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.
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
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