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.
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 SHOOTING3–5
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
MILEffect on vehicle
Diagnosis code that is
being detected (malfunc-
Light OFFLight OFFNormal control
tion is not confirmed).
Diagnosis code in which
the malfunction is con-
Light ONLight ON *1Failsafe control *2
firmed
Stored diagnosis codeLight OFFLight OFFNormal control
HYBRID/TROUBLE SHOOTING3–7
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 nameDeletion from vehicle conditionDeletion 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
NoneInstant 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 SHOOTING3–9
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 #1NORMAL JUDGMENT #2NORMAL 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.
PresentPresentDeletion using the procedure (1) or (2)
PresentNone—
(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 SHOOTING3–11
! 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 SHOOTING3–13
! 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
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 SHOOTING3–21
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 distanceKm
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 conditionRoad surface state
When starting
During acceleration
During steady running
During deceleration
During braking
During stoppage
During parking
During turning
During ABS operation
Others
( )
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 SHOOTING3–25
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☆
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