

DTC: P0BA1......................................................3-1025

DTC: P0C30......................................................3-1030

DTC: P3004 ......................................................3-1036

DTC: P3011 ......................................................3-1039

DTC: P3012 ......................................................3-1044

DTC: P3013 ......................................................3-1049

DTC: P3014 ......................................................3-1054

DTC: P3015 ......................................................3-1059

DTC: P3016 ......................................................3-1064

DTC: P3017 ......................................................3-1069

DTC: P3018 ......................................................3-1074

DTC: P3019 ......................................................3-1079

DTC: P301B ......................................................3-1084

DTC: P3020 ......................................................3-1087

DTC: P3021 ......................................................3-1092

DTC: P3022 ......................................................3-1097

DTC: P3023 ......................................................3-1102

DTC: P3024 ......................................................3-1107

DTC: P3025 ......................................................3-1112

DTC: P3026 ......................................................3-1117

DTC: P3027 ......................................................3-1122

DTC: P3028 ......................................................3-1127

DTC: P3029 ......................................................3-1132

DTC: P302F ......................................................3-1137

DTC: P3065 ......................................................3-1142

DTC: P308A ......................................................3-1147

DTC: U0074 ......................................................3-1152

DTC: U0293 ......................................................3-1156

HYBRID 3–3

HYBRID/TROUBLE SHOOTING3–4

HV BATTERY ECU

HV SYSTEM ALARM

HV WARNING LIGHT

ENGINE ECU

VEHICLE CONTROL ECU

CLUTCH ECU

MIL

HV ECU OR COMMUNICATION
FUNCTION PERFORM
ALARMING ONLY WHEN THE
FUNCTION FAILS.

INVERTER

MALFUNCTION INFORMATION
MIL ON REQUEST

MALFUNCTION INFORMATION

MIL ON REQUEST

MALFUNCTION
INFORMATION

MIL ON
REQUEST

MIL ON REQUEST

HV ECU

READ CODE AND
DIAGNOSE

READ CODE AND DIAGNOSE

READ CODE AND
DIAGNOSE

SERVICE TOOL

HYBRID CONTROL SYSTEM:

CAN:

SIGNAL LINE:

SHTS03ZZZ0300001

TROUBLE SHOOTING

HYBRID CONTROL SYSTEM

TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM

CONFIGURATION DIAGRAM OF HYBRID TROUBLE SHOOTING SYSTEM

EN01H03ZZZ030602002001

HYBRID/TROUBLE SHOOTING 3–5

LIGHT ON OR LIGHT OFF

HV WARNING LIGHT

HV ECU

MALFUNCTION
INFORMATION

HV BATTERY ECU

INVERTER

CLUTCH ECU

CAN:

SIGNAL LINE:

SHTS03ZZZ0300002

LIGHT ON OR
LIGHT OFF

MIL

HV ECU

MIL ON
REQUEST

ENGINE ECU

MIL ON
REQUEST

HV BATTERY ECU

INVERTER

VEHICLE CONTROL

ECU

CAN:

SIGNAL LINE:

SHTS03ZZZ0300003

1. HV WARNING LIGHT LIGHTING PROCESS

(1) The HV ECU controls the HV warning light.
(2) The HV warning light turns on in case of malfunction of the HV ECU, the HV battery ECU, the inverter, or the

clutch ECU.

(3) The HV ECU receives information regarding malfunction of the HV battery ECU, the inverter, and the clutch ECU

via CAN.

2. ABOUT MIL

(1) The engine ECU controls whether to turn on or turn off MIL.
(2) When a malfunction relevant to emission occurs in the HV system or vehicle control ECU, the MIL light ON

request is sent from the HV ECU to the engine ECU using CAN.

(3) HV battery ECU, inverter and vehicle control ECU send the MIL light ON request to the engine ECU using CAN

via HV ECU.

3. DEFINITION OF MALFUNCTION

DCY#3
CONFIRMATION TIME

t

COMPLETION
OF DCY#2

COMPLETION
OF DCY#2

COMPLETION
OF DCY#1

COMPLETION OF
DCY#1

DCY#1
CONFIRMATION TIME

DCY#2
CONFIRMATION TIME

ON

LOCK

[r/min]

IDLING SPEED-150 [r/min]

COMPLETION OF

HV BATTERY ECU DCY

COMPLETION OF

INVERTER DCY

STARTER KEY

DCY

COMPLETION OF

HV ECU DCY

ENGINE
SPEED

0

0

0

SHTS03ZZZ0300004

(1) Driving cycle

The driving cycle (hereinafter referred to as "DCY") is confirmed when the engine revolution becomes equal to or
more than the value calculated using the following formula [idling speed minus 150 r/min] after the starter key is
turned to the "ON" position. DCY is completed when the starter key is turned to the "LOCK" position.

HYBRID/TROUBLE SHOOTING3–6

* Completion of DCY is the timing to delete the Permanent diagnosis code and Pending diagnosis code.

(2) Definition of diagnosis code

The following table shows malfunctions that are displayed on the service tool.

Pending diagnosis code

Confirmed diagnosis

Permanent diagnosis

*1 This light lights for malfunctions relevant to emission.
*2 If a malfunction is recovered, control is switched from failsafe control to normal control; however the
Confirmed diagnosis code is not deleted.

Code name

code

code

Definition of diagnosis

code

HV warning

light

MIL Effect on vehicle

Diagnosis code that is

being detected (malfunc-

Light OFF Light OFF Normal control

tion is not confirmed).

Diagnosis code in which

the malfunction is con-

Light ON Light ON *1 Failsafe control *2

firmed

Stored diagnosis code Light OFF Light OFF Normal control

HYBRID/TROUBLE SHOOTING 3–7

COMPLETION OF
DCY#1

COMPLETION OF
DCY#2

DETECTION OF
MALFUNCTION

CONFIRMATION

DETECTION OF
MALFUNCTION

CONFIRMATION

LIGHT ON

LIGHT ON

DCY

VEHICLE CONDITION

PENDING MALFUNCTION

CONFIRMED MALFUNCTION

HV WARNING LIGHT

MIL

SHTS03ZZZ0300005

CONFIRMATION

LIGHT ON

LIGHT ON

COMPLETION OF
DCY#1

COMPLETION OF
DCY#2

DETECTION OF
MALFUNCTION

DCY

VEHICLE CONDITION

PENDING MALFUNCTION *1

CONFIRMED MALFUNCTION

HV WARNING LIGHT

MIL

SHTS03ZZZ0300006

(3) Pending diagnosis code

Represents the diagnosis code in which the malfunction is confirmed by detecting the malfunction in 2DCY or
more. The following table shows examples in which the malfunction is confirmed in 2DCY.

(4) Confirmed diagnosis code

Represents the diagnosis code in which the malfunction is confirmed by detecting the malfunction in 1DCY.

*1 For the malfunction in which the Confirmed malfunction is confirmed in DCY, the Pending malfunction
is not confirmed.

HYBRID/TROUBLE SHOOTING3–8

CONFIRMATION

CONFIRMATION

LIGHT ON

LIGHT ON

COMPLETION OF
DCY#1

COMPLETION OF
DCY#2

DETECTION OF
MALFUNCTION

DCY

VEHICLE CONDITION

CONFIRMED MALFUNCTION

PERMANENT MALFUNCTION

HV WARNING LIGHT

MIL

SHTS03ZZZ0300007

(5) Permanent diagnosis code

Permanent malfunction is confirmed by confirming the Confirmed malfunction.

(6) Deletion of diagnosis code

Code name Deletion from vehicle condition Deletion using the service tool

This code is deleted when condition

Pending diagnosis code

to be judged normal is satisfied and

malfunction detection condition is

Instant deletion

not satisfied in 1DCY

Confirmed diagnosis

code

None Instant deletion

This code is deleted after performing

the predetermined operation when

Permanent diagnosis

code

This code is deleted when condition

to be judged normal is satisfied in

3DCY. *1

condition to be judged normal is sat­isfied and malfunction detection con-

dition is not satisfied in 1DCY after

deleting the diagnosis code using

the service tool. *1

*1 Refer to the following figure and 4. Procedure for deleting the Permanent malfunction for details.

HYBRID/TROUBLE SHOOTING 3–9

CONFIRMATION

DELETION

DELETION

LIGHT OFF

LIGHT OFF

LIGHT ON

LIGHT ON

CONFIRMATION

CONFIRMATION

COMPLETION OF
DCY#1

COMPLETION OF
DCY#2

COMPLETION OF
DCY#3

COMPLETION OF
DCY#4

COMPLETION OF
DCY#5

DETECTION OF
MALFUNCTION

DETECTION OF
MALFUNCTION

DCY

VEHICLE CONDITION

PENDING MALFUNCTION

CONFIRMED MALFUNCTION

PERMANENT MALFUNCTION

HV WARNING LIGHT

MIL

NORMAL JUDGMENT #1 NORMAL JUDGMENT #2 NORMAL JUDGMENT #3

NORMAL JUDGMENT

DCY#1

NORMAL JUDGMENT

DCY#2

NORMAL JUDGMENT

DCY#3

SHTS03ZZZ0300008

CONFIRMATION

DELETION

DELETION

DELETION

DELETION OF THE MALFUNCTION
CODE USING THE SERVICE TOOL

LIGHT OFF

LIGHT OFF

LIGHT ON

LIGHT ON

CONFIRMATION

CONFIRMATION

COMPLETION OF
DCY#1

COMPLETION OF
DCY#2

COMPLETION OF
DCY#3

COMPLETION OF
DCY#4

DETECTION OF
MALFUNCTION

DETECTION OF
MALFUNCTION

DCY

VEHICLE CONDITION

PENDING MALFUNCTION

CONFIRMED MALFUNCTION

PERMANENT MALFUNCTION

HV WARNING LIGHT

MIL

NORMAL JUDGMENT #1

*1

SHTS03ZZZ0300009

•

The following figure shows deletion of the Pending diagnosis code and deletion of the Permanent diagnosis
code in 3DCY.

• The following figure shows clearing of Pending malfunction code, Confirmed malfunction code, and Perma-

nent malfunction code by using the service tool.

*1 Refer to 4. Procedure for deleting the Permanent malfunction (1).

HYBRID/TROUBLE SHOOTING3–10

! CAUTION

! CAUTION

4. PROCEDURE FOR DELETING THE PERMANENT MALFUNCTION
There are two procedures for deleting the Permanent diagnosis code.

Confirmed diagnosis code Permanent diagnosis code Deletion procedure

None Present Deletion using the procedure (1)

Present Present Deletion using the procedure (1) or (2)

Present None —

(1) Procedure for deleting the Permanent diagnosis code after deleting the diagnosis code using the service tool

a. Turn the starter key "ON".
b. Delete the diagnosis codes using the service tool.

- Delete diagnosis codes from the following systems.

• ECU of the HV system in which the Permanent diagnosis code is occurring.

(Deletion of engine ECU must be performed after performing deletion in the order of HV battery ECU 
Inverter  HV ECU.)

• Engine ECU

c. Set the starter key to the "LOCK" position and wait for 30 seconds or more.
d. Turn the starter key "ON".
e. Start the engine.
f. Idle the engine for 6 minutes or more.
g. Keep the engine revolution at 1,150 r/min or more for 6 minutes or longer.
h. Set the starter key to the "LOCK" position and wait for 30 seconds or more.
i. Turn the starter key "ON".
j. Start the engine.
k. Wait for 30 seconds or more.
l. Set the starter key to the "LOCK" position.

• Trouble shooting the malfunction is conducted before following the above procedure, therefore the malfunction

does not occur or the malfunction does not occur while following the above procedure.

• The HV warning light must turn off when the diagnosis code is deleted at (b).

When the HV warning light turns off, it is possible to check that there is no malfunction in the HV system.

• Condition to be judged normal for the malfunction occurred in the above steps (d) to (g) must be satisfied.

Condition to be judged normal varies depending on malfunction.

(2) Procedure for deleting the Permanent diagnosis code in 3DCY

a. Turn the starter key "ON".
b. Start the engine.
c. Idle the engine for 2 minutes or more.
d. Set the starter key to the "LOCK" position.
e. Wait for 30 seconds or more.
f. Repeat the steps from (a) to (e) for 3 times in total (3DCY).
g. Turn the starter key "ON".
h. Start the engine.
i. Wait for 30 seconds or more.
j. Set the starter key to the "LOCK" position.

• The above procedure is satisfied when making normal driving operation; therefore the Permanent diagnosis

code may be deleted when making similar driving operation if the malfunction is recovered.

• Trouble shooting the malfunction is conducted before following the above procedure, therefore the malfunction

does not occur or the malfunction does not occur while following the above procedure.

• Condition to be judged normal for the malfunction occurred in the above steps (a) to (d) must be satisfied. Con-

dition to be judged normal varies depending on malfunction.

HYBRID/TROUBLE SHOOTING 3–11

! CAUTION

5. TROUBLE SHOOTING PROCEDURE

(1) Trouble shooting procedure (when using genuine Hino service tool)

a. Check the DTC of the HV ECU using the service tool (trouble shooting tool).
b. Record the DTC and TC No. (detailed DTC) of freeze frame data.
c. Perform trouble shooting for the relevant DTC. For an inverter/HV battery line malfunction, read the DTC of

each ECU for trouble shooting according to the HV ECU diagnostic chart.

d. After trouble shooting, delete the DTC of each ECU using the service tool and conduct a trial running to check

that the malfunction does not recur.

• When inspecting the high voltage line, wear insulating gloves because of a risk of electrical shock. Before per-

forming inspection, be sure to remove the service plug after the starter key is turned to the "LOCK" position.
When inspecting the HV battery, wear safety glasses.
Do not touch the terminals of the high voltage line for 7 minutes after removing the service plug.

• One diagnosis code (DTC) may contain more than 1 malfunction. Read TC No. (detailed DTC) of freeze frame

data with the trouble shooting tool and perform trouble shooting according to the relevant trouble shooting
chart.

• When inspecting the harness, first check the connector for fitting looseness, and the fitting surface for entry of

foreign matters.

• There may be irregular contact or temporary noise due to partial fitting of the connector if parts are returned to

normal without repairing or replacing parts using the diagnostic chart.

• The service tool or trouble shooting tool described in the trouble shooting chart indicates the genuine Hino ser-

vice tool.

• If the starter key is turned "ON" in the state that connectors, etc. are disconnected while performing the trouble

shooting chart, the malfunction may be recorded due to disconnection of a connector. In such case, be sure to
delete the diagnosis code using the trouble shooting tool.

HINT
If there is no malfunction and the engine does not stop with the idling stop function, the following cases are con­ceivable.

• A vehicle is not running at vehicle speed of 5 km/h or more from the last idling stop.

• The change lever is located at a position other than "D" and "4".

• When the turn signal light and the hazard light are ON. (Even if the turn signal light switch signal and the hazard

light switch signal transmitted to the HV ECU are Low, the engine does not stop automatically by use of the
idling stop function.)

• When a vehicle stopped on a sloped road.

• While PTO is operating.

• While DPR is operating.

• Capacity of the HV battery is low.

• Engine coolant temperature is low.

• The engine is still running. (The engine is running at approximately 1 km/h or more.)

• When the status of the idling stop cancel switch is "ON".

• Brake vacuum pressure is low. (Even if the low brake vacuum pressure switch signal transmitted to the HV ECU

becomes Low, the engine does not stop automatically by use of the idling stop function.)

HYBRID/TROUBLE SHOOTING3–12

!WARNING

!CAUTION

1

2

3

SHTS03ZZZ0300010

SAFETY MEASURES FOR HIGH-VOLTAGE

WORK

EN01H03ZZZ030602002002

1. CAUTIONS ON INSPECTION OF HYBRID CONTROL SYSTEM

(1) To inspect the high-voltage system or disconnect the low-

voltage connector in the PCU box, be sure to take actions to
prevent electric shocks, i.e. wearing insulated gloves and dis­connection of service plug. Removed service plug should be
put in a pocket so as to prevent other engineers from using it
by mistake during work.

Note that the SMR is turned "ON" and high-voltage circuit is acti­vated when the starter key is turned to "ON."

Since any failure may occur when the starter key is turned to "ON"
with the service plug removed, never turn the starter key to "ON"
unless otherwise instructed in this document.

(2) All wire harness connectors for the high-voltage circuit are

orange colored. Further, "HIGH VOLTAGE" caution label is
attached to high-voltage components such as the hybrid bat­tery. Do not touch these wiring and components unnecessar­ily.

(3) Turn the starter key "LOCK" and remove the service plug.

Then wait for at least 7 minutes before starting the work.

NOTICE
In the 7 minutes the high-voltage capacitor in the inverter dis­charges.

HYBRID/TROUBLE SHOOTING 3–13

! CAUTION

INCORRECT

SHTS03ZZZ0300011

(4) Check the insulated gloves for damage such as cracks and

break before use. Also, do not use wet insulated gloves.

(5) Do not carry on any metal product such as a pen and scale

which may fall to cause short circuit while working.

(6) Be sure to wear insulated gloves when it is necessary to

touch any high-voltage terminal without insulating coating.

(7) After disconnecting high-voltage connectors and terminals,

insulate them with insulator tape without delay.

(8) After working on high-voltage components, check for any

component or tool left, tightening condition of high-voltage
terminals and connector conditions again before connecting

the service plug.
(9) Do not reserve the hybrid battery.
(10) Do not disassemble the hybrid battery.

High voltage is applied to the hybrid battery even when the ser­vice plug is disconnected. Further, high-alkaline electrolyte is
used.

(11) Make sure to use the insulated tools.

Recommended tools: FACON's Facom-quality insulated tools
(12) Turn the starter key to "LOCK" for resistance inspection.
(13) Turn the starter key to "LOCK" before removing/installing

connectors.
(14) Alert other workers with indication such as "High-voltage

work. Don't touch" on the vehicle during works on high-volt-

age components.

(The next page is an example of the indication. You may copy

and use it.)

HYBRID/TROUBLE SHOOTING3–14

SHTS03ZZZ0300012

HYBRID/TROUBLE SHOOTING 3–15

WHITE

WHITE

ORANGE

BLACK

BLACK

BLACK

DARK GRAY

WHITE

WHITE

WHITE

132

23

456789

11112

2316221521

142013

2417251826

19

10

1

9 10111213141516

2345678

1

12 13 14 15 16 17 18 19 20 21 22

10 1123456789

1

5

23

6748

11 12 13 14 15 16 17 18 19

23456789

20

2423 25 26 27 28 29

21 22

30

110

1234

1

2

3

4

56789

10 11

30 31

12

13

14

15

1617 1819 20
2122 2324 25 26272829
3233 3435 36 373839 40

78910

11 123413 14 15 16

17 18 19 20 21 22 23 24

12 56

1819

20 21 22 23 24 25 26

7 8 9 1011121314151617

123456

BATTERY ECU (CAN)A

B

F

G

J/C DIAG CAN

INVERTER COOLING WATER PUMP

BATTERY ECU (TEMPERATURE MONITORING)

C

H

HV ECU1

BATTERY ECU (VOLTAGE MONITORING)

D

I

HV ECU2

INVERTER

E

J

HV ECU3

INVERTER COOLING RADIATOR FAN

SHTS03ZZZ0300013

LIST OF CONNECTOR SYMBOLS

EN01H03ZZZ030602002003

HYBRID/TROUBLE SHOOTING3–16

123456

16 17

78910

12 13 14 15 18 19 20 211122

12 11 10

1

65

78

9

234

10 11 12

234

56

78

9

1

21

17 16

34567

8

101112131415

181920212223

9

24

3456789

1011 1213 1415

1819 202122 2324

2

17

1

16

21

1234

12

34

GRAY BLACK

WHITE

(RELAY BLOCK SIDE)

BLACK

BLACK BLACK

BLACK

WHITE

WHITE

BLACK BLACK

1234

5678

9 101112

13 14 15 16

4321

8765

12 11 10 9

16 15 14 13

(RELAY BLOCK SIDE)

(COMPONENT SIDE)

(COMPONENT SIDE)

3

5

L

N

2

1

3

5

2

1

12

INVERTER START RELAY

L

N

HV BATTERY START RELAY

O J/C CTRL CAN

P PCU HARNESS 16-PIN

R

HV BATTERY COOLING FAN

S

SMR DRIVE

SERVICE PLUG SWITCH

T

X PCU HARNESS 24-PIN

K

COOLANT TEMPERATURE SENSOR

PCU HARNESS 12-PINY

SHTS03ZZZ0300014

HYBRID/TROUBLE SHOOTING 3–17













BLACK WHITE

BLACK WHITE

WHITE

WHITE

WHITE

12

2

13

1

2

12 3 4 5 6

816

17

7

9101112131415

21

201918 22 23 24

123

456

1526374

8

123456789101112

242322212019181716151413

E’: BATT IN(-)C’: BATT OUT(-)

F’: BATT IN(+)D’: BATT OUT(+)

I’

J’

H’

G’

10

12 13 14 15 16 17 1819 20

23456789

21

241123 2526 27 28 292230

1

1212223234245256267278289

29 301031113212331334143515361637173818391940

20

METER 1

d-1

A’

RESOLVER

B’

ROTATION MACHINE TEMPERATURE SENSOR

C’ D’ E’ F’

G’ H’

HIGH VOLTAGE J/B (IN BATTERY PACK)

INVERTER HIGH VOLTAGE

I’ J’ SERVICE PLUG

a

STARTER SWITCH

b

AT ECU

c

VEHICLE CONTROL ECU

d-2 METER 2

SHTS03ZZZ0300015

HYBRID/TROUBLE SHOOTING3–18

BLACK

BLACK BLACK

BLACK

1212223234245256267278289

29 301031113212331334143515361637173818391940

20

5

1

3

2

4

6789

1314

24151617 1819 20 2122 23

252627 28 2930 3132 3334

161514131211109

87654321

h: BATT(-)

m: BATT(+)

p: INV(+)

3

1

2

5

q: INV(-)

k: DDC(-)

I: DDC(+)

1011

12

e

f

ABS ECU

CLUTCH ECU

k, l, m, n, p, q

HIGH VOLTAGE J/B (IN ECU-BOX)

r

IG1-1 RELAY

t

NEUTRAL SWITCH

h

DLC3

1

10

5432

8967

SHTS03ZZZ0300016

HYBRID/TROUBLE SHOOTING 3–19

F_HV_10A

INVERTER

START RELAY

W/TEMP_SSR

MF_PWR_1_50A

F_AM2_10A

F_AM1_10A

CANL

SMR1

HIGH VOLTAGE J/B

(IN BATTERY PACK)

HIGH VOLTAGE J/B

(IN ECU BOX)

HOUSING GND

SMR2

SMR3

IG2

IGCT

AM

CANH

BATTERY ECU

SERVICE PLUG

288V

HV BATTERY

CURRENT

SENSOR

GND

L1L

L

x

PCI_B_2 20A

PCI_B_20A

x

L

3

np

J/B (+)

l

25

WATER PUMP

RADIATOR FAN

HV BATTERY

START RELAY

F

F

E

F

F

E

E

4

1

3

3

2

R

RP

P

R

3

A1A2A

13

A18A

19

A

12

9

P13P

14

4

1

2

111

RP

212

P

15

P

6

P

7

P

2
3
4
5
1

P

16

N1N

x

NN

3

123

25

1

2

3

4

5

6

7

8
9

12

11

10

14

13

15
16

18

19

20

21
22
23
24
25

mq

J/B (-)

k

P
P
P
P

HV BATTERY

COOLING FAN

KEY CYLINDER

ON

ST

THW

E2

K

K

a

6

2

1

17

SMR: System Main Relay

SHTS03ZZZ0300017

HV SYSTEM WIRING DIAGRAM

EN01H03ZZZ030602002004

HYBRID/TROUBLE SHOOTING3–20

DCU

F_ECU_IG_NO.1_10A

VEHICLE SPEED

PULSE

HV WARNING

LIGHT

IG1-1

76

61

15 2520 19

X

J

o

J

X

VEHICLE

CONTROL

ECU

VCM WARN SW

or

A/C WARN SW

HYD WARN SW

HAZ SW

TURN SW

WHEEL SPEED

SENSOR

ABS

ECU

METER

CANL1

CANH1

32

D

9

3

D

I

8

7

D

I

21 22

D

CANL2

CN4-26 SLD4

CN4-35 THA1

CN4-34 P5A1

R1

CANH2

33

DD

23

D

30

D

31

D

10

D

11

D

25

D

38D39D40D16D5

D

34D35D26

D

24

D

12

D

14

D

13

D

15

D

27

D

3Y8

Y

4

Y

ROTATION

MACHINE

THERMISTER

ROTATION

MACHINE

16

X

W1

V1

U1

CN4-40 CON3

CN4-39 CON2

CN3-38 CON1

CN4-16 ILK1

CN4-5 ILKO

INVERTER

PCU

INTERNAL

CIRCUIT

HV ECU

CAN J/C
(CONTROL)

CAN J/C (DIAG)

cc

ABS

ECU

20

H

29

Y

1

R2

Y

2

S1

Y

5

S2

Y

6

RESOLVER

S3

Y

10

S4

F+

F-

GND

+B

ON

Y

11

SLD3

Y

9

19

J

21

J

22

J

G

h

h

h
h
h

DLC3

15

56
34

78

12

ff

X

xxx

X

CLUTCH

ECU

13

23

I

1

127

8

12 13

16

1411109543

24 21 22

20 8 9

14

16

6

14
13

4

ee

21 20

AT

ECU

ENGINE

ECU

bb

METER

d2 d2

I2J1H

XX

4J3

X

J

24

X

d1

1

2

3

4

5

6

7

8

9

14

15
16

18

17

19

20

21
22
23
24
25

d1

tt

r

22

NSSW

22

f

23

18

19

5

7

12

d1

H

11

X

4

H

20

X

19

H

19

X

10

H

9

X

11

RL

H

18

5

H

30

12

I

17

I

18

11

10

H

26

13

H

24

H

25

J

5

15

SHTS03ZZZ0300018

NOTICE
For connector symbols, refer to "List of connector symbols."
Reference: HYBRID, TROUBLE SHOOTING, HYBRID CONTROL SYSTEM, LIST OF CONNECTOR SYMBOLS (Page
3-15)

HYBRID/TROUBLE SHOOTING 3–21

Gradual braking
Sudden braking
Operation by left foot

Engine

HV

Details of the

vehicle

Result of interviewConfirmation result of vehicle

Vehicle type

Date of occurrence

Warehousing date

Travel distance Km

Registration date

Sex

Male

Urban area
Mountain

( )

Suburb
Others

Female

Age group

Age

Occupation

Previous vehicle

Frequency of use

Others

Others

Main place
for use

Characteristic of the customer

(Scheduled) delivery date of the vehicle

Frame No.

Unit No. or the like

Option

Details of interview (Please describe the situation prior to the occurrence and before and
after the occurrence in a time-series manner as much as possible.)

Cold area Others ()

Frequency / date /
week month

Running condition Road surface state

When starting
During acceleration
During steady running
During deceleration
During braking
During stoppage
During parking
During turning
During ABS operation
Others
( )

Vehicle speed [km/h]

Shift position (display) Lighting of warning light

Brake operation

Frequency of occurrence

A/C status

1234
5

at operation

6R

Engine status

Flat (horizonal) road
Upward ° Downward
Inclination ° .%
Distance km
Dry paved road
Wet paved road
Rough paved road
Unpaved road
Snow road, compressed

snow road, frozen road
Uneven road, curbstone
Others
  (      )

At start
Immediately after the
start
After minutes after
the start
After minutes after
the start of running
At the stoppage of the
system

During engine stoppage
During engine start
During engine rotation

Yes No
Charge
Engine
Others
(ޓޓޓޓ)

Yes No
Engine
Brake
ABS
Brake
HV
Others
( )

Always
Sometimes
Only one time

Vehicle state

Confirmation result of warning lamp Confirmation result of diagnosis code

Charge

Weather:
Air temperature: °C
Amount of remaining fuel
(fuel gauge)
Remaining amount

A/C
OFF

FULL
Unknown

SHTS03ZZZ0300019

HEARING SHEET

1. HEARING OF REQUESTS FROM CUSTOMER

(1) As the steps of trouble shooting are advanced, hear requests from customer without fault by referring this hear-

ing sheet.

EN01H03ZZZ030602002005

HYBRID/TROUBLE SHOOTING3–22

HYBRID ECU

DIAGNOSIS CODE TABLE

Symbol Lighting pattern

☆ Light is turned on when any fault occurs, and off when the fault is resolved

DTC

No.

P0500

P0501

P0562

Diagnosis code

name

Abnormality in
vehicle speed
sensor

Abnormality in
characteristics
of vehicle
speed sensor

Abnormality in
power supply
voltage

TC

Description of

No.

51

5B

71

malfunction

No vehicle
speed signal
input

Abnormality in
characteristics
of the vehicle
speed sensor

Control power
supply voltage
reduction

Vehicle behavior for occur-

rence of malfunction

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working. 1 ☆☆

HV system stop
Since the hybrid system
stops, the following symp­tom occur.

- The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.

- Idling stop is not working.

- Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

EN01H03ZZZ030602003001

Number

of mal-

function

confir-

mation

DCY

1 ☆☆

1 ☆

HV

Warning

Light

MIL

P060B

P0617

P062F

P0810

Abnormality in
A/D converter

Malfunction of
starter switch

Abnormality in
EEPROM

Abnormality in
clutch system
(idling stop
inhibited)

Abnormality in

B2

the A/D con­verter

Sticking the

59

starter signal
circuit to High

EEPROM

B3

abnormality

Abnormality in
the clutch ECU

9C

(idling stop is
prohibited.)

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working. 1 ☆☆

Recording a diagnosis code
may not be available.

Idling stop may not work. 1 ☆

1 ☆☆

1 ☆☆

DTC

No.

Diagnosis code

name

TC

Description of

No.

HYBRID/TROUBLE SHOOTING 3–23

Number

malfunction

Vehicle behavior for occur-

rence of malfunction

of mal-

function

confir­mation

DCY

HV

Warning

Light

MIL

P0810

P0A01

P0A02

P0A03

Abnormality in
clutch system
(idling stop
available)

Abnormality in
characteristics
of inverter cool­ant tempera­ture sensor

Coolant tem­perature sen­sor Low
abnormality

Coolant tem­perature sen­sor High
abnormality

Abnormality in
the clutch ECU

9D

(idling stop is
available.)

Abnormality in
characteristics

7B

of the inverter
coolant temper­ature sensor

GND short cir­cuit of the
inverter cool-

78

ant tempera­ture sensor
circuit

Inverter cool­ant tempera­ture sensor
circuit discon-

79

nected or
power supply
(positive side)
shorted

Idling stop may not work. 1 ☆

Behavior of vehicle does not
vary.

Behavior of vehicle does not
vary.

Behavior of vehicle does not
vary.

2 ☆☆

1 ☆☆

1 ☆☆

P0A06

P0A07

P0A0F

P0A1D

HV water pump
drive signal
Low abnormal­ity

HV water pump
drive signal
High abnormal­ity

Engine system
abnormality

Abnormality in
HV ECU func­tion

Disconnection
or GND short
circuit of the HV

7F

water pump
drive signal cir­cuit

HV water pump
drive signal cir-

7E

cuit power sup­ply (positive
side) shorted

31 Engine misfire

Sticking of the

12

control CAN
register

Behavior of vehicle does not
vary.

Behavior of vehicle does not
vary.

The engine does not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.
CHG, AST, ECO and SOC
lights may turn off.

1 ☆☆

1 ☆☆

1

1 ☆☆

DTC

No.

P0A1D

P0A78

Diagnosis code

name

Abnormality in
HV ECU func­tion

Abnormality in
the inverter

TC

Description of

No.

17

21

malfunction

Sticking of the
DIAG CAN reg­ister

Serious abnor­mality in the
inverter

HYBRID/TROUBLE SHOOTING3–24

Number

Vehicle behavior for occur-

rence of malfunction

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.
CHG, AST, ECO and SOC
lights may turn off.

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop may not work.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

of mal-

function

confir-

mation

DCY

1 ☆☆

1 ☆

HV

Warning

Light

MIL

P0A78

P0A7E

P0A82

P0A84

Abnormality in
the inverter

Abnormality in
high tempera­ture of HV bat­tery

Abnormality in
function of HV
battery cooling
fan

Abnormality in
HV battery
cooling fan
drive signal
Low

Slight abnor-

22

mality in the
inverter

Abnormally
high tempera-

48

ture of the HV
battery

Abnormality in
the HV battery

67

cooling FAN
function

Disconnection
or GND short
circuit of the HV

66

battery cooling
FAN drive sig­nal circuit

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop may not work.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Behavior of vehicle does not
vary.

Behavior of vehicle does not
vary.

1 ☆

1 ☆☆

2 ☆☆

1 ☆☆

P0A85

Abnormality in
HV battery
cooling fan
drive signal
High

HV battery
cooling fan
drive signal cir-

65

cuit power sup­ply (positive
side) shorted

Behavior of vehicle does not
vary.

1

☆☆

DTC

No.

P0A90

Diagnosis code

name

Abnormality in
motor function

TC

Description of

No.

2A

malfunction

Abnormality in
the motor func­tion

HYBRID/TROUBLE SHOOTING 3–25

Number

Vehicle behavior for occur-

rence of malfunction

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

of mal-

function

confir­mation

DCY

1 ☆☆

HV

Warning

Light

MIL

P0A92

P0A93

P0AFD

P0BCA

P0C73

P3000

Abnormality in
charging per­formance

Abnormality in
inverter cool­ing system

Abnormality in
low tempera­ture of HV bat­tery

Abnormality in
HV battery
cooling fan
revolving num­ber signal High

Abnormality in
HV water pump
function

Abnormality in
status of HV
battery ECU IG
signal

Abnormality in

29

HV battery
charging power

Abnormally
high tempera-

7A

ture of the
inverter coolant

Abnormally low

6B

temperature of
the HV battery

HV battery
cooling fan
speed signal

68

circuit power
supply (positive
side) shorted

Abnormality in

80

the HV water
pump function

Abnormality in
the HV battery

42

ECU IG signal
status

Behavior of vehicle does not
vary.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working. 2 ☆☆

Behavior of vehicle does not
vary.

Behavior of vehicle does not
vary.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

2 ☆☆

1 ☆☆

1 ☆☆

2 ☆☆

1 ☆

P3001

Abnormality in
HV battery line

Abnormality in
the HV battery

41

ECU memory
system

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

1 ☆

DTC

No.

P3001

P3001

Diagnosis code

name

Abnormality in
HV battery line

Abnormality in
HV battery line

TC

Description of

No.

43

44

malfunction

Abnormality in
the HV battery
system

Abnormality in
the HV battery
system

HYBRID/TROUBLE SHOOTING3–26

Number

Vehicle behavior for occur-

rence of malfunction

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

of mal-

function

confir-

mation

DCY

1 ☆

1 ☆

HV

Warning

Light

MIL

P3001

P3001

P3001

Abnormality in
HV battery line

Abnormality in
HV battery line

Abnormality in
HV battery line

Disconnection
of the HV bat-

45

tery high volt­age fuse

Request for
stopping dis-

46

charge of the
HV battery

Auxiliary
charge request

47

for the HV bat­tery

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

- The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.

- Idling stop is not working.

- Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

1 ☆

1 ☆

1 ☆

DTC

No.

P3001

P3001

Diagnosis code

name

Abnormality in
HV battery line

Abnormality in
HV battery line

TC

Description of

No.

4A

4B

malfunction

Abnormal
external over­load in the HV
battery

Abnormality in
the HV battery
voltage detec­tion circuit

HYBRID/TROUBLE SHOOTING 3–27

Number

Vehicle behavior for occur-

rence of malfunction

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

of mal-

function

confir­mation

DCY

1 ☆

1 ☆

HV

Warning

Light

MIL

P3001

P3009

P3128

P3129

P314C

Abnormality in
HV battery line

Abnormality in
leakage

Abnormality in
HV radiator fan
revolution num­ber Low

Abnormality in
HV radiator fan
revolution num­ber High

Abnormality in
HV water pump
revolution num­ber signal Low

Stoppage of the
regeneration
function

4C

according to
request for
stopping
charge

Electrical leak-

49

age

HV radiator fan

7D

revolution sig­nal Low failure

HV radiator fan

7C

revolution sig­nal High failure

GND short cir­cuit of the HV

82

water pump
revolution sig­nal circuit

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Behavior of vehicle does not
vary.

Behavior of vehicle does not
vary.

Behavior of vehicle does not
vary.

Behavior of vehicle does not
vary.

1 ☆

1

2 ☆☆

2 ☆☆

1 ☆☆

DTC

No.

Diagnosis code

name

TC

Description of

No.

HYBRID/TROUBLE SHOOTING3–28

malfunction

Vehicle behavior for occur-

rence of malfunction

Number

of mal-

function

confir-

mation

DCY

HV

Warning

Light

MIL

P314D

P324B

P324C

Abnormality in
HV water pump
revolution num­ber signal High

Abnormality in
inverter start
relay Low

Abnormality in
inverter start
relay High

Disconnection
of the HV water

81

pump revolu­tion signal cir­cuit

GND short cir­cuit of the

62

inverter start
relay excitation
circuit

Inverter actu­ate relay excita­tion circuit

61

disconnected
or power sup­ply (positive
side) shorted

Behavior of vehicle does not
vary.

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

The engine may not start
running. However, the
engine starts up by the
starter for starter-equipped
vehicles.
Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

1 ☆☆

1 ☆☆

1 ☆☆

P33B1

P33B2

U0073

U0074

Abnormality in
HV battery ECU
start relay Low

Abnormality in
HV battery ECU
start relay High

Abnormality in
CAN communi­cation with HV
ECU (control
CAN)

Abnormality in
CAN communi­cation with HV
ECU (DIAG
CAN)

GND short cir­cuit of the HV

64

battery ECU
start relay exci­tation circuit

The HV battery
ECU start relay
excitation cir­cuit discon-

63

nected or
power supply
(positive side)
shorted

Control CAN
communica-

11

tion disabled
due to bus off

DIAG CAN com­munication dis-

16

abled due to
bus off

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.
CHG, AST, ECO, SOC light
turns off.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

1 ☆☆

1 ☆☆

1 ☆☆

1 ☆☆

DTC

No.

U0100

U0101

U0110

Diagnosis code

name

Engine ECU
CAN communi­cation blackout

TCM ECU CAN
communica­tion blackout

Inverter CAN
communica­tion blackout

TC

Description of

No.

13

18

14

malfunction

Engine ECU
CAN communi­cation blackout

AT ECU CAN
communica­tion blackout

Inverter CAN
communica­tion blackout

HYBRID/TROUBLE SHOOTING 3–29

Number

Vehicle behavior for occur-

rence of malfunction

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

of mal-

function

confir­mation

DCY

1 ☆☆

1 ☆

1 ☆☆

HV

Warning

Light

MIL

U0111

U0121

U0155

U110A

U1136

HV battery ECU
CAN communi­cation blackout

ABS ECU CAN
communica­tion blackout

Meter ECU CAN
communica­tion blackout

Vehicle control
ECU CAN com­munication
blackout

Clutch ECU
CAN communi­cation blackout

HV battery ECU

15

CAN communi­cation blackout

ABS ECU CAN

24

communica­tion blackout

Meter ECU CAN

25

communica­tion blackout

Vehicle control
ECU CAN com-

26

munication
blackout

Clutch ECU

27

CAN communi­cation blackout

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

Idling stop is not working. 1 ☆

Idling stop is not working. 1 ☆

Idling stop is not working. 1 ☆

Idling stop is not working.
Lowering the speed during
deceleration may decrease
to deactivate the regenera­tion function.

1 ☆☆

1 ☆

HYBRID/TROUBLE SHOOTING3–30

FREEZE FRAME DATA LIST

EN01H03ZZZ030602003002

Item Description Display range Unit

TC No. Detailed code of DTC No. 00 - $FF —

Stop light switch (CAN reception)

DPR regenerating signal
(CAN reception)

Idling stop authorized state
(CAN reception)

Idling stop request signal

Driver request torque rate

Engine torque rate

Standard engine torque Engine torque to be a standard 0 - 1,000 Nm

Accelerator pedal opening
(CAN reception)

Represents brake pedal communication input
status. Pedal ON = 1 / Pedal OFF = 0

Received from the engine during DPR regenerat­ing. ON = 1 / OFF = 0

Received from the engine when enabling idling
stop (ON = 1 / OFF = 0).

Sent to the engine for auto stop of idling stop.
ON = 1 / OFF = 0

Ratio of torque based on accelerator pedal open­ing to standard engine torque

Ratio of torque based on fuel injection quantity to
standard engine torque

Represents the accelerator pedal opening. 0 - 100 %

0 - 1 —

0 - 1 —

0 - 1 —

0 - 1 —

-128 - 127 %

-128 - 127 %

Engine revolution
(CAN reception)

Engine control request mode

Required engine torque limiting
value

Specified value of motor torque

Effective motor torque value Torque calculated from actual current id, iq -32,768 - 32,767 Nm

Actual motor torque value Represents the motor output torque. -32,768 - 32,767 Nm

Vehicle speed Represents a vehicle speed. 0 - 200 km/h

Motor revolution Represents the motor revolution. -32,768 - 32,767 r/min

HV battery voltage Represents the HV battery DC voltage. 0 - 600 V

HV battery current Represents HV battery DC current. -500 - 500 A

Power supply voltage Represents the HV ECU power supply voltage. 0 - 40 V

Represents the engine revolution. 0 - 4,000 r/min

Represents the operation request to the engine.

0 = No request, 1 = Rotational request, 2 = Rota­tional restriction, 3 = Torque limiting, Torque
instruction = 4

Ratio of limiting request torque to the engine to
standard engine torque

Represents a torque command value to the
inverter.

0 - 4 —

-128 - 127 %

-32,768 - 32,767 Nm

HV battery capacity (SOC) Represents the HV battery capacity (SOC). 0 - 100 %

Maximum temperature of HV bat­tery

Minimum temperature of HV bat­tery

HV battery discharge limit value Represents the HV battery discharge limit value. 0 - 200 kW

Represents the maximum temperature of the HV
battery.

Represents the minimum temperature the HV bat­tery.

-128 - 127 C

-128 - 127 C

HYBRID/TROUBLE SHOOTING 3–31

Item Description Display range Unit

HV battery charge limit value Represents the HV battery charge limit value. 0 - 200 kW

Represents the judged value of gear position.

Gear position (CAN reception)

Neutral= 0 / 1st gear = 1 / 2nd gear = 2 /
3rd gear = 3 / 4th gear = 4 / 5th gear = 5 /
6th gear = 6 / R = 10

0 - 10 —

HV warning light

Inverter start relay

HV battery ECU start relay

Engine intake air temperature Represents the engine intake air temperature. -40 - 210 C

Starter signal

Idling stop cancel switch
(CAN reception)

ABS activation signal
(CAN reception)

Exhaust brake switch
(CAN reception)

HV control mode information

Represents the HV warning light output status.
ON = 1 / OFF = 0

Represents the inverter start relay output status.
ON = 1 / OFF = 0

Represents the HV battery ECU start relay output
status. ON = 1 / OFF = 0

Represents the starter signal input status.
ON = 1 / OFF = 0

Represents the idling stop cancel switch signal
input status. Idling stop cancel status ON = ON.
ON = 1 / OFF = 0

Represents the ABS activation signal input sta­tus. ON = 1 / OFF = 0

Represents the retarder lever signal input status.
ON = 1 / OFF = 0

Represents the operating condition of the HV
system.
0 = OFF
1 = Engine startup
2 = At acceleration by motor
3 = Deceleration by motor + retarder
4 = Deceleration by motor or foot brake
5 = Battery charging
6 = Engine stop
7 = Forced battery charging
8 = At manufacturing inspection
9 = At EV
10 = At gear shifting

0 - 1 —

0 - 1 —

0 - 1 —

0 - 1 —

0 - 1 —

0 - 1 —

0 - 1 —

0 - 15 —

Engine loss torque rate Represents the engine loss torque rate. -128 - 127 %

Required engine revolution value Required revolution to engine 0 - 4,000 r/min

Instruction of motor revolution Instructed revolution to motor -32,768 - 32,767 r/min

Motor temperature Motor temperature 0 - 200 C

Inverter internal temperature Inverter internal temperature 0 - 200 C

Starter key Starter key status ON = 1 / OFF = 0 0 - 1 —

System main relay 3 (SMR3) state

Clutch operation permission sig­nal

HV battery leakage crest value HV battery leakage crest value 0 - 4.995 V

Represents the system main relay 3 (SMR3) out­put state. ON = 1 / OFF = 0

Represents the clutch operation permission state
sent from the clutch ECU. Prohibit = 0 / Enable = 1

0 - 1 —

0 - 1 —

HYBRID/TROUBLE SHOOTING3–32

Item Description Display range Unit

Select lever position
(CAN reception)

Clutch state (CAN reception)

Shift transmission condition
(CAN reception)

Vehicle driving mode

System required torque System required torque -32,768 - 32,767 Nm

Turn signal light actuation signal

Clutch oil temperature Clutch oil temperature -40 - 215 C

HV system coolant temperature HV system coolant temperature -128 - 127 C

HV battery cooling FAN drive
request Duty

HV battery cooling FAN drive
request revolution

Select lever position
AT-P = 0 / AT-RL = 1 / AT-N = 2 / AT-D = 3 /
AT-4 range = 4 / AT-3 range = 5 / AT-Others = 6

Clutch state Engaged = 0 / partial clutch = 1 /
disengaged = 2 / unknown = 3

Shift transmission condition OFF = 0 / UP = 1 /
DOWN = 2 / Changing gear = 3

HINT
The indication of "UP" means "Charging gear".

Vehicle driving mode Normal = 0, ECO = 1, PWR =
2

Turn signal light actuation signal OFF = 0, Right
turn = 1, Left turn = 2, Hazard = 3

HV battery cooling FAN drive request Duty 0 - 100 %

HV battery cooling FAN drive request revolution 0 - 10,000 r/min

0 - 255 —

0 - 3 —

0 - 3 —

0 - 2 —

0 - 3 —

HV battery cooling FAN revolution

HV battery cooling FAN revolu­tion

HV battery cooling FAN revolu­tion voltage

HV radiator fan revolution HV radiator fan revolution 0 - 10,000 r/min

HV water pump drive request
Duty

HV water pump drive request rev­olution

HV water pump revolution

HV system coolant temperature
sensor voltage

HINT
Even if the HV battery cooling FAN drive request
revolution is 0 r/min, 0-100 r/min appears.

HV battery cooling FAN revolution voltage 0 - 5 V

HV water pump drive request Duty 0 - 100 %

HV water pump drive request revolution 0 - 10,000 r/min

HV water pump revolution
HINT

Even if the HV water pump drive request revolu­tion is 0 r/min, approximately 0-480 r/min appears.

HV system coolant temperature sensor voltage 0 - 5 V

0 - 10,000 r/min

0 - 10,000 r/min

HYBRID/TROUBLE SHOOTING 3–33

LIST OF DATA MONITOR ITEMS

EN01H03ZZZ030602003003

Item Description

Number of diagnosis codes Number of recorded diagnosis codes 0 - 255 Codes

Stop light switch (CAN reception)

DPR regenerating signal
(CAN reception)

Idling stop authorized state
(CAN reception)

Idling stop request signal

Accelerator pedal opening
(CAN reception)

Engine revolution (CAN reception) Represents the engine revolution. 0 - 4,000 r/min

Vehicle speed Represents a vehicle speed. 0 - 200 km/h

Motor revolution Represents the motor revolution.

Represents the brake pedal communication
input status. Pedal ON = 1 / Pedal OFF = 0

Received from the engine during DPR regener­ating. ON = 1 / OFF = 0

Received from the engine when enabling idling
stop (ON = 1 / OFF = 0).

Sent to the engine for auto stop of idling stop.
ON = 1 / OFF = 0

Represents the accelerator pedal opening. 0 - 100 %

Display

range

0 - 1 —

0 - 1 —

0 - 1 —

0 - 1 —

-32,768 ­32,767

Unit

r/min

HV battery voltage Represents the HV battery DC voltage. 0 - 600 V

HV battery current Represents the HV battery DC current. -500 - 500 A

Power supply voltage Represents the HV ECU power supply voltage. 0 - 40 V

HV battery capacity (SOC) Represents the HV battery capacity (SOC). 0 - 100 %

Maximum temperature of the HV
battery

Minimum temperature of the HV
battery

HV battery discharge limit value

HV battery charge limit value Represents the HV battery charge limit value. 0 - 200 kW

Gear position (CAN reception)

HV warning light

Inverter start relay

Represents the maximum temperature of the
HV battery.

Represents the minimum temperature the HV
battery.

Represents the HV battery discharge limit
value.

Represents the judged value of gear position.
Neutral = 0 / 1st gear = 1 / 2nd gear = 2 /
3rd gear = 3 / 4th gear = 4 / 5th gear = 5 /
6th gear= 6 / R = 10

Represents the HV warning light output status.
ON = 1 / OFF = 0

Represents the inverter start relay output sta­tus. ON = 1 / OFF = 0

-128 - 127 C

-128 - 127 C

0 - 200 kW

0 - 10 —

0 - 1 —

0 - 1 —

HV battery ECU start relay

Engine intake air temperature Represents the engine intake air temperature. -40 - 210 C

Starter signal

Represents the HV battery ECU start relay out­put status. ON = 1 / OFF = 0

Represents starter signal input status.
ON = 1 / OFF = 0

0 - 1 —

0 - 1 —

HYBRID/TROUBLE SHOOTING3–34

Item Description

Idling stop cancel switch
(CAN reception)

ABS activation signal
(CAN reception)

Exhaust brake switch
(CAN reception)

Motor temperature Motor temperature 0 - 200 C

Inverter internal temperature Inverter internal temperature 0 - 200 C

Starter key Starter key status ON = 1 / OFF = 0 0 - 1 —

System main relay 3 (SMR3) state

Clutch operation permission signal

HV battery leakage crest value HV battery leakage crest value 0 - 4.995 V

Select lever position
(CAN reception)

Represents the idling stop cancel switch signal
input status. Idling stop cancel status ON = ON.
ON = 1 / OFF = 0

Represents the ABS activation signal input sta­tus. ON = 1 / OFF = 0

Represents the retarder lever signal input sta­tus. ON = 1 / OFF = 0

Represents the system main relay 3 (SMR3)
output state. ON = 1 / OFF = 0

Represents the clutch operation permission
state sent from the clutch ECU. Prohibit = 0 /
Enable = 1

Select lever position
AT-P = 0 / AT-RL = 1 / AT-N = 2 / AT-D = 3 /
AT-4 range = 4 / AT-3 range = 5 / AT-Others = 6

Display

range

0 - 1 —

0 - 1 —

0 - 1 —

0 - 1 —

0 - 1 —

0 - 255 —

Unit

Clutch state (CAN reception)

Shift transmission condition
(CAN reception)

Vehicle driving mode

System required torque System required torque

Turn signal light actuation signal

Clutch oil temperature Clutch oil temperature -40 - 215 C

HV system coolant temperature HV system coolant temperature -128 - 127 C

HV battery cooling FAN drive
request duty

HV battery cooling FAN drive
request revolution

HV battery cooling FAN revolution

Clutch state Engaged = 0 / partial clutch = 1 /
disengaged = 2 / unknown = 3

Shift transmission condition OFF = 0 / UP = 1 /
DOWN = 2 / Changing gear = 3

HINT
The indication of "UP" means "Charging gear".

Vehicle driving mode Normal = 0, ECO = 1, PWR
= 2

Turn signal light actuation signal OFF = 0, Right
turn = 1, Left turn = 2, Hazard = 3

HV battery cooling FAN drive request duty 0 - 100 %

HV battery cooling FAN drive request revolution 0 - 10,000 r/min

HV battery cooling FAN revolution
HINT

Even if the HV battery cooling FAN drive
request revolution is 0 r/min, 0-100 r/min
appears.

0 - 3 —

0 - 3 —

0 - 2 —

-32,768 ­32,767

0 - 3 —

0 - 10,000 r/min

Nm

HV battery cooling FAN revolution
voltage

HV battery cooling FAN revolution voltage 0 - 5 V

HYBRID/TROUBLE SHOOTING 3–35

Item Description

HV radiator fan revolution HV radiator fan revolution 0 - 10,000 r/min

HV water pump drive request duty HV water pump drive request duty 0 - 100 %

HV water pump drive request revo­lution

HV water pump revolution

HV system coolant temperature
sensor voltage

HV water pump drive request revolution 0 - 10,000 r/min

HV water pump revolution
HINT

Even if the HV water pump drive request revolu­tion is 0 r/min, approximately 0-480 r/min
appears.

HV system coolant temperature sensor voltage 0 - 5 V

Display

range

0 - 10,000 r/min

Unit

HYBRID/TROUBLE SHOOTING3–36

(Example)

SHTS03ZZZ0300020

SHTS03ZZZ0300021

COMMON INSPECTION CHART

EN01H03ZZZ030602003004

• If common inspection requirements are described in the trouble shooting chart, conduct inspection using the common

inspection chart.

.

1. Chart for inspection of the signal line at the PCU lower side wire harness for short circuit

2. Chart for inspection of the signal line at the PCU upper side wire harness for short circuit

• Target connector terminals described in the common inspection chart represent terminals of connectors specified in the

trouble shooting chart.

• As shown in the following figure, if measurement of resistance of the terminal is required on the common inspection

chart, do not determine the terminal as "NG" and proceed to measurement of the next terminal.

(1) CHART FOR INSPECTION OF THE SIGNAL LINE AT THE PCU LOWER SIDE WIRE HARNESS FOR SHORT CIR­CUIT

Inspection of the signal line to the PCU harness 24-pin connector at the PCU lower side wire

1

harness for short circuit

1. Set the starter key to the "LOCK" position and remove the PCU
harness 24-pin connector and the PCU harness 16-pin connector.

TARGET
CONNECTORS

2. Measure resistance between the connector terminal specified in
the trouble shooting chart and the PCU harness 24-pin connector
(PCU lower harness side).
Target connectors  1st to 24th (except 17th)

Standard value: 10 k or more

NO

Common inspection NG

YES

HYBRID/TROUBLE SHOOTING 3–37

TARGET
CONNECTORS

SHTS03ZZZ0300022

TARGET
CONNECTORS

SHTS03ZZZ0300023

Inspection of the signal line to the PCU harness 12-pin connector at the PCU lower side wire

2

harness for short circuit

1. Set the starter key to the "LOCK" position and remove the PCU
harness 12-pin connector.

2. Measure resistance between the connector terminal specified in
the trouble shooting chart and the PCU harness 12-pin connector
(PCU lower harness side).
Target connectors  1st to 11th (except 7th and 12th)

Standard value: 10 k or more

NO

Common inspection NG

YES

Inspection of the signal line to the PCU harness 16-pin connector at the PCU lower side wire

3

harness for short circuit

1. Set the starter key to the "LOCK" position.

2. Measure resistance between the connector terminal specified in
the trouble shooting chart and the PCU harness 16-pin connector
(PCU lower harness side).
Target connectors  1st to 16th (except 10th)

Standard value: 10 k or more

NO

Common inspection NG

YES

Inspection of the signal line at the PCU lower side wire harness for short circuit

4

1. Set the starter key to the "LOCK" position.

2. Disconnect the following connectors.

• Inverter start relay

• HV battery start relay

• Inverter cooling radiator fan connector

• Inverter cooling water pump connector

• Coolant temperature sensor connector

• Inverter connector

TARGET

SHTS03ZZZ0300024

SHTS03ZZZ0300025

TARGET
CONNECTORS

SHTS03ZZZ0300026

TARGET
CONNECTORS

SHTS03ZZZ0300027

CONNECTORS

TARGET
CONNECTORS

HYBRID/TROUBLE SHOOTING3–38

3. Measure resistance between the connector terminal specified in
the trouble shooting chart and the HV battery start relay (relay
block side).
Target connectors  1st to 5th (except 4th)

4. Measure resistance between the connector terminal specified in
the trouble shooting chart and the inverter start relay (relay block
side).
Target connectors  1st to 5th (except 4th)

5. Measure resistance between the connector terminal specified in
the trouble shooting chart and the inverter cooling radiator fan con­nector (PCU lower harness side).
Target connectors  1st to 3rd

6. Measure resistance between the connector terminal specified in
the trouble shooting chart and the inverter cooling water pump
connector (PCU lower harness side).
Target connectors  1st to 3rd

HYBRID/TROUBLE SHOOTING 3–39

TARGET
CONNECTORS

SHTS03ZZZ0300028

TARGET
CONNECTORS

SHTS03ZZZ0300029

7. Measure resistance between the connector terminal specified in
the trouble shooting chart and the coolant temperature sensor
connector (PCU lower harness side).
Target connectors  1st and 2nd

8. Measure resistance between the connector terminal specified in
the trouble shooting chart and the inverter connector (PCU lower
harness side).
Target connectors  8th and 9th

YES

Common inspection OK

Standard value: 10 k or more

NO

Common inspection NG

HYBRID/TROUBLE SHOOTING3–40

SHTS03ZZZ0300030

(2) CHART FOR INSPECTION OF THE SIGNAL LINE AT THE PCU UPPER SIDE WIRE HARNESS FOR SHORT CIR­CUIT

Inspection of the signal line to the PCU harness 16-pin connector at the PCU upper side wire

1

harness for short circuit

1. Set the starter key to the "LOCK" position.

TARGET
CONNECTORS

YES

Common inspection OK

2. Disconnect the following connectors.

• PCU harness 16-pin connector

• HV battery cooling fan connector

• Battery ECU (CAN) connector

3. Measure resistance between the connector terminal specified in
the trouble shooting chart and the PCU harness 16-pin connector
(PCU upper harness side).
Target connectors  1st to 16th (except 10th)

Standard value: 10 k or more

NO

Common inspection NG

HYBRID/TROUBLE SHOOTING 3–41

ABS ECUHV ECU Speed pulse

Combination

meter

d1 f

Wheel speed

sensor

22

d1XJ

2318

22

24

SHTS03ZZZ0300031

DTC: P0500 (TC51)

DTC: P0500 (TC51) Abnormality in vehicle speed sensor

INFORMATION

1. Technical description

• –

<Description of malfunction>

• The signal from the vehicle speed sensor cannot be detected.

EN01H03ZZZ030602003005

2. DTC set condition

(1) DTC detection condition

• The starter key is set to the ON position.

• The control power supply voltage is 10 V or more.

• The number of the motor revolution is 1000 r/min or more.

• The motor revolution sensor shows no abnormality.

• Vehicle speed information from the vehicle control ECU is 3 mph or more.

• The vehicle speed sensor of vehicle control ECU shows no abnormality.

• The accelerator opening is 5% or more.

• The accelerator sensor shows no abnormality.

(2) Judgement criteria

• The signal input of vehicle speed sensor remains 0 Hz for 10 seconds or more.

3. Reset condition

• The signal input of vehicle speed sensor remains 3 mph or more for 10 seconds or more.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON

• HV warning light: ON

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• The idling stop function becomes inoperative.

• The regeneration function stops, which may reduce the feeling of deceleration during deceleration.

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

HYBRID/TROUBLE SHOOTING3–42

7. After-inspection work

• Clear the recorded DTC.

• Check that no DTC is detected after test-driving the vehicle.

8. Estimated failure factors

• Disconnection or short circuit of harness

• Improper contact or fitting of connector

• Malfunction of vehicle speed sensor

• Malfunction of HV ECU

• Malfunction of ABS ECU

• Malfunction of meter ECU

HYBRID/TROUBLE SHOOTING 3–43

NOYES

NOYES

SHTS03ZZZ0300032

SHTS03ZZZ0300033

INSPECTION PROCEDURE: P0500 (TC51)

Inspecting the ABS ECU [HINO-DX]

1

1. Set the starter key to the "LOCK" position.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. Select [Brake] on the diagnosis tool screen.

5. In [Fault Information], check if any DTC related to the vehicle

Is any DTC detected from the ABS?

speed sensor system is detected.

Perform troubleshooting for each DTC of

Go to step 2.

ABS ECU.

Inspecting the continuity of vehicle wire harness (between ABS ECU and the combination

2

meter)

1. Set the starter key to the "LOCK" position.

2. Disconnect the connectors of ABS ECU and combination meter
(40P).

3. Using the electrical tester, measure the resistance between the
ABS ECU vehicle-side connector and the terminal of combination
meter (40P) vehicle-side connector.

Measurement

conditions

Starter key: LOCK

Tester

connections

ABS ECU vehicle­side connector –
Combination
meter (40P) vehi­cle-side connector
22nd terminal –
22nd terminal

Standard values

Less than 1 

Is the measured value within the range of standard value?

Go to step 3. Repair or replace the vehicle wire harness

(between the ABS ECU and the combination
meter).

HYBRID/TROUBLE SHOOTING3–44

NOYES

SHTS03ZZZ0300034

Inspecting the continuity of vehicle wire harness (between the combination meter and the

3

PCU harness vehicle-side connector)

1. Disconnect the PCU harness (24P) connector.

2. Using the electrical tester, measure the resistance between the
vehicle-side connector of combination meter (40P) and the vehi­cle-side connector terminal of PCU harness (24P).

Measurement

conditions

Starter key: LOCK

Tester

connections

Combination
meter (40P) vehi­cle-side connec­tor – PCU harness
(24P) vehicle side­connector
23rd terminal –
18th terminal

Standard values

Less than 1 

Is the measured value within the range of standard value?

Go to step 4. Repair or replace the vehicle wire harness

(between the combination meter and the PCU
harness connector).

HYBRID/TROUBLE SHOOTING 3–45

NOYES

NOYES

SHTS03ZZZ0300035

VEHICLE GND

SHTS03ZZZ0300036

Inspecting the continuity of PCU wire harness (lower side)

4

1. Disconnect the HV ECU3 connector.

2. Using the electrical tester, measure the resistance between the
lower-side connector of PCU harness (24P) and the HV ECU3
connector terminal.

Measurement

conditions

Starter key: LOCK

Tester

connections

PCU harness (24P)
lower-side con­nector – HV ECU3
connector
18th terminal –
24th terminal

Standard values

Less than 1 

Is the measured value within the range of standard value?

Go to step 5. Replace the PCU wire harness (lower side).

Inspecting the PCU wire harness (lower side) for short circuit

5

1. Using the electrical tester, measure the resistance between the
lower-side connector terminals of PCU harness (24P).

2. Using the electrical tester, measure the resistance between the
lower-side connector 18th terminal of PCU harness (24P) and the
ground.

Measurement

conditions

Starter key: LOCK

Tester

connections

PCU harness (24P)
lower-side con­nector
18th terminal –
24th terminal
18th terminal –
GND

Standard values

10 k or more

Is the measured value within the range of standard value?

Go to step 6. Replace the PCU wire harness (lower side).

HYBRID/TROUBLE SHOOTING3–46

NOYES

NOYES

SHTS03ZZZ0300037

Inspecting the engine ECU [HINO-DX]

6

1. Connect the diagnosis tool (HINO-DX) to the vehicle.

2. Set the starter key to the "ON" position.

3. Select [Engine] on the diagnosis tool screen.

4. In [Fault Information], check if any DTC related to the vehicle
speed signal system is detected.

Is any DTC detected from the engine ECU?

Inspect the combination meter. Go to step 7.

Inspecting the PCU wire harness signal line for short circuit

7

1. Set the starter key to the "LOCK" position.

2. For the 18th terminal of PCU harness (24P) lower-side connector,
inspect the signal line of PCU wire harness (lower side) for short
circuit. (See "Inspecting the PCU harness signal line for short cir­cuit.")

Measurement

conditions

Starter key: LOCK

Is any defect found?

Tester

connections

PCU harness (24P)
lower-side con­nector
18th terminal –
Each signal line

Standard values

10 k or more

Replace the PCU wire harness (lower side). Go to step 8.

NOYES

Reproduction check [HINO-DX]

SHTS03ZZZ0300038

8

Is DTC P0500-51 detected?

HYBRID/TROUBLE SHOOTING 3–47

1. Connect all the connectors that have been disconnected to restore
the system.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. Clear the malfunction history.

5. Perform a test run. (For 1 minutes at the vehicle speed of 10 km/h
or more)

6. In [Fault Information] on the diagnosis tool screen, check if P0500­51 is detected.

Replace the HV ECU. The inspection is completed.(If no repair or

parts replacement is performed, there may
be an improper contact due to connector dis­connection.)

HYBRID/TROUBLE SHOOTING3–48

CHECKLIST: P0500 (TC51)

P0500 (TC51) Abnormality in vehicle speed sensor Inspection Procedure

Step Action Description Judgement

1. Set the starter key to the
"LOCK" position.

DTC is
detected from
the ABS: Go to
YES.

DTC is not
detected from
the ABS: Go to
NO.

Inspecting the

1

ABS ECU
[HINO-DX]

2. Connect the diagnosis tool
(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. Select [Brake] on the diagnosis
tool screen.

5. In [Fault Information], check if
any DTC related to the vehicle
speed sensor system is
detected.

1. Set the starter key to the
"LOCK" position.

2. Disconnect the connectors of

Inspecting the
continuity of
vehicle wire
harness

2

(between ABS
ECU and the
combination
meter)

ABS ECU and combination
meter (40P).

3. Using the electrical tester, mea­sure the resistance between
the ABS ECU vehicle-side con­nector and the terminal of com­bination meter (40P) vehicle­side connector.

<Measurement conditions>
Starter key: LOCK
<Tester connections>
ABS ECU vehicle-side connector
– Combination meter (40P) vehi-

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

cle-side connector
22nd terminal – 22nd terminal
<Standard values>
Less than 1 

1. Disconnect the PCU harness
(24P) connector.

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

Inspecting the
continuity of
vehicle wire
harness
(between the

3

combination
meter and the
PCU harness
vehicle-side
connector)

2. Using the electrical tester, mea­sure the resistance between
the vehicle-side connector of
combination meter (40P) and
the vehicle-side connector ter­minal of PCU harness (24P).

<Measurement conditions>
Starter key: LOCK
<Tester connections>
Combination meter (40P) vehicle­side connector – PCU harness
(24P) vehicle side-connector
23rd terminal – 18th terminal
<Standard values>
Less than 1 

Check

(Yes/No)

Yes No

Perform trou­bleshooting for
each DTC of
ABS ECU.

Go to step 3.

Go to step 4.

Go to step 2.

Repair or
replace the
vehicle wire
harness
(between the
ABS ECU and
the combina­tion meter).

Repair or
replace the
vehicle wire
harness
(between the
combination
meter and the
PCU harness
connector).

HYBRID/TROUBLE SHOOTING 3–49

P0500 (TC51) Abnormality in vehicle speed sensor Inspection Procedure

Step Action Description Judgement

1. Disconnect the HV ECU3 con­The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

Inspecting the
continuity of

4

PCU wire har­ness (lower
side)

nector.

2. Using the electrical tester, mea-

sure the resistance between
the lower-side connector of
PCU harness (24P) and the HV

ECU3 connector terminal.
<Measurement conditions>
Starter key: LOCK
<Tester connections>
PCU harness (24P) lower-side
connector – HV ECU3 connector
18th terminal – 24th terminal
<Standard values>
Less than 1 

1. Using the electrical tester, mea-

sure the resistance between

Inspecting the
PCU wire har-

5

ness (lower
side) for short
circuit

the lower-side connector termi-

nals of PCU harness (24P).

2. Using the electrical tester, mea-

sure the resistance between

the lower-side connector 18th

terminal of PCU harness (24P)

and the ground.
<Measurement conditions>
Starter key: LOCK
<Tester connections>
PCU harness (24P) lower-side
connector
18th terminal – 24th terminal

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

18th terminal – GND
<Standard values>
10 k or more

Inspecting the

6

engine ECU
[HINO-DX]

1. Connect the diagnosis tool

(HINO-DX) to the vehicle.

2. Set the starter key to the "ON"

position.

3. Select [Engine] on the diagno-

sis tool screen.

4. In [Fault Information], check if

any DTC related to the vehicle

speed signal system is

detected.

DTC is
detected from
the engine
ECU: Go to
YES.

DTC is not
detected from
the engine
ECU: Go to
NO.

Check

(Yes/No)

Yes No

Go to step 5.

Go to step 6.

Inspect the
combination
meter.

Replace the
PCU wire har­ness (lower
side).

Replace the
PCU wire har­ness (lower
side).

Go to step 7.

HYBRID/TROUBLE SHOOTING3–50

P0500 (TC51) Abnormality in vehicle speed sensor Inspection Procedure

Step Action Description Judgement

1. Set the starter key to the
"LOCK" position.

2. For the 18th terminal of PCU
harness (24P) lower-side con­nector, inspect the signal line of

Defect is
found: Go to
YES.

Defect is not
found: Go to
NO.

Inspecting the
PCU wire har-

7

ness signal
line for short
circuit

PCU wire harness (lower side)
for short circuit. (See "Inspect­ing the PCU harness signal line
for short circuit.")

<Measurement conditions>
Starter key: LOCK
<Tester connections>
PCU harness (24P) lower-side
connector
18th terminal – Each signal line
<Standard values>
10 k or more

1. Connect all the connectors that
have been disconnected to
restore the system.

2. Connect the diagnosis tool

DTC P0500­51 is detected:
Go to
YES.DTC
P0500-51 is
not detected:
Go to NO.

Reproduction

8

check [HINO­DX]

(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. Clear the malfunction history.

5. Perform a test run. (For 1 min­utes at the vehicle speed of 10
km/h or more)

6. In [Fault Information] on the
diagnosis tool screen, check if
P0500-51 is detected.

Check

(Yes/No)

Yes No

Replace the
PCU wire har­ness (lower
side).

Replace the
HV ECU.

Go to step 8.

The inspec­tion is com­pleted.(If no
repair or parts
replacement is
performed,
there may be
an improper
contact due to
connector dis­connection.)

HYBRID/TROUBLE SHOOTING 3–51

ABS ECUHV ECU Speed pulse

Combination

meter

d1 f

Wheel speed

sensor

22

d1XJ

2318

22

24

SHTS03ZZZ0300039

DTC: P0501 (TC5B)

EN01H03ZZZ030602003006

DTC: P0501 (TC5B) Abnormality in characteristics of vehicle speed sensor

INFORMATION

1. Technical description

• –

<Description of malfunction>

• Detected the abnormality in the vehicle speed sensor. (Abnormality in characteristics of vehicle speed sensor)

2. DTC set condition

(1) DTC detection condition

• The starter key is set to the ON position.

• The control power supply voltage is 10V or more.

(2) Judgement criteria

• The signal input of vehicle speed sensor remains 112 mph or more for 10 seconds or more.

3. Reset condition

• The signal input of vehicle speed sensor remains less than 112 mph for 10 seconds or more.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON

• HV warning light: ON

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• The idling stop function becomes inoperative.

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

7. After-inspection work

• Clear the recorded DTC.

• Check that no DTC is detected after test-driving the vehicle.

8. Estimated failure factors

• Disconnection or short circuit of harness

• Improper contact or fitting of connector

• Malfunction of vehicle speed sensor

• Malfunction of HV ECU

• Malfunction of ABS ECU

• Malfunction of meter ECU

HYBRID/TROUBLE SHOOTING3–52

HYBRID/TROUBLE SHOOTING 3–53

NOYES

NOYES

SHTS03ZZZ0300040

INSPECTION PROCEDURE: P0501 (TC5B)

Inspecting the ABS ECU [HINO-DX]

1

1. Set the starter key to the "LOCK" position.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. Select [Brake] on the diagnosis tool screen.

5. In [Fault Information], check if any DTC related to the vehicle

Is any DTC detected from the ABS?

speed sensor system is detected.

Perform troubleshooting for each DTC of

Go to step 2.

ABS ECU.

Inspecting the signal line of PCU wire harness (lower side) for short circuit

2

1. Set the starter key to the "LOCK" position.

2. Disconnect the HV ECU3 connector.

3. For the 18th terminal of PCU harness (24P) lower-side connector,
inspect the signal line of PCU wire harness (lower side) for short
circuit. (See "Inspecting the PCU harness signal line for short cir­cuit.")

Measurement

conditions

Starter key: LOCK

connections

PCU harness (24P)
lower-side con­nector
18th terminal –
Each signal line

Tester

Standard values

10 k or more

Is any defect found?

Replace the PCU wire harness (lower side). Go to step 3.

NOYES

NOYES

Inspecting the engine ECU [HINO-DX]

SHTS03ZZZ0300041

SHTS03ZZZ0300042

3

HYBRID/TROUBLE SHOOTING3–54

1. Set the starter key to the "ON" position.

2. Select [Engine] on the diagnosis tool screen.

3. Select [Data Monitor] and monitor [Vehicle speed] while driving at
the speed of 20 km/h.

Measurement

conditions

• Starter key: ON

• Drive at the

vehicle speed of
20 km/h.

Measured item Standard values

The monitored
vehicle speed is

Vehicle speed

approximately the
same as the driv­ing speed.

Is the measured value within the range of standard value?

Go to step 4. Inspect the vehicle-side wire harness related

to vehicle speed signals and the combination
meter.

Reproduction check [HINO-DX]

4

1. Connect all the connectors that have been disconnected to restore
the system.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. Clear the malfunction history.

5. Perform a test run. (For 1 minutes at the vehicle speed of 10 km/h
or more)

6. In [Fault Information] on the diagnosis tool screen, check if P0501­5B is detected.

Is DTC P0501-5B detected?

Replace the HV ECU. The inspection is completed.(If no repair or

parts replacement is performed, there may
be an improper contact due to connector dis­connection.)

CHECKLIST: P0501 (TC5B)

HYBRID/TROUBLE SHOOTING 3–55

P0501 (TC5B)

Abnormality in characteristics of

vehicle speed sensor

Step Action Description Judgement

1. Set the starter key to the
"LOCK" position.

DTC is
detected from
the ABS: Go to
YES.

DTC is not
detected from
the ABS: Go to
NO.

Inspecting the

1

ABS ECU
[HINO-DX]

2. Connect the diagnosis tool
(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. Select [Brake] on the diagnosis
tool screen.

5. In [Fault Information], check if
any DTC related to the vehicle
speed sensor system is
detected.

1. Set the starter key to the
"LOCK" position.

2. Disconnect the HV ECU3 con­nector.

3. For the 18th terminal of PCU

Inspecting the
signal line of
PCU wire har-

2

ness (lower
side) for short
circuit

harness (24P) lower-side con­nector, inspect the signal line of
PCU wire harness (lower side)
for short circuit. (See "Inspect­ing the PCU harness signal line
for short circuit.")

<Measurement conditions>
Starter key: LOCK

Defect is
found: Go to
YES.

Defect is not
found: Go to
NO.

<Tester connections>
PCU harness (24P) lower-side
connector
18th terminal – Each signal line
<Standard values>
10 k or more

1. Set the starter key to the "ON"
position.

Inspecting the

3

engine ECU
[HINO-DX]

2. Select [Engine] on the diagno­sis tool screen.

3. Select [Data Monitor] and mon­itor [Vehicle speed] while driv­ing at the speed of 20 km/h.

<Measurement conditions>

• Starter key: ON

• Drive at the vehicle speed of 20

km/h.

<Measured item>
Vehicle speed
18th terminal – Each signal line
<Standard values>

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

The monitored vehicle speed is
approximately the same as the
driving speed.

Check

(Yes/No)

Inspection Procedure

Yes No

Perform trou­bleshooting for
each DTC of

Go to step 2.

ABS ECU.

Replace the
PCU wire har­ness (lower

Go to step 3.

side).

Inspect the
vehicle-side
wire harness

Go to step 4.

related to vehi­cle speed sig­nals and the
combination
meter.

HYBRID/TROUBLE SHOOTING3–56

P0501 (TC5B)

Abnormality in characteristics of

vehicle speed sensor

Step Action Description Judgement

1. Connect all the connectors that
have been disconnected to
restore the system.

2. Connect the diagnosis tool

DTC P0501­5B is detected:
Go to
YES.DTC
P0501-5B is
not detected:
Go to NO.

Reproduction

4

check [HINO­DX]

(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. Clear the malfunction history.

5. Perform a test run. (For 1 min­utes at the vehicle speed of 10
km/h or more)

6. In [Fault Information] on the
diagnosis tool screen, check if
P0501-5B is detected.

Check

(Yes/No)

Inspection Procedure

Yes No

The inspec­tion is com­pleted.(If no
repair or parts

Replace the
HV ECU.

replacement is
performed,
there may be
an improper
contact due to
connector dis­connection.)

HYBRID/TROUBLE SHOOTING 3–57

HV ECU

F_HV_10A

XJ

21

SHTS03ZZZ0300043

DTC: P0562 (TC71)

DTC: P0562 (TC71) Abnormality in power supply voltage

INFORMATION

1. Technical description

• –

<Description of malfunction>

• Detected a reduction in 12 V line battery voltage (control power supply voltage).

EN01H03ZZZ030602003007

2. DTC set condition

(1) DTC detection condition

• The starter key is set to the ON position.

(2) Judgement criteria

• The control power supply voltage remains less than 8 V for 3 seconds or more.

3. Reset condition

• The control power supply voltage remains more than 10 V for 5 seconds or more.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF

• HV warning light: ON

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• The hybrid system stops, causing the following phenomena:

- The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with
the starter.)

- Idling stop becomes unavailable.

- The regeneration function stops, which may reduce the feeling of deceleration during deceleration.

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

7. After-inspection work

• Clear the recorded DTC.

• Check that no DTC is detected after test-driving the vehicle.

8. Estimated failure factors

• Capacity reduction of 12 V battery

• Disconnection or short circuit of harness

• Improper contact or fitting of connector

• Malfunction of HV ECU

HYBRID/TROUBLE SHOOTING3–58

HYBRID/TROUBLE SHOOTING 3–59

NOYES

NOYES

SHTS03ZZZ0300044

SHTS03ZZZ0300045

INSPECTION PROCEDURE: P0562 (TC71)

Reading the DTC [HINO-DX]

1

1. Set the starter key to the "LOCK" position.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. In [Fault Information] on the diagnosis tool screen, check if DTC

Is DTC P060B-B2 detected?

P060B-B2 other than P0562-71 is detected.

Perform troubleshooting for each of related
DTC.

Inspecting the vehicle wire harness

2

1. Set the starter key to the "LOCK" position.

2. Disconnect the PCU harness (24P) connector.

3. Using the electrical tester, measure the voltage between the vehi­cle-side connector terminals of PCU harness (24P).

Measurement

conditions

Starter key: LOCK

Is the measured value within the range of standard value?

Go to step 2.

connections

PCU harness (24P)
vehicle-side con­nector
2nd terminal –
16th terminal

Tester

Standard values

10 – 16 V

Go to step 3. Inspect the power supply circuit

([HV 10 A] fuse and wire harness).

HYBRID/TROUBLE SHOOTING3–60

NO

YES

NOYES

SHTS03ZZZ0300046

Inspecting the PCU wire harness (lower side)

3

1. Connect the PCU harness (24P) connector.

2. Disconnect the HV ECU3 connector.

3. Using the electrical tester, measure the voltage between the HV
ECU3 connector terminals.

Measurement

conditions

Starter key: LOCK

Tester

connections

HV ECU3 connec­tor
1st terminal –
5th terminal

Standard values

10 – 16 V

Is the measured value within the range of standard value?

Go to step 4. Replace the PCU wire harness (lower side).

Inspecting the signal line of PCU wire harness (lower side) for short circuit

4

1. Disconnect the PCU harness (24P) connector.

2. For the 2nd terminal of PCU harness (24P) lower-side connector,
inspect the signal line of PCU wire harness (lower side) for short
circuit. (See "Inspecting the PCU harness signal line for short cir­cuit.")

Measurement

conditions

Starter key: LOCK

connections

PCU harness (24P)
lower-side con­nector
2nd terminal –
Each signal line

Is any defect found?

Replace the PCU wire harness (lower side). Go to step 5.

Tester

Standard values

10 k or more

HYBRID/TROUBLE SHOOTING 3–61

NOYES

NOYES

SHTS03ZZZ0300047

Inspecting the signal line of PCU wire harness (upper side) for short circuit

5

1. Disconnect the connectors of PCU harness (16P) and battery
ECU (26P).

2. For the 13th terminal of PCU harness (16P) connector, inspect the
signal line of PCU wire harness (upper side) for short circuit.
(See "Inspecting the PCU harness signal line for short circuit.")

Measurement

conditions

Starter key: LOCK

Is any defect found?

Replace the PCU wire harness (upper side). Go to step 6.

Inspecting the HV ECU [HINO-DX]

6

1. Connect all the connectors that have been disconnected to restore
the system.

2. Set the starter key to the "ON" position.

Tester

connections

PCU harness (16P)
upper-side con­nector
16th terminal –
Each signal line

Standard values

10 k or more

3. Select [Data Monitor] on the diagnosis tool screen and monitor
[Power supply voltage] of HV ECU.

Measurement

conditions

Starter key: ON

Measured item Standard values

Power supply volt­age

Is the measured value within the range of standard value?

Go to step 7. Replace the HV ECU.

10 – 16 V

NOYES

Reproduction check [HINO-DX]

SHTS03ZZZ0300048

7

Is DTC P0562-71 detected?

HYBRID/TROUBLE SHOOTING3–62

1. Clear the malfunction history.

2. Set the starter key to the "ON" position and wait for 1 minute.

3. In [Fault Information] on the diagnosis tool screen, check if DTC
P0562-71 is detected.

Re-inspect the 12 V battery and power supply
circuit.

The inspection is completed.

HYBRID/TROUBLE SHOOTING 3–63

CHECKLIST: P0562 (TC71)

P0562 (TC71) Abnormality in power supply voltage Inspection Procedure

Step Action Description Judgement

1. Set the starter key to the

Reading the

1

DTC [HINO­DX]

"LOCK" position.

2. Connect the diagnosis tool
(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. In [Fault Information] on the
diagnosis tool screen, check if
DTC P060B-B2 other than

DTC P060B­B2 is detected:
Go to YES.

DTC P060B­B2 is not
detected: Go
to NO.

P0562-71 is detected.

1. Set the starter key to the

Inspecting the

2

vehicle wire
harness

"LOCK" position.

2. Disconnect the PCU harness
(24P) connector.

3. Using the electrical tester, mea­sure the voltage between the
vehicle-side connector termi­nals of PCU harness (24P).

<Measurement conditions>
Starter key: LOCK
<Tester connections>
PCU harness (24P) vehicle-side
connector
2nd terminal – 16th terminal

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

<Standard values>
10 – 16 V

Inspecting the
PCU wire har-

3

ness (lower
side)

1. Connect the PCU harness
(24P) connector.

2. Disconnect the HV ECU3 con­nector.

3. Using the electrical tester, mea­sure the voltage between the
HV ECU3 connector terminals.

<Measurement conditions>
Starter key: LOCK
<Tester connections>
HV ECU3 connector
1st terminal – 5th terminal
<Standard values>

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

10 – 16 V

Check

(Yes/No)

Yes No

Perform trou­bleshooting for
each of related
DTC.

Go to step 3.

Go to step 4.

Go to step 2.

Inspect the
power supply
circuit
([HV 10 A]
fuse and wire
harness).

Replace the
PCU wire har­ness (lower
side).

HYBRID/TROUBLE SHOOTING3–64

P0562 (TC71) Abnormality in power supply voltage Inspection Procedure

Step Action Description Judgement

1. Disconnect the PCU harness
(24P) connector.

2. For the 2nd terminal of PCU
harness (24P) lower-side con­nector, inspect the signal line of

Inspecting the
signal line of
PCU wire har-

4

ness (lower
side) for short
circuit

PCU wire harness (lower side)
for short circuit. (See "Inspect­ing the PCU harness signal line
for short circuit.")

<Measurement conditions>
Starter key: LOCK
<Tester connections>

Defect is
found: Go to
YES.

Defect is not
found: Go to
NO.

PCU harness (24P) lower-side
connector
2nd terminal – Each signal line
<Standard values>
10 k or more

1. Disconnect the connectors of
PCU harness (16P) and battery
ECU (26P).

2. For the 13th terminal of PCU
harness (16P) connector,

Inspecting the
signal line of
PCU wire har-

5

ness (upper
side) for short
circuit

inspect the signal line of PCU
wire harness (upper side) for
short circuit. (See "Inspecting
the PCU harness signal line for
short circuit.")

<Measurement conditions>
Starter key: ON

Defect is
found: Go to
YES.

Defect is not
found: Go to
NO.

<Tester connections>
PCU harness (16P) upper-side
connector
16th terminal – Each signal line
<Standard values>
10 k or more

1. Connect all the connectors that

Inspecting the

6

HV ECU
[HINO-DX]

have been disconnected to
restore the system.

2. Set the starter key to the "ON"
position.

3. Select [Data Monitor] on the
diagnosis tool screen and mon­itor [Power supply voltage] of
HV ECU.

<Measurement conditions>
Starter key: ON
<Measured item>
Power supply voltage
<Standard values>

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

10 – 16 V

Check

(Yes/No)

Yes No

Replace the
PCU wire har­ness (lower
side).

Replace the
PCU wire har­ness (upper
side).

Go to step 7.

Go to step 5.

Go to step 6.

Replace the
HV ECU.

HYBRID/TROUBLE SHOOTING 3–65

P0562 (TC71) Abnormality in power supply voltage Inspection Procedure

Step Action Description Judgement

DTC P0562­71 is detected:
Go to YES.

DTC P0562­71 is not
detected: Go
to NO.

Reproduction

7

check [HINO­DX]

1. Clear the malfunction history.

2. Set the starter key to the "ON"
position and wait for 1 minute.

3. In [Fault Information] on the
diagnosis tool screen, check if
DTC P0562-71 is detected.

Check

(Yes/No)

Yes No

Re-inspect the
12 V battery
and power
supply circuit.

The inspec­tion is com­pleted.

HYBRID/TROUBLE SHOOTING3–66

DTC: P060B (TCB2)

DTC: P060B (TCB2) Abnormality in A/D converter

INFORMATION

1. Technical description

• –

<Description of malfunction>

• Detected an abnormality of A/D converter in the HV ECU.

2. DTC set condition

(1) DTC detection condition

• The starter key is set to the ON position.

(2) Judgement criteria

• A/D conversion failed 3 times successively.

3. Reset condition

• A/D conversion is successfully completed 3 times successively.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON

• HV warning light: ON

EN01H03ZZZ030602003008

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• The idling stop function becomes inoperative.

• The regeneration function stops, which may reduce the feeling of deceleration during deceleration.

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

7. After-inspection work

• Clear the recorded DTC.

• Check that no DTC is detected after test-driving the vehicle.

8. Estimated failure factors

• Malfunction of HV ECU

HYBRID/TROUBLE SHOOTING 3–67

NO

YES

SHTS03ZZZ0300049

INSPECTION PROCEDURE: P060B (TCB2)

Reproduction check [HINO-DX]

1

1. Set the starter key to the "LOCK" position.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. Clear the malfunction history.

5. Start the engine and keep it idling for 1 minute.

6. In [Fault Information] on the diagnosis tool screen, check if P060B-

Is DTC P060B-B2 detected?

B2 is detected.

Replace the HV ECU. The inspection is completed. (The abnormal-

ity may have been caused by a temporary
factor such as noise.)

HYBRID/TROUBLE SHOOTING3–68

CHECKLIST: P060B (TCB2)

P060B (TCB2) Abnormality in A/D converter Inspection Procedure

Step Action Description Judgement

1. Set the starter key to the
"LOCK" position.

Reproduction

1

check [HINO­DX]

2. Connect the diagnosis tool
(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. Clear the malfunction history.

5. Start the engine and keep it
idling for 1 minute.

DTC P060B­B2 is detected:
Go to YES.

DTC P060B­B2 is not
detected: Go
to NO.

6. In [Fault Information] on the
diagnosis tool screen, check if
P060B-B2 is detected.

Check

(Yes/No)

Yes No

Replace the
HV ECU.

The inspec­tion is com­pleted.(The
abnormality
may have
been caused
by a temporary
factor such as
noise.)

HYBRID/TROUBLE SHOOTING 3–69

HV ECU

Neutral switch

F_AM2_10A

at t

X

H

1066

12

54

Starter key

SHTS03ZZZ0300050

DTC: P0617 (TC59)

DTC: P0617 (TC59) Malfunction of starter switch

INFORMATION

1. Technical description

• –

EN01H03ZZZ030602003009

<Description of malfunction>

• Detected an abnormality in the starter key (starter signal circuit is stuck to High).

2. DTC set condition

(1) DTC detection condition

• The starter key is set to the ON position.

• The control power supply voltage is 10 V or more.

• The vehicle speed is 12 mph or more.

• The number of the motor revolution is 1000 r/min or more.

• The motor revolution sensor shows no abnormality.

(2) Judgement criteria

• The starter signal remains ON for 20 seconds or more.

3. Reset condition

• The starter signal remains OFF for 0.1 second or more.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON

• HV warning light: ON

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• The idling stop function becomes inoperative.

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

HYBRID/TROUBLE SHOOTING3–70

7. After-inspection work

• Clear the recorded DTC.

• Check that no DTC is detected after test-driving the vehicle.

8. Estimated failure factors

• Disconnection or short circuit of harness

• Improper contact or fitting of connector

• Malfunction of starter key

• Malfunction of HV ECU

HYBRID/TROUBLE SHOOTING 3–71

NOYES

NOYES

SHTS03ZZZ0300051

VEHICLE GND

SHTS03ZZZ0300052

INSPECTION PROCEDURE: P0617 (TC59)

Inspecting the neutral switch 1

1

1. Set the starter key to the "LOCK" position.

2. Disconnect the neutral switch connector.

3. Set the starter key to the "ON" position.

4. Set the shift lever to the N position.

5. Using the electrical tester, measure the resistance between the
neutral switch connector terminals.

Measurement

conditions

Starter key: ON
Shift lever:
N position

Tester

connections

Neutral switch
connector
6th terminal –
10th terminal

Is the measured value within the range of standard value?

Go to step 2. Replace the neutral switch.

Inspecting the neutral switch 2

2

1. Using the electrical tester, measure the resistance between each
terminal of neutral switch connector and the ground.

Measurement

conditions

Tester

connections

Standard values

Less than 3 

Standard values

Neutral switch

Starter key: ON
Shift lever:
N position

connector
6th terminal –
GND
10th terminal –
GND

Is the measured value within the range of standard value?

Go to step 3. Replace the neutral switch.

10 k or more

HYBRID/TROUBLE SHOOTING3–72

NOYES

NOYES

VEHICLE GND

SHTS03ZZZ0300053

SHTS03ZZZ0300054

Inspecting the vehicle wire harness for short circuit 1 (starter key signal circuit)

3

1. Set the starter key to the "LOCK" position.

2. Disconnect the connectors of starter key and PCU harness (24P).

3. Set the starter key to the "ON" position.

4. Using the electrical tester, measure the voltage between the 6th
terminal of starter key vehicle-side connector and the ground.

Measurement

conditions

Tester

connections

Standard values

Starter key vehi-

Starter key: ON

cle-side connector
6th terminal –

Less than 1 V

GND

Is the measured value within the range of standard value?

Go to step 4. Repair or replace the wire harness.(Starter

key signal circuit)

Inspecting the key cylinder

4

1. Using the electrical tester, measure the voltage between the 6th
terminal of key cylinder connector and the ground.

VEHICLE GND

Measurement

conditions

Tester

connections

Standard values

Key cylinder con-

Starter key: ON

nector
6th terminal –
GND

Is the measured value within the range of standard value?

Go to step 5. Replace the key cylinder.

Less than 1 V

HYBRID/TROUBLE SHOOTING 3–73

NO

YES

NOYES

VEHICLE GND

SHTS03ZZZ0300055

VEHICLE GND

SHTS03ZZZ0300056

Inspecting the vehicle wire harness for short circuit 2 (starter key signal circuit)

5

1. Using the electrical tester, measure the voltage between the 12th
terminal of PCU harness (24P) vehicle-side connector and the
ground.

Measurement

conditions

Starter key: ON

Tester

connections

PCU harness (24P)
vehicle-side con­nector
12th terminal –
GND

Is the measured value within the range of standard value?

Go to step 6. Repair or replace the wire harness.

(Starter key signal circuit)

Inspecting the PCU wire harness (lower side) for short circuit

6

1. Set the starter key to the "LOCK" position.

2. Connect the PCU harness (24P) connector.

Standard values

Less than 1 V

3. Disconnect the HV ECU1 connector.

4. Set the starter key to the "ON" position.

5. Using the electrical tester, measure the voltage between the 54th
terminal of HV ECU1 connector and the ground.

Measurement

conditions

Starter key: ON

Tester

connections

HV ECU1 connec­tor
4th terminal –
GND

Standard values

Less than 1 V

Is the measured value within the range of standard value?

Go to step 7. Replace the PCU wire harness (lower side).

HYBRID/TROUBLE SHOOTING3–74

NOYES

NOYES

SHTS03ZZZ0300057

Inspecting the signal line of PCU wire harness (lower side) for short circuit

7

1. Set the starter key to the "LOCK" position.

2. For the 12th terminal of PCU harness (24P) lower-side connector,
inspect the signal line of PCU wire harness (lower side) for short
circuit. (See "Inspecting the PCU harness signal line for short cir­cuit.")

Measurement

conditions

Starter key: LOCK

Is any defect found?

Replace the PCU wire harness (lower side). Go to step 8.

Reproduction check [HINO-DX]

8

1. Connect all the connectors that have been disconnected to restore
the system.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

Tester

connections

PCU harness (24P)
lower-side con­nector
12th terminal –
Each signal line

Standard values

10 k or more

3. Set the starter key to the "ON" position.

4. Clear the malfunction history.

5. Perform a test run. (The vehicle speed and the engine speed
remain at 25 km/h or more and 1500 r/min or more, respectively,
for 30 seconds or more.)

6. In [Fault Information] on the diagnosis tool screen, check if P0617­59 is detected.

Is DTC P0617-59 detected?

Replace the HV ECU. The inspection is completed.

(If no repair or parts replacement is per­formed, there may be an improper contact
due to connector disconnection.)

HYBRID/TROUBLE SHOOTING 3–75

CHECKLIST: P0617 (TC59)

P0617 (TC59) Malfunction of starter switch Inspection Procedure

Step Action Description Judgement

1. Set the starter key to the
"LOCK" position.

2. Disconnect the neutral switch

Inspecting the

1

neutral switch
1

connector.

3. Set the starter key to the "ON"
position.

4. Set the shift lever to the N posi­tion.

5. Using the electrical tester, mea­sure the resistance between
the neutral switch connector
terminals.

<Measurement conditions>
Starter key: ON
Shift lever: N position
<Tester connections>

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

Neutral switch connector
6th terminal – 10th terminal
<Standard values>
Less than 3 

Inspecting the

2

neutral switch
2

1. Using the electrical tester, mea­sure the resistance between
each terminal of neutral switch
connector and the ground.

<Measurement conditions>
Starter key: ON
Shift lever: N position
<Tester connections>
Neutral switch connector
6th terminal – GND
10th terminal – GND
<Standard values>
10 k or more

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

Check

(Yes/No)

Yes No

Go to step 2.

Go to step 3.

Replace the
neutral switch.

Replace the
neutral switch.

HYBRID/TROUBLE SHOOTING3–76

P0617 (TC59) Malfunction of starter switch Inspection Procedure

Step Action Description Judgement

1. Set the starter key to the
"LOCK" position.

2. Disconnect the connectors of

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

Inspecting the
vehicle wire
harness for

3

short circuit 1
(starter key
signal circuit)

starter key and PCU harness
(24P).

3. Set the starter key to the "ON"
position.

4. Using the electrical tester, mea­sure the voltage between the
6th terminal of starter key vehi­cle-side connector and the
ground.

<Measurement conditions>
Starter key: ON
<Tester connections>
Starter key vehicle-side connector
6th terminal – GND
<Standard values>
Less than 1 V

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go

Inspecting the

4

key cylinder

1. Using the electrical tester, mea­sure the voltage between the
6th terminal of key cylinder
connector and the ground.

<Measurement conditions>
Starter key: ON
<Tester connections>
Key cylinder connector
6th terminal – GND
<Standard values>
Less than 1 V

to NO.

Inspecting the
vehicle wire
harness for

5

short circuit 2
(starter key
signal circuit)

1. Using the electrical tester, mea­sure the voltage between the
12th terminal of PCU harness
(24P) vehicle-side connector
and the ground.

<Measurement conditions>
Starter key: ON
<Tester connections>
PCU harness (24P) vehicle-side
connector
12th terminal – GND
<Standard values>
Less than 1 V

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

Check

(Yes/No)

Yes No

Go to step 4.

Go to step 5.

Go to step 6.

Repair or
replace the
wire har­ness.(Starter
key signal cir­cuit)

Replace the
key cylinder.

Repair or
replace the
wire harness.
(Starter key
signal circuit)

HYBRID/TROUBLE SHOOTING 3–77

P0617 (TC59) Malfunction of starter switch Inspection Procedure

Step Action Description Judgement

1. Set the starter key to the
"LOCK" position.

2. Connect the PCU harness

Inspecting the
PCU wire har-

6

ness (lower
side) for short
circuit

(24P) connector.

3. Disconnect the HV ECU1 con­nector.

4. Set the starter key to the "ON"
position.

5. Using the electrical tester, mea­sure the voltage between the
54th terminal of HV ECU1 con­nector and the ground.

<Measurement conditions>
Starter key: ON
<Tester connections>
HV ECU1 connector

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

4th terminal – GND
<Standard values>
Less than 1 V

1. Set the starter key to the
"LOCK" position.

2. For the 12th terminal of PCU
harness (24P) lower-side con­nector, inspect the signal line of

Inspecting the
signal line of
PCU wire har-

7

ness (lower
side) for short
circuit

PCU wire harness (lower side)
for short circuit. (See "Inspect­ing the PCU harness signal line
for short circuit.")

<Measurement conditions>
Starter key: LOCK
<Tester connections>

Defect is
found: Go to
YES.

Defect is not
found: Go to
NO.

PCU harness (24P) lower-side
connector
12th terminal – Each signal line
<Standard values>
10 k or more

1. Connect all the connectors that
have been disconnected to
restore the system.

2. Connect the diagnosis tool

Reproduction

8

check [HINO­DX]

(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. Clear the malfunction history.

5. Perform a test run. (The vehicle
speed and the engine speed
remain at 25 km/h or more and
1500 r/min or more, respec-

DTC P0617­59 is detected:
Go to YES.

DTC P0617­59 is not
detected: Go
to NO.

tively, for 30 seconds or more.)

6. In [Fault Information] on the
diagnosis tool screen, check if
P0617-59 is detected.

Check

(Yes/No)

Yes No

Go to step 7.

Replace the
PCU wire har­ness (lower
side).

Replace the
HV ECU.

Replace the
PCU wire har­ness (lower
side).

Go to step 8.

The inspec­tion is com­pleted.
(If no repair or
parts replace­ment is per­formed, there
may be an
improper con­tact due to
connector dis­connection.)

HYBRID/TROUBLE SHOOTING3–78

DTC: P062F (TCB3)

DTC: P062F (TCB3) Abnormality in EEPROM

INFORMATION

1. Technical description

• –

<Description of malfunction>

• Detected an abnormality of EEPROM in the HV ECU.

2. DTC set condition

(1) DTC detection condition

• The starter key is set to the ON position.

• The control power supply voltage is 8 V or more.

(2) Judgement criteria

• Failure of access to EEPROM

3. Reset condition

• Successful access to EEPROM

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON

• HV warning light: ON

EN01H03ZZZ030602003010

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• Recording of malfunction code (DTC) may become unavailable.

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

7. After-inspection work

• Clear the recorded DTC.

• Check that no DTC is detected after test-driving the vehicle.

8. Estimated failure factors

• Malfunction of HV ECU

HYBRID/TROUBLE SHOOTING 3–79

NOYES

NOYES

SHTS03ZZZ0300058

SHTS03ZZZ0300059

INSPECTION PROCEDURE: P062F (TCB3)

Reading the DTC [HINO-DX]

1

1. Set the starter key to the "LOCK" position.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. In [Fault Information] on the diagnosis tool screen, check if DTC

Is DTC P0562-71 detected?

P0562-71 other than P062F-B3 is detected.

Perform troubleshooting for each of related

Go to step 2.

DTC.

Reproduction check [HINO-DX]

2

1. Clear the malfunction history.

2. Set the starter key to the "ON" position and wait for 1 minute.

3. In [Fault Information] on the diagnosis tool screen, check if P062F­B3 is detected.

Is DTC P062F-B3 detected?

Replace the HV ECU. The inspection is completed.

(The abnormality may have been caused by a
temporary factor such as noise.)

HYBRID/TROUBLE SHOOTING3–80

CHECKLIST: P062F (TCB3)

P062F (TCB3) Abnormality in EEPROM Inspection Procedure

Step Action Description Judgement

1. Set the starter key to the

Reading the

1

DTC [HINO­DX]

"LOCK" position.

2. Connect the diagnosis tool
(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. In [Fault Information] on the
diagnosis tool screen, check if
DTC P0562-71 other than

DTC P0562­71 is detected:
Go to YES.

DTC P0562­71 is not
detected: Go
to NO.

P062F-B3 is detected.

DTC P062F­B3 is detected:
Go to YES.

DTC P062F­B3 is not
detected: Go
to NO.

Reproduction

2

check [HINO­DX]

1. Clear the malfunction history.

2. Set the starter key to the "ON"
position and wait for 1 minute.

3. In [Fault Information] on the
diagnosis tool screen, check if
P062F-B3 is detected.

Check

(Yes/No)

Yes No

Perform trou­bleshooting for
each of related
DTC.

Replace the
HV ECU.

Go to step 2.

The inspec­tion is com­pleted.
(The abnor­mality may
have been
caused by a
temporary fac­tor such as
noise.)

HYBRID/TROUBLE SHOOTING 3–81

ABS ECU

CAN H2

CAN L2

HV PCU

HV ECU

Inverter

7

6

(CA1-)

(CA1+)

3

2

(CA2-)

(CA2+)

9

18

7

19

8

20

J/C CAN2

9

18

7

19

8

20

J/C CAN1

AT ECU

Clutch ECU

Combination meter

21

20

20

19

10

21

14

13

48

49

47

46

4

8

3

5

10

6

9

J/C CAN2

J/C CTRL CAN

7

1

2

15

25

15

24

23

13

(CSL4)

X-21

(CA2+)

X-23

(CA1+)

X-24

(CSL2)

(CA1-)

X-22

(CA2-)

21

22

O-3

O-8

O-2

O-13

O-12

O-1

O-7

O-9

J-10

J-20

O-4

O-10

D-22

D-33

To GROUND CIRCUIT

SHTS03ZZZ0300060

DTC: P0810 (TC9C)

DTC: P0810 (TC9C) Abnormality in clutch system (idling stop inhibited)

INFORMATION

EN01H03ZZZ030602003011

1. Technical description

• –

<Description of malfunction>

• Detected an abnormality in the clutch system.

2. DTC set condition

(1) DTC detection condition

• CAN communication with the clutch ECU is normal.

(2) Judgement criteria

• When any of the following abnormality is received from the clutch ECU:

- Notification of power supply abnormality

- Notification of oil temperature sensor abnormality

- Notification of solenoid abnormality

- Notification that receiving from AT ECU is unavailable and that the communication has been disrupted

- Notification of abnormality in electric oil pump for the clutch

- Notification of clutch disengagement abnormality

- Notification of clutch slip abnormality

- Notification of clutch revolution alignment abnormality

- Notification that the HV damper friction material is worn

HYBRID/TROUBLE SHOOTING3–82

3. Reset condition

• When the notification that there is none of the following abnormality is received from the clutch ECU:

- Notification of power supply abnormality

- Notification of oil temperature sensor abnormality

- Notification of solenoid abnormality

- Notification that receiving from AT ECU is unavailable and that the communication has been disrupted

- Notification of abnormality in electric oil pump for the clutch

- Notification of clutch disengagement abnormality

- Notification of clutch slip abnormality

- Notification of clutch revolution alignment abnormality

- Notification that the HV damper friction material is worn

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF

• HV warning light: ON

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• The idling stop function may become inoperative.

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

7. After-inspection work

• Clear the recorded DTC.

• Check that no DTC is detected after test-driving the vehicle.

8. Estimated failure factors

• Malfunctioning of clutch system

HYBRID/TROUBLE SHOOTING 3–83

NOYES

SHTS03ZZZ0300061

INSPECTION PROCEDURE: P0810 (TC9C)

Reading the DTC [HINO-DX]

1

1. Set the starter key to the "LOCK" position.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. In [Fault Information] on the diagnosis tool screen, check if any

Is any DTC other than P0810-9C detected?

DTC other than P0810-9C is detected.

Perform troubleshooting for each of related
DTC.

Perform troubleshooting of the clutch ECU.

CHECKLIST: P0810 (TC9C)

HYBRID/TROUBLE SHOOTING3–84

P0810 (TC9C)

Abnormality in clutch system

(idling stop inhibited)

Step Action Description Judgement

Reading the

1

DTC [HINO­DX]

1. Set the starter key to the
"LOCK" position.

2. Connect the diagnosis tool
(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. In [Fault Information] on the
diagnosis tool screen, check if
any DTC other than P0810-9C
is detected.

DTC other
than P0810­9C is detected:
Go to YES.

DTC other
than P0810­9C is not
detected: Go
to NO.

Check

(Yes/No)

Inspection Procedure

Yes No

Perform trou­bleshooting for
each of related
DTC.

Perform trou­bleshooting of
the clutch
ECU.

HYBRID/TROUBLE SHOOTING 3–85

ABS ECU

CAN H2

CAN L2

HV PCU

HV ECU

Inverter

7

6

(CA1-)

(CA1+)

3

2

(CA2-)

(CA2+)

9

18

7

19

8

20

J/C CAN2

9

18

7

19

8

20

J/C CAN1

AT ECU

Clutch ECU

Combination meter

21

20

20

19

10

21

14

13

48

49

47

46

4

8

3

5

10

6

9

J/C CAN2

J/C CTRL CAN

7

1

2

15

25

15

24

23

13

(CSL4)

X-21

(CA2+)

X-23

(CA1+)

X-24

(CSL2)

(CA1-)

X-22

(CA2-)

21

22

O-3

O-8

O-2

O-13

O-12

O-1

O-7

O-9

J-10

J-20

O-4

O-10

D-22

D-33

To GROUND CIRCUIT

SHTS03ZZZ0300062

DTC: P0810 (TC9D)

DTC: P0810 (TC9D) Abnormality in clutch system (idling stop available)

INFORMATION

EN01H03ZZZ030602003012

1. Technical description

• –

<Description of malfunction>

• Detected an abnormality in the clutch system.

2. DTC set condition

(1) DTC detection condition

3. Reset condition

• CAN communication with the clutch ECU is normal.

(2) Judgement criteria

• When any of the following abnormality is received from the clutch ECU:

• When the notification that there is none of the following abnormality is received from the clutch ECU:

- Notification that the electric oil pump power supply relay for the clutch is stuck to ON

- Notification that the clutch ECU power supply is stuck

- Notification that the clutch ECU starter key signal is stuck

- Notification that the electric oil pump power supply relay for the clutch is stuck to ON

- Notification that the clutch ECU power supply is stuck

- Notification that the clutch ECU starter key signal is stuck

HYBRID/TROUBLE SHOOTING3–86

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF

• HV warning light: ON

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• The idling stop function may become inoperative.

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

7. After-inspection work

• Clear the recorded DTC.

• Check that any DTC will not be detected after test-driving the vehicle.

8. Estimated failure factors

• Malfunctioning of clutch system

HYBRID/TROUBLE SHOOTING 3–87

NOYES

SHTS03ZZZ0300063

INSPECTION PROCEDURE: P0810 (TC9D)

Reading the DTC [HINO-DX]

1

1. Set the starter key to the "LOCK" position.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. In [Fault Information] on the diagnosis tool screen, check if any

Is any DTC other than P0810-9D detected?

DTC other than P0810-9D is detected.

Perform troubleshooting for each of related
DTC.

Perform troubleshooting of the clutch ECU.

CHECKLIST: P0810 (TC9D)

HYBRID/TROUBLE SHOOTING3–88

P0810 (TC9D)

Abnormality in clutch system

(idling stop available)

Step Action Description Judgement

Reading the

1

DTC [HINO­DX]

1. Set the starter key to the
"LOCK" position.

2. Connect the diagnosis tool
(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. In [Fault Information] on the
diagnosis tool screen, check if
any DTC other than P0810-9D
is detected.

DTC other
than P0810­9D is detected:
Go to YES.

DTC other
than P0810­9D is not
detected: Go
to NO.

Check

(Yes/No)

Inspection Procedure

Yes No

Perform trou­bleshooting for
each of related
DTC.

Perform trou­bleshooting of
the clutch
ECU.

HYBRID/TROUBLE SHOOTING 3–89

HV ECU

Coolant temperature sensor

H

H

K

K

79

80

2

1

THW

E2

SHTS03ZZZ0300064

DTC: P0A01 (TC7B)

EN01H03ZZZ030602003013

DTC: P0A01 (TC7B) Abnormality in characteristics of inverter coolant temperature sensor

INFORMATION

1. Technical description

• –

<Description of malfunction>

• Detected an abnormality in the inverter cooling circuit (abnormality in the characteristics of inverter coolant temper-

ature sensor).

2. DTC set condition

(1) DTC detection condition

• The starter key is set to the ON position.

• The control power supply voltage is 10 V or more.

• The drive duty of HV water pump is 40% or more.

• The drive duty of HV water pump is 60% or less.

• The square sum of motor current for 20 seconds is 200,000 A

2

or more.

• The motor current sensor shows no abnormality.

• The output of inverter start relay is ON.

(2) Judgement criteria

• The difference in the inverter coolant temperature (Max-Min) for 20 seconds is less than 0.5 C {32.9 F}.

3. Reset condition

• The difference in the inverter coolant temperature (Max-Min) for 20 seconds is 0.5 C {32.9 F} or more.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON

• HV warning light: ON

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe)>

• –

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work

• Check the battery voltage to make sure that there is no abnormality.

HYBRID/TROUBLE SHOOTING3–90

7. After-inspection work

• Clear the recorded DTC.

• Check that no DTC is detected after test-driving the vehicle.

8. Estimated failure factors

• Disconnection or short circuit of harness

• Malfunction of inverter cooling circuit

• Malfunction of inverter coolant temperature sensor

• Malfunction of HV ECU

HYBRID/TROUBLE SHOOTING 3–91

NOYES

NOYES

INSPECTION PROCEDURE: P0A01 (TC7B)

Inspecting the coolant line route

1

1. Check the coolant line route (radiator, inverter, and hose) for any

Is any defect found?

damage or water leakage.

Repair or replace the defective part.
After repair/replacement, perform the inspec­tion again.

Inspecting the coolant level

2

1. Remove the radiator cap and check the height from the coolant
level to the filling port.

Is the coolant level about 10 mm from the filling port?

Go to step 3. Add coolant. (See "Adding coolant.")

Go to step 2.

After adding coolant, perform the inspection
again.

HYBRID/TROUBLE SHOOTING3–92

NOYES

NOYES

SHTS03ZZZ0300065

SHTS03ZZZ0300066

Reading the DTC [HINO-DX]

3

Is any DTC other than P0A01-7B detected?

1. Set the starter key to the "LOCK" position.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. In [Fault Information] on the diagnosis tool screen, check if any
other coolant temperature sensor system DTC (listed below) is
detected.

• P060B-B2, P0A02-78, P0A03-79, P0A06-7F, P0A07-7E, P0A93-7A,

P0C73-80, P314C-82, P314D-81

Perform troubleshooting for each of related
DTC.

Inspecting the coolant temperature sensor

4

Go to step 4.

1. Set the starter key to the "LOCK" position.

2. Disconnect the connector of coolant temperature sensor.

3. Using the electrical tester, measure the resistance between the
terminals of coolant temperature sensor connector.

Measurement

conditions

Starter key: LOCK

Tester

connections

Coolant tempera­ture sensor con­nector (sensor
side)
1st terminal –
2nd terminal

Standard values

0 C {32 F}:

5.3 k – 6.2 k
20 C {68 F}:

2.3 k – 2.6 k
30 C {86 F}:

1.5 k – 1.8 k

Is the measured value within the range of standard value?

Go to step 5. Replace the coolant temperature sensor.

HYBRID/TROUBLE SHOOTING 3–93

NOYES

Inspecting the signal line of PCU wire harness (lower side) for short circuit

5

1. Set the starter key to the "LOCK" position.

2. For the 2nd terminal of coolant temperature sensor connector,
inspect the signal line of PCU wire harness (lower side) for short
circuit. (See "Inspecting the PCU harness signal line for short cir­cuit.")

Measurement

conditions

Starter key: LOCK

connections

Coolant tempera­ture sensor con­nector
2nd terminal –
Each signal line

Is any defect found?

Replace the PCU wire harness (lower side). Go to step 6.

Tester

Standard values

10 k or more

NOYES

Reproduction check [HINO-DX]

SHTS03ZZZ0300067

6

HYBRID/TROUBLE SHOOTING3–94

1. Connect all the connectors that have been disconnected to restore
the system.

2. Connect the diagnosis tool (HINO-DX) to the vehicle.

3. Set the starter key to the "ON" position.

4. Clear the malfunction history.

5. In [Data Monitor] on the diagnosis tool screen, measure [HV sys­tem coolant temperature].

Measurement

conditions

Starter key: ON

Measured item Standard values

HV system coolant
temperature

Equivalent to
ambient tempera­ture

Is the measured value within the range of standard value?

Replace the HV ECU. The inspection is completed.

(If no repair or parts replacement is per­formed, there may be an improper contact
due to connector disconnection.)

CHECKLIST: P0A01 (TC7B)

HYBRID/TROUBLE SHOOTING 3–95

P0A01 (TC7B)

Abnormality in characteristics of inverter

coolant temperature sensor

Step Action Description Judgement

Defect is
found: Go to
YES.

Defect is not

Inspecting the

1

coolant line
route

1. Check the coolant line route
(radiator, inverter, and hose) for
any damage or water leakage.

found: Go to
NO.

Coolant level
is about 10
mm from the
filling port: Go
to YES.

Coolant level

Inspecting the

2

coolant level

1. Remove the radiator cap and
check the height from the cool­ant level to the filling port.

is not about 10
mm from the
filling port: Go
to NO.

1. Set the starter key to the
"LOCK" position.

2. Connect the diagnosis tool

Reading the

3

DTC [HINO­DX]

(HINO-DX) to the vehicle.

3. Set the starter key to the "ON"
position.

4. In [Fault Information] on the
diagnosis tool screen, check if
any other coolant temperature
sensor system DTC (listed
below) is detected.

• P060B-B2, P0A02-78,

P0A03-79, P0A06-7F,

DTC other
than P0A01­7B is detected:
Go to YES.

DTC other
than P0A01­7B is not
detected: Go
to NO.

P0A07-7E, P0A93-7A,
P0C73-80, P314C-82,
P314D-81

Check

(Yes/No)

Inspection Procedure

Yes No

Repair or
replace the
defective part.
After repair/
replacement,

Go to step 2.

perform the
inspection
again.

Add coolant.
(See "Adding
coolant.")

Go to step 3.

After adding
coolant, per­form the
inspection
again.

Perform trou­bleshooting for
each of related

Go to step 4.

DTC.

HYBRID/TROUBLE SHOOTING3–96

P0A01 (TC7B)

Abnormality in characteristics of inverter

coolant temperature sensor

Step Action Description Judgement

1. Set the starter key to the
"LOCK" position.

Inspecting the
coolant tem-

4

perature sen­sor

2. Disconnect the connector of
coolant temperature sensor.

3. Using the electrical tester, mea­sure the resistance between
the terminals of coolant tem­perature sensor connector.

<Measurement conditions>
Starter key: LOCK
<Tester connections>
Coolant temperature sensor con­nector (sensor side)
1st terminal – 2nd terminal
<Standard values>

The mea­sured value is
within the
range of stan­dard value: Go
to YES.

The mea­sured value is
not within the
range of stan­dard value: Go
to NO.

0 C {32 F}: 5.3 k – 6.2 k
20 C {68 F}: 2.3 k – 2.6 k
30 C {86 F}: 1.5 k – 1.8 k

1. Set the starter key to the
"LOCK" position.

2. For the 2nd terminal of coolant
temperature sensor connector,
inspect the signal line of PCU

Inspecting the
signal line of
PCU wire har-

5

ness (lower
side) for short
circuit

wire harness (lower side) for
short circuit. (See "Inspecting
the PCU harness signal line for
short circuit.")

<Measurement conditions>
Starter key: LOCK
<Tester connections>

Defect is
found: Go to
YES.

Defect is not
found: Go to
NO.

Coolant temperature sensor con­nector
2nd terminal – Each signal line
<Standard values>
10 k or more

Check

(Yes/No)

Inspection Procedure

Yes No

Replace the

Go to step 5.

coolant tem­perature sen­sor.

Replace the
PCU wire har­ness (lower

Go to step 6.

side).