Hino Motors HINO 155, HINO 195h, HINO 155h, HINO 195 Workshop Manual

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-LJ05E07A

Trouble shooting Workshop Manual

's Manual.

Manual Name Pub. No.

S1-LXJE05A

S1-LXJE05A EWD

S7-LXJE05A 2/5 S7-LXJE05A 3/5 S7-LXJE05A 4/5 S7-LXJE05A 5/5

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

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

MANUAL No. S7-LXJE05A 1/5 (U.S.A.), S7-LXJE06A 1/5 (CANADA)

CHAPTER

GENERAL INTRODUCTION 1-001

ENGINE 2-001 (J05E)

MODELS HINO 155, 155h, 195, 195h

Production Code XFC710, XFC720, XFC730, XFC740,

XJC700, XJC710, XJC720,XJC730, XJC740

INDEX: TROUBLE SHOOTING GROUP 1/2

GENERAL INTRODUCTION

ENGINE

HYBRID

WORKSHOP MANUAL

TRANSMISSION

CLUTCH

PROPELLER SHAFT

AXLE

DIFFERENTIAL

BRAKE

STEERING

SUSPENSION

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

GENERAL INTRODUCTION 1–1

GENERAL INTRODUCTION

HOW TO IDENTIFY VEHICLE TYPE .............. 1-2

HOW TO IDENTIFY VEHICLE TYPE ...........................1-2

VEHICLE TYPE ......................................................1-2

VEHICLE IDENTIFICATION NUMBER (VIN)

STRUCTURE ..........................................................1-3

APPEARANCE OF VEHICLE ......................... 1-4

APPEARANCE.............................................................1-4

APPEARANCE OF VEHICLE .................................1-4

1-001

SAFETY INSTRUCTIONS AND

READINESS TO WORK .................................. 1-5

WARNING ....................................................................1-5

GENERAL PRECAUTIONS ....................................1-5

IDENTIFICATION INFORMATION ........................1-10

SAFETY INSTRUCTIONS FOR WORK.....................1-13

PRECAUTIONS ....................................................1-13

INTRODUCTION TO WORKSHOP MANUAL............1-17

GENERAL .............................................................1-17

INTRODUCTION TO DESCRIPTIONS................. 1-18

DEFINITION OF TERM.........................................1-21

TROUBLE SHOOTING.................................. 1-22

TROUBLESHOOTING WITH

DIAGNOSIS MONITOR ..............................................1-22

TROUBLESHOOTING PROCEDURE ..................1-22

APPARATUS FOR TROUBLE SHOOTING...........1-24

TROUBLE DIAGNOSIS USING THE COMPUTER

(HINO DX Ⅱ ) .............................................................1-25

STEP OF TROUBLE DIAGNOSIS ........................1-25

APPARATUS FOR TROUBLE DIAGNOSIS.......... 1-26

GLOSSARY ................................................... 1-27

DEFINITION OF ABBREVIATION .............................1-27

LIST OF ABBREVIATION .....................................1-27

GLOSSARY OF SAE AND HINO TERMS ............ 1-30

GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE1–2

ԝԞ

L ࡯

CLASSIFICATION

REPORTED MODEL

J05E-UG (HV)

J05E-TP (Diesel)

㧦ENGINE MODEL

㧦VEHICLE MODEL

HEAVY DUTY TRACK

㧦CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE

CAB WIDTH

DRIVE WHEEL BASE

FRAME ASSEMBLY WIDTH

FRAME

FORM

WIDE 2WD MEDIUMOPEN

WIDE 2WD LONGOPEN

WIDE 2WD SUPER LONGOPEN

840 mm {33 in.}

2,900 mm {114 in.}

3,500 mm {138 in.}

3,800 mm {150 in.}

4,100 mm {161 in.}

ԝ0㧦TYPE OF SUSPENSION

FRONT RIGID, REAR RIGID

CAB FORM BRAKE TYPE

㧦CAB FORM, BRAKE TYPE

㧦STEERING WHEEL POSITION

LEFT HAND DRIVE

SINGLE CAB VACUUM

CREW CAB VACUUM

SINGLE CAB HYDRAULIC

CREW CAB HYDRAULIC

㧦DECK HEIGHT

HIGH FLOOR CAB

㧦TRANSMISSION

6AT

㧦DECK FORM

CHASSIS WITH CAB

㧦ENGINE HORSEPOWER, FUEL

FUEL

HORSEPOWER EXHAUST

VERY HIGH US13 (13OBD)

DIESEL OIL

㧦LOADING CAPACITY, GVW, REAR TIRES

㧦DESTINATION

DESTINATION

U.S., CANADA

6.58 t {14,500 lbs}

8.14 t {17,950 lbs},

8.85 t {19,500 lbs}

WIDE 2WD SUPER LONGOPEN 4,400 mm {173 in.}

REAR DOUBLE

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HOW TO IDENTIFY VEHICLE TYPE

VEHICLE TYPE

EN01H01ZZZ010102001001

GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE 1–3

WMI VDS CD VIS

(1) (2) (3) (4) (5) (6) (7) (8) (9)

(10) (11) (12) (13) (14) (15) (16)

JHH KDL 2H X C K00100

(17)

MANUFACTURER ,TYPE

MODEL, CAB TYPE,

WHEEL BASE,

BRAKE SYSTEM

MODEL YEAR

ENGINE MODEL

ASSEMBLY PLANTSERIES

MAKE

CHECK DIGIT

SEQUENTIAL NUMBER

CODE

JHN INCOMPLETE VEHICLE

TYPEMANUFACTURER

HINO MOTORS, LTD.

2AY

INCOMPLETE VEHICLE

HINO MOTORS

CANADA, LTD.

CODE CODE YEARYEAR

K 2019

L 2020

M 2021

E 2014

F 2015

G 2016

CODE

PM Hybrid

APPLICATIONENGINE MODEL

J05E-UG

DM DieselJ05E-TP

CODE

For USA

For Canada

ASSEMBLY PLANT

CODE

MAKE

SERIES GVWR

HINO

6,580 kg

{14,500 lbs.}

8,140 - 8,850 kg

{17,950 - 19,500 lbs.}

CODE CLASS MODEL

PRODUCTION

CODE

CAB TYPE WHEEL BASE

BRAKE

SYSTEM

CODE

ASSEMBLY PLANT

HINO MOTORS, LTD.

Hamura Plant in Japan

HINO MOTORS, LTD.

Hamura Plant in Japan

Canada Plant (COE)

N 2022

P 2023

H 2017

J 2018

HINO 195h

HINO 195

HINO 155

HINO 195

HINO 155

XFC710

HINO 155h

XFC720

HINO 155h

XFC740

HINO 195h

XFC720

HINO 195h

XFC740

HINO 155h

XFC710

HINO 195h

XFC720

HINO 195h

XFC740

HINO 155h

XFC740

HINO 155h

XFC720

HINO 195 XJC710

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

CREW CAB

COE

CREW CAB

COE

CREW CAB

COE

CREW CAB

3500mm{138 in.}

2900mm{114 in.}

3800mm{150 in.}

4400mm{173 in.}

XJC700

XJC710

XJC720

XJC740

XJC720

XJC740

XJC720

XJC740

HYDRAULIC

HINO 195h

XFC730

HINO 195 XJC730

COE

SINGLE CAB

4100mm{161 in.} HYDRAULIC

HYDRAULIC

VACUUM

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VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE

EN01H01ZZZ010102001002

GENERAL INTRODUCTION/APPEARANCE OF VEHICLE1–4

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APPEARANCE OF VEHICLE

APPEARANCE

APPEARANCE OF VEHICLE

EN01H01ZZZ020101003001

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–5

SAFETY INSTRUCTIONS AND READINESS TO WORK

WARNING

GENERAL PRECAUTIONS

EN01H01ZZZ030101001001

Some recommended and standard maintenance services for your vehicle are included in this section. When performing maintenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a malfunction of the vehicle which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your Hino dealer.

WARNING

When working on your vehicle, observe the following general precautions to prevent death, personal injury and/ or property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chapter.

• Always wear safety glasses or goggles to protect your eyes.

• Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.

• Bind long hair securely behind the head.

• When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and

block the wheels.

• Always turn off the starter switch to stop the engine, unless the operation requires the engine running.

Removing the key from the switch is recommended.

• To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radia-

tor, muffler, exhaust pipe and tail pipe.

• Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.

• Take utmost care when working on the battery. It contains corrosive sulfuric acid.

• Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which

can result in personal injury and/or property damage.

• Read carefully and observe the instructions specified on the jack before using it.

• Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a

vehicle supported only by a jack.

• If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly

applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.

• Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.

• Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when

the engine is running.

• Be careful not to damage lines and hoses by stepping or holding your feet on them.

• Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can

cause personal injury.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–6

! WARNING

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PRECAUTIONS IN TILTING AND LOWERING THE CAB

Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may result in death, serious injury and/or property damage.

• Park the vehicle on a level place and ensure ample space around the cab before tilting the cab.

• Apply the parking brake firmly and place the gearshift lever in “N” position (“P” position if your vehicle is

equipped with automatic transmission).

• Stop the engine and block the wheels.

• Remove any articles in or over the cab and close the doors firmly.

• Make sure there is no one in or around the cab and there are no obstacles in front of the vehicle or above the

cab.

• The catch (E), stopper (F), stay (G) and other parts such as the engine, radiator, and exhaust pipe can be very

hot while your vehicle is operated. Be sure to confirm they have been cooled down before you start working under the cab.

• Never raise or lower the cab only by yourself if your cab is equipped with heavy component such as a roof rack.

• Never put your body under the cab while raising or lowering the cab.

• Make sure the cab stopper stay is securely locked by the catch (E) and raise the stopper (F) to lock the catch (E)

completely after raising the cab.

• Before lowering the cab, make sure that any object such as hand tools, gloves or cloth are not left under the

cab.

• Make sure the handle (B) is caught by the catch after lowering the cab.

Read the Owner’s manual for details.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–7

DEFINITION OF SAFETY TERMS

Indicates an extremely hazardous situation if proper procedures are not followed and could result in death or serious injury.

Indicates a potential hazardous situation if proper procedures are not followed and could result in death or serious injury.

Indicates a hazardous situation if proper procedures are not followed and could result in serious injury or damage to parts/equipment.

Indicates the need to follow proper procedures and to pay attention to precautions so that efficient service is provided.

Provides additional information to help you to perform the repair efficiently.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–8

TOWING

• When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to

protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with the bumper.

1. Towing procedures

(1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle

shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and entry of dirt or foreign matter.

(2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the

frame.

(3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and ver-

tical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in

towing a vehicle trapped in a gutter. (4) Keep the gear shift lever in Neutral. (5) Make sure that the starter switch is kept in the "ON" position, if the engine is not running. (6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vac-

uum will be available for the brake. This is dangerous, as the brake system does not function if the engine is not

running.

In addition, the power steering system will not function. The steering wheel, therefore, will become unusually

hard to turn, making it impossible to control the vehicle. (7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed. (8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.

2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed for that purpose.

(1) Front end towing (with front wheels raised off the ground)

When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of axle lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed for vehicles equipped with either manual or automatic transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with lubricant if necessary.

(2) Rear end towing

When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straightahead position.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–9

CLEAN AIR ACT

1. Heavy-duty engine rebuilding practices.

§ 86.004-40

• The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards

and are applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reassembly, and also may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine. Any deviation from the provisions contained in this section is a prohibited act under section 203(a) (3) of the Clean Air Act (42 U.S.C. 7522(a) (3)).

(1) When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical

basis for knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configuration (i.e., tolerances, calibrations, specifications) and the model year(s) of the resulting engine configuration must be identified. A reasonable basis would exist if:

a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and

function of motor vehicle engines would reasonably believe that the parts perform the same function with respect to emissions control as the original parts; and

b. Any parameter adjustment or design element change is made only:

• In accordance with the original engine manufacturer's instructions; or

• Where data or other reasonable technical basis exists that such parameter adjustment or design element

change, when performed on the engine or similar engines, is not expected to adversely affect in-use emissions.

(2) When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a

configuration of the same or later model year as the original engine. When an engine is being replaced, the replacement engine must be an engine of (or rebuilt to) a configuration of the same or later model year as the original engine.

(3) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or

reset without diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are installed to satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface. Diagnostic systems must be free of all such codes when the rebuilt engine is returned to service. Such signals may not be rendered inoperative during the rebuilding process.

(4) When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt

engine, all critical emissions-related components listed in § 86.004-25(2) not otherwise addressed by paragraphs (1) through (3) of this section must be checked and cleaned, adjusted, repaired, or replaced as necessary, following manufacturer recommended practices.

(5) Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The

records shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the engine and emissions-related control components including a listing of parts and components used, engine parameter adjustments, emissions-related codes or signals responded to and reset, and work performed under paragraph (4) of this section.

a. Parties may keep records in whatever format or system they choose as long as the records are understand-

able to an EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an understandable format when requested.

b. Parties are not required to keep records of information that is not reasonably available through normal busi-

ness practices including information on activities not conducted by themselves or information that they cannot reasonably access.

c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual

engine rebuilt in cases where those rebuild practices are followed routinely.

d. Records must be kept for a minimum of two years after the engine is rebuilt.

2. Maintenance instructions.

§ 86.010-38

(1) For each new diesel-fueled engine subject to the standards prescribed in § 86.007-11, as applicable, the manu-

facturer shall furnish or cause to be furnished to the ultimate purchaser a statement that

"This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for highway diesel fuel, including a 15 ppm sulfur cap)."

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–10

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IDENTIFICATION INFORMATION

EN01H01ZZZ030101001002

1. VEHICLE IDENTIFICATION NUMBER

(1) The vehicle identification number (VIN) is stamped on the

right frame, as shown in the illustration. This number has also been stamped on the manufacture's plate.

A: Vehicle Identification Number (VIN) B: Manufacturer's Plate

(2) VIN

See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page.

(3) PRODUCTION CODE AND VEHICLE COMPONENTS

MODEL (CLASS) HINO 155h (4) HINO 155 (4) HINO 195h (5) HINO 195 (5)

XJC700 XJC710 XJC720 XJC740

PRODUCTION CODE

XFC710 XFC720 XFC740

TRANSMISSION SERIES A465

1st 3.742

2nd 2.003

3rd 1.343

TRANSMISSION RATIO

4th 1.000

5th 0.773

6th 0.634

REAR AXLE SERIES SH13

SERVICE BRAKE Vacuum Hydraulic

PARKING BRAKE ACTING ON DIFFERENTIAL OUTPUT SHAFT

SUSPENSION LEAF

XFC710 XFC720 XFC730 XFC740

XJC700 XJC710 XJC720 XJC730 XJC740

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–11

FOR ALL MODELS

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SHTS01ZZZ0300010

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2. VEHICLE NOISE EMISSION CONTROL INFORMATION

• The Vehicle Noise Emission Control Information is affixed to the

left pillar of the cab. The name of manufacturer, production year and month, and noise emission applicable to medium and heavy trucks in conformity with U.S. EPA Regulations are displayed.

3. ENGINE SERIAL NUMBER

(1) The engine serial number is stamped on the cylinder block,

as shown in the illustration.

A: J05E

4. TRANSMISSION SERIAL NUMBER

(1) The transmission serial number is stamped on the transmis-

sion, as shown in the illustration.

A: A465

5. CLEAN IDLE CERTIFIED LABEL FOR U.S.

• Make sure that the following clean engine idling certified label is

affixed to the outside of the left door. By the CARB below, the label must be affixed there to prove that the new vehicle with diesel engine manufactured from Jan., 2008 conforms to this low.

CARB § 1956.8. Exhaust Emission Standard and Test Procedure (a) (b) Heavy-Duty Diesel Engine Idling Requirements

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–12

Vehicle emission control information

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6. VEHICLE EMISSION CONTROL INFORMATION

• The Vehicle Emission Control Information is affixed to the side

of the right door. The name of manufacturer, production year and month, and emission applicable to medium and heavy trucks in conformity with U.S. EPA Regulations are displayed.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–13

! WARNING

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SAFETY INSTRUCTIONS FOR WORK

PRECAUTIONS

EN01H01ZZZ030101004001

1. SAFETY INSTRUCTIONS FOR HANDLING ELECTRICAL SYSTEMS

(1) Removing the battery cable

• Be sure to wait for at least ten minutes after the starter key is turned to "LOCK" position before you disconnect

the battery terminals from the battery, as the vehicle data is recorded on ECU and DCU starts working for the exhaust gas after treatment after the starter key is turned to "LOCK" position. Otherwise, the vehicle data will not be recorded on ECU properly and DCU will not complete working properly, which may result in the malfunction of DPR system and DEF-SCR system.

• The MIL (malfunction indicator light) may come on when the starter key is turned to "ON" position again, even if

you wait for at least ten minutes before disconnecting the battery terminals from the battery after the starter key is turned to "LOCK" position. In this case, use HINO DXⅡ to clear the DTC (P204F and P068A), to turn off the MIL and to conduct DPR regeneration manually.

a. Before electrical system work, remove the cable from the minus terminal of the battery in order to avoid burn-

ing caused by short-circuiting.

b. To remove the battery cable, fully release the nut to avoid damage to the battery terminal. Never twist the ter-

minal.

Loosen

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–14

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(2) Handling of electronic parts

a. Never give an impact to electronic parts of a computer or relay. b. Keep electronic parts away from high temperatures and humidity. c. Never splash water onto electronic parts in washing the vehicle. d. Do not remove the harness connector, electric component box, and cover except for repair and inspection.

If removal is necessary, pay attention that water and foreign matters do not attach or enter to the connector, terminals, electric component box, and cover. In restoration, make sure there is no attachment or entry of water and foreign matters and mount them properly, because it causes degradation of waterproof function.

Incorrect

(3) Handling of wire harness

a. Perform marking on a clamp and a clip and secure then in original position so that the wire harness will not

interfere with the end and acute angle section of the body and a bolt.

b. To attach a part, take care not to bite the wire harness.

Incorrect

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–15

! WARNING

Incorrect

Correct

SHTS01ZZZ0300017

(4) Handling of connectors

a. When removing a connector, hold a connector (area shown in an arrow in the figure) and then pull it off. Do not

pull wire harnesses. b. Pull off a lockable connector after unlocking. c. When connecting a lockable connector, make sure to insert a lockable connector until it makes a click sound. d. When inserting a test lead, insert it from the back of a connector. e. If it is difficult to insert a test lead from the back of a connector, make and use an inspection harness.

(5) Installation of battery disconnect switch

• Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF-SCR

(DCU) may damage or result in the malfunction of DEF-SCR system.

• Be sure to read and follow the procedures and instructions on the service bulletin before the installation of the

battery disconnect switch.

(6) Handling of battery disconnect switch

• Wait for at least ten minute before using the battery disconnect switch after the starter key is turned to "LOCK"

position. Otherwise, the vehicle data will not be recorded on ECU properly, which may result in the malfunction of DPR system.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–16

Connect the ground of the ARC welding machine near the place on the frame to be welded but not connect it to plated parts such as fuel pipes, brake pipes and leaf spring.

Disconnect the ground terminal for battery at the connecting point on the frame and disconnect the ground for computer as well.

Chassis frame

Battery

Alternator etc

Computer

ARC welding

machine

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2. PRECAUTION FOR ELECTRIC WELDING Electrical components such as the alternator and tachograph are directly connected to the battery and one end is earthed to the chassis frame. Under these conditions, welding current will flow back along the earth circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, electrical components, etc. Consequently, the following precautions are always to be taken during welding.

(1) Disconnect the earth terminal of the battery at the frame fitment and earth the welding equipment securely to the

frame itself. (Do not fit the welding equipment earth to such things as the tire rims, brake pipes or fuel pipes and

leaf spring, etc.) a. Turn the starter switch off. b. Disconnect the battery’s negative terminal of the battery. c. Earth welding equipment securely, near to the area to be welded. d. Put back battery negative ground as original condition. e. Finally check the functioning of all instruments.

(2) In order to prevent damage to ancillary equipment components from sparks during welding, take steps such as

putting fire-resistant covers over things like the engine, meters, steering wheel, hoses, leaf spring and tires.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–17

GENERAL INFORMATION

INTRODUCTION TO WORKSHOP MANUAL

GENERAL

EN01H01ZZZ030102002001

1. SCOPE OF REPAIR DESCRIPTIONS

(1) There are three major processes in repair work: i.e. "trouble shooting", "removal/installation, replacement, over-

haul, assembly, inspection and adjustment" and "final inspection".

(2) This document covers only the first process (trouble shooting) and the second process (removal/installation,

replacement, overhaul, assembly, inspection and adjustment) and omits the third process (final inspection).

(3) The element tasks listed below are omitted from this document but must be done in actual repair work.

a. Jacking and lifting b. Cleaning and washing of removed parts as required c. Visual check

2. STANDARD VALUE

(1) Standard values, limits, required actions and tightening torques are tabulated in this document.

3. REQUIRED ITEMS

(1) Special tools, tools, instruments, oil and grease and other items to be prepared before starting work are listed in

the section titled "REQUIRED ITEMS". Note that general tools, jacks, rigid racks and other required items supposedly available at a general service shop are omitted from the list.

4. REPRESENTATION OF SECTION AND TITLE

(1) Under a title containing a system name such as "ENGINE CONTROL SYSTEM", the descriptions cover

"INSPECTION", "ADJUSTMENT", "REPLACEMENT" and "OVERHAUL" of components.

(2) Under a title containing a part name such as "AIR COMPRESSOR ASSEMBLY", the descriptions cover

"REPLACEMENT" and "OVERHAUL".

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–18

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A possible cause and remedy/prevention are indicated for every item, respectively.

INTRODUCTION TO DESCRIPTIONS

1. TROUBLE SHOOTING FOR EACH TROUBLE SYMPTOM WITH REFERENCE TO THE CHART

EN01H01ZZZ030102002002

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–19

2. INTRODUCTION TO TROUBLE SHOOTING

(1) This document covers the trouble shooting steps 2 and 3 listed below.

(1) Hearing "Step 1"

(2) Prior check (3) Reproducing technique

(4) Trouble shooting for each diagnosis code (5) Trouble shooting for each trouble symptom

(6) Verification test "Step 4"

(2) Prior check

"Step 2"

"Step 3"

• Take the following prior check steps.

Diagnosis inspectiondiagnosis deletiontrouble symptom verification (use a reproducing technique if not reproducible.)diagnosis recheck

• Prior to a reproduction test, identify a system suspected to have a trouble, attach a tester and

other apparatuses and then conduct both a symptom check and an examination on a sus-

Prior check

pected trouble. For a suspected cause of a trouble symptom, the trouble shooting chart.

• Instantaneous occurrence of a trouble symptom will also trigger a failure code. If no troubles

are observed, use a reproducing technique in performing each trouble shooting activity.

• Trouble symptom verification

If not reproducible, take the steps 2, 3 and 4. If not reproducible, use a reproducing technique (e.g. adjust external conditions and inspect each wire harness and connector part).

Identify a fact through adequate hearings on the situation and environment where a trouble has occurred.

Conduct a diagnosis inspection, a symptom check, a functional inspection and a basic inspection to identify a symptom. If a symptom check does not gain enough reproducibility, use a reproducing technique.

Sort the inspection results obtained from the step 2 and conduct an systematized inspection in accordance with the procedures for trouble shooting for each trouble symptom.

Verify that the same trouble will not occur after trouble shooting. If a trouble is not reproducible enough, conduct a verification test under the reproduced conditions and environment.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK1–20

ENGINE (COMMON ITEMS)/TROUBLESHOOTING2–466

INSPECTION PROCEDURE: P0606

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

2. Connect the diagnostic tester (HINO DX ൖ ) to the vehicle.

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

4. On the diagnostic tester screen, select [VCS] and check that no vehicle speed signal-related DTC, P0501 or P0503, is detected.

NOYES

1. Inspect the CAN communication line.

NOYES

Reading DTC [HINO DX ൖ ]

SHTS029990300431

Is DTC P0501 or P0503 detected?

Perform troubleshooting for related DTC. Go to step 2.

Inspecting the CAN communication line

Is any defect found?

Repair or replace the CAN communication line.

Replace the vehicle control ECU.

SHTS01ZZZ0300020

3. INTRODUCTION TO TROUBLE SHOOTING FOR EACH DIAGNOSIS MONITOR CODE

(1) The "diagnosis code list" and the "trouble shooting for each code" are contained in this document to address

each system for which a diagnosis monitor code will be output. If a diagnosis monitor code is already identified, it is possible to immediately proceed with a trouble shooting process based on the code list.

GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–21

DEFINITION OF TERM

Terms used in this document are defined as follows.

DIRECTION

1. CHASSIS RELATED

(1) Longitudinal direction

a. The forward direction and the reverse direction of a vehicle are respectively defined as front and rear in the

installed position in a vehicle.

(2) Rotational direction

a. The clockwise direction and the counterclockwise direction viewed from the rear side of a vehicle are defined

as right-handed and left-handed respectively.

(3) Vertical direction

a. The upward direction and the downward direction in the installed position in a vehicle are defined as an upper

side and a lower side respectively.

(4) Lateral direction

a. The leftward direction and the rightward direction viewed from the back of a vehicle are respectively defined as

a left side and a right side in the installed position in a vehicle.

2. INDIVIDUAL DEVICES

(1) Longitudinal direction

a. The input side and the output side of motive power are defined as a front side and a rear side respectively.

(2) Rotational direction

a. The clockwise direction and the counterclockwise direction viewed from the back side are defined as right-

handed and left-handed respectively.

(3) Vertical direction

a. The upward direction and the downward direction of a device in its installed position in a vehicle (chassis) are

defined as an upper side and a lower side respectively.

(4) Lateral direction

a. The leftward direction and the rightward direction as viewed from the back side are defined as a left side and a

right side respectively.

EN01H01ZZZ030102002003

STANDARD VALUE

Represents a basic dimension (excluding a tolerance), and a clearance arising from tolerances when two parts are assembled.

REPAIR LIMIT

Represents a numerical value indicating need of correction. A symbol "+" or "-" indicated next to a repair limit represents an increase or a decrease from a standard value.

SERVICE LIMIT

Represents a numerical value indicating need of replacement. A symbol "+" or "-" indicated next to a repair limit represents an increase or a decrease from a standard value.

GENERAL INTRODUCTION/TROUBLE SHOOTING1–22

!CAUTION

SHTS01ZZZ0400001

TROUBLE SHOOTING

TROUBLESHOOTING WITH DIAGNOSIS MONITOR

DLC3

TC TS

TROUBLESHOOTING PROCEDURE

EN01H01ZZZ040301002001

NOTICE

• Before reading the diagnosis code, turn the starter key to "ON"

and check that the check engine warning light comes on.

• Inspection is not available in check mode.

1. CONNECTION OF DIAGNOSIS CHECK WIRE

(1) Turn the starter key to the "LOCK" position. (2) Use a SST to short circuit DLC3 12(TS) or 13(TC)  4(CG)

terminals.

SST: 09843-18040

Diagnosis check wire

HINT The terminals to be shorted vary depending on the device to be diagnosed.

• Never fail to connect connectors to correct locations. Other

wise failure may occur.

• Use the dedicated diagnosis check wire.

GENERAL INTRODUCTION/TROUBLE SHOOTING 1–23

The operation is repeated

Light ON

Light OFF

Indication of diagnosis monitor code (example)

When codes 32 and 21 are indicated:

0.5 second 0.5 second

1.5 second

4.3 second

Code 21

Code 32

When the system is normal

0.3 second

Light ON

Light OFF

SHTS01ZZZ0400002

2. INDICATION OF DIAGNOSIS MONITOR CODE

(1) A diagnosis monitor code can be identified by viewing the

diagnosis monitor and the check engine light. The example shown below represents how to identify diagnosis monitor codes 32 and 21. Intervals between light flashings will identify a diagnosis monitor code. For the first code, the number "3" in the ten's place of the first code will be represented by three 0.5-second flashings, followed by an interval of 1.5 seconds. Then, the light will flash twice. For the next code, after an interval of 4.3 seconds, two flashings will be followed by one flashing in the similar fashion to the first code. This flashing pattern will be repeated. If no system malfunctions are detected, the light will repeat a 0.3-second flashing pattern.

NOTICE As individual systems have different diagnosis monitor code outputting patterns, follow the descriptions provided for each system.

HINT

• This figure indicates a typical indication of diagnosis monitor

codes. For details, refer to the descriptions provided for individual systems.

• If no malfunctions are detected, the "diagnosis monitor code 1"

will be indicated.

• Malfunction codes will be repeatedly output in the ascending

order regardless of present or past malfunction codes.

HINT

• If no code is indicated (light not flashing), it is suspected that

the TC or TS terminal line is broken or the computer is faulty.

• If the check engine warning light is always on, it is suspected

that the wire harness is shorted (for example, jammed) or the computer is faulty.

• If any meaningless code is out, the computer is suspected of

being faulty.

GENERAL INTRODUCTION/TROUBLE SHOOTING1–24

Dedicated harness (S0963-02300)

SHTS01ZZZ0400003

•

If the check engine warning light is lit and no code is output at 1,000 r/min or more, once turn the starter key to "LOCK" and then recheck.

(2) Release DLC3 12(TS) or 13(TS)  14(CG) terminals.

APPARATUS FOR TROUBLE SHOOTING

1. TAG CODE AND SYSTEM NAME LIST FOR DEDICATED HARNESS

No. Tag name Name of system to be diagnosed

1 STD: ENG Common rail

3 STD: AIR BAG Not used

5 STD: ABS/ASR ABS

7 STD: ES START Not used

10 STD: VSC Not used

11 STD: TIRE Not used

2 OPT: RTD/4WD Not used

4 OPT: SHAKAN Not used

6 OPT: AIR SUS Not used

8 OPT: IDL STOP Not used

9 OPT: ATM Not used

EN01H01ZZZ040301002002

12 OPT: PRO SHIFT Not used

GENERAL INTRODUCTION/TROUBLE SHOOTING 1–25

SHTS01ZZZ0400004

Trouble diagnosis connector

SHTS01ZZZ0400005

TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DX Ⅱ )

STEP OF TROUBLE DIAGNOSIS

EN01H01ZZZ040301003001

1. PREPARATION FOR CONNECTING HINO DX Ⅱ

(1) The "HINO DX Ⅱ " is a failure diagnosis tool for the common

rail fuel injection system and the chassis system. For connecting the computer to a vehicle, the "DST-i" and the dedicated cable will be required.

SPECIAL TOOL: Computer interface

Part name Part No.

DENSO DST-i Set (Without LCD)

DENSO DST-i Set (With LCD)

HINT Install the "Hino Diagnostic eXplorer Ⅱ " (HINO DX Ⅱ ) software in a computer. For detailed installation procedures, refer to the HINO DX Ⅱ OPERATION MANUAL supplied on the Global Service Portal Site (Hino-GSPS).

Without Bluetooth 95171-01021

With Bluetooth 95171-01041

Without Bluetooth 95171-01031

With Bluetooth 95171-01051

2. CONNECTION OF HINO DX Ⅱ

(1) Connect the DST-i to the trouble diagnosis connector located

in the electrical component box in the instrument panel or located in the electrical component box behind the rearmost seat.

(2) Connect the computer in which the HINO DX Ⅱ is installed, to

the DST-i. (3) Turn the starter key to "ON". (4) Turn on the power switch of the computer to start the HINO

DX Ⅱ .

GENERAL INTRODUCTION/TROUBLE SHOOTING1–26

APPARATUS FOR TROUBLE DIAGNOSIS

1. APPARATUS FOR TROUBLE DIAGNOSIS

Part name Part No. Illustration of appearance Outline/function

Laptop computer*

DENSO DST-i Set (without LCD)

—

Without Bluetooth

95171-01021

With Bluetooth

95171-01041

The following specifications are necessary for operation of HINO DX Ⅱ .

• Operating system (OS): Windows7

Professional 32 bit.

• Browser: Microsoft Internet Explorer

8.0, 9.0

• CPU: 32 bit processors more than

1GHz.

• Memory: More than 1Gbyte.

• HDD: More than 100Gbyte.

Computer interface These parts are supplied by DENSO Distributor.

EN01H01ZZZ040301003002

DENSO DST-i Set (with LCD)

Signal check harness

Without Bluetooth

95171-01031

With Bluetooth

95171-01051

09843-E4050

(For engine ECU)

09843-E9030

(For DCU)

Red

Blue

Inserting this harness between the ECU and the harness of the vehicle, you can diagnose the ECU using tester rods with-

Engine

ECU

Black

White

out cutting off the power.

—

): Complete function of HINO DX Ⅱ is confirmed on "Panasonic CF-D1".

GENERAL INTRODUCTION/GLOSSARY 1–27

GLOSSARY

DEFINITION OF ABBREVIATION

LIST OF ABBREVIATION

Abbreviations Meaning, or Official Name

A/C Air Conditioner

ABS Anti-lock Brake System

ACC Accessory

ACU Auto Clutch Unit

AMT Automated Manual Transmission

ATC After Turbo Catalyst

ATF Automatic Transmission Fluid

CA Crank Angle

CAN Controller Area Network

CD-ROM Compact Disc Read Only Memory

CPU Central Processing Unit

dB Decibel

DC Direct Current

EN01H01ZZZ060102001001

D-CAT Diesel-Clean Advanced Technology System

DC motor Direct Current Motor

DCU Dosing Control Unit

DEF Diesel Exhaust Fluid

DPR Diesel Particulate active Reduction system

DSS Driving Support System

ECU Electronic Control Unit

EEPROM Electronically Erasable and Programmable Read Only Memory

EGR Exhaust Gas Recirculation

ELR Emergency Locking Retractor

ENG Engine

EOP Electric Oil Pump

ES START Easy and Smooth start system

F/A Front Axle

FCCB Fuel Control Cylinder Balance

FCV Fuel Cutoff Valve

GENERAL INTRODUCTION/GLOSSARY1–28

Abbreviations Meaning, or Official Name

FF shift Feather touch & Finger shift

FL Fusible link

Fr Front

FRP Fiber Reinforced Plastic

FUP Front Underrun Protector

GCU Glow Control Unit

GND Ground

GVW Gross Vehicle Weight

Hi High

HINO DX Hino Diagnostic eXplorer

HV Hybrid Vehicle

HVAC Heating, Ventilating and Air-Conditioning unit

I.S.C. Idle Speed Control

IC Integrated Circuits

ID Identification

IPD Intelligent Power Device

IS Idling Stop

ISO International Organization for Standardization

JIS Japanese Industrial Standards

LED Light Emitting Diode

LEV Low Emission Vehicle

LH Left Hand

LLC Long Life Coolant

Lo Low

MAX Maximum

MIN Minimum

MS evaporator Multi-tank and Super slim structure evaporator

MT Manual Transmission

No. Number

NOx Nitrogen Oxide

NMR No load Maximum Revolution

OHC Over Head Camshaft

PC Personal Computer

PCD Pitch Circle Diameter

PCS Pre-Crash Safety

GENERAL INTRODUCTION/GLOSSARY 1–29

Abbreviations Meaning, or Official Name

PCV Pump Control Valve

PCV valve Positive Crankcase Ventilation valve

PM Particulate Matter

PPG Glass-fiber-reinforced Polypropylene

ppm Parts Per Million

PS Power Steering

PTO Power Take-Off

PVD Physical Vapor Deposit

PWR Power

QR code Quick Response Code

R/A Rear Axle

RH Right Hand

SCR Selective Catalytic Reduction

SCV Suction Control Valve

SST Special Service Tool

SW Switch

SVS Service Vehicle Soon

T/M Transmission

VCS Vehicle Control System

VNT Variable Nozzle Turbo

VSS Vehicle Speed control System

GENERAL INTRODUCTION/GLOSSARY1–30

GLOSSARY OF SAE AND HINO TERMS

EN01H01ZZZ060102001002

This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as well as their HINO equivalents.

SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS

A/T AUTOMATIC TRANSMISSION Automatic transmission

AAT AMBIENT AIR TEMPERATURE Ambient Air Temperature

ACL AIR CLEANER Air cleaner

ACL Element ACL (Air Cleaner) Element Air Cleaner element

ACL Element AIR CLEANER Element Air Cleaner element

ACL Housing AIR CLEANER Housing Air cleaner body assembly

ACL Housing Cover AIR CLEANER Housing Cover Air Cleaner Housing Cover

AFTDEF

AFTDEFDU

AFTDOC

AFTER TREATMENT DIESEL EXHAUST FLUID

AFTER TREATMENT DIESEL EXHAUST FLUID DOSING UNIT

AFTER TREATMENT DIESEL OXIDATION CATALYST

DEF

DCU

DOC (Diesel Oxidation Catalyst)

AFTDOS AFTER TREATMENT DOSER AFTDOS Dosing

AFTDPF

AFTDPFDP

AFTEGT

AP ACCELERATOR PEDAL Accelerator pedal

AP Sensor ACCELERATOR PEDAL Sensor Accelerator Pedal Position Sensor

APP ACCELERATOR PEDAL POSITION Accelerator Pedal Position

CAC CHARGE AIR COOLER Intercooler

CPP Switch CLUTCH PEDAL POSITION Switch Clutch Switch

DCC DIAGNOSTIC CONNECTOR, Cab Diagnosis connector

DCU DIAGNOSTIC CONNECTOR, Under-hood Diagnosis connector

DRIVER DRIVER Driver

DTC DIAGNOSTIC TROUBLE CODE Diagnosis Trouble Code

DTM Switch DIAGNOSTIC TEST MODE Switch Diagnosis switch

AFTER TREATMENT DIESEL PARTICULATE FILTER

AFTER TREATMENT DIESEL PARTICULATE FILTER DIFFERENTIAL PRESSURE

AFTER TREATMENT EXHAUST GAS TEMPERATURE

DPR filter

DPR differential pressure

Exhaust gas temperature

EBP EXHAUST BACK PRESSURE Back pressure

EBP EXHAUST BACK PRESSURE Exhaust back pressure

EBP Sensor EXHAUST BACK PRESSURE Sensor Back Pressure Sensor

EBPR Valve

EXHAUST BACK PRESSURE REGULATOR Valve

Exhaust control valve

GENERAL INTRODUCTION/GLOSSARY 1–31

SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS

EC ENGINE CONTROL Engine control

ECT ENGINE COOLANT TEMPERATURE Coolant Temperature

ECT ENGINE COOLANT TEMPERATURE Water Temperature

EFT ENGINE FUEL TEMPERATURE Fuel temperature

EFT Sensor ENGINE FUEL TEMPERATURE Sensor Fuel temperature sensor

EGR EXHAUST GAS RECIRCULATION EGR

EGR Valve EXHAUST GAS RECIRCULATION Valve EGR valve

EGRT

EGRT Sensor

EGT EXHAUST GAS TEMPERATURE Exhaust gas temperature

EI ELECTRONIC IGNITION Ignition coil

EOP ENGINE OIL PRESSURE Oil Pressure

EOT ENGINE OIL TEMPERATURE Oil Temperature

FP FUEL PUMP Fuel pump

FUEL PRESSURE Sensor

GLOW PLUG GLOW PLUG Glow plug

GND GROUND GROUND

IA INTAKE AIR Air Intake

IA System INTAKE AIR System Air Intake System

IAT INTAKE AIR TEMPERATURE Intake temperature

IAT Sensor INTAKE AIR TEMPERATURE Sensor Intake temperature sensor

EXHAUST GAS RECIRCULATION TEMPERATURE

EXHAUST GAS RECIRCULATION TEMPERATURE Sensor

FUEL PRESSURE Sensor Fuel Pressure sensor

EGR temperature

EGR exit temperature sensor

IDLE IDLE Idle

IMAT INTAKE MANIFOLD AIR TEMPERATURE Intake manifold Air temperature sensor

IMAT INTAKE MANIFOLD TEMPERATURE Intake manifold temperature sensor

INJ INJECTOR Injector

MAF Sensor MASS AIR FLOW Sensor Air flow sensor

MIL MALFUNCTION INDICATOR LAMP Check engine

OSS Sensor OUTPUT SHAFT SPEED Sensor Output Speed Sensor

OSS Sensor OUTPUT SHAFT SPEED Sensor Speed Sensor

PC Solenoid Valve PRESSURE CONTROL Solenoid Valve Solenoid control valves

PCV POS CRANKCASE VENTILATION PCV (Positive Crankcase Vent)

PCV Valve POS CRANKCASE VENTILATION Valve PCV (Positive Crankcase Vent) Valve

PCV Valve POS CRANKCASE VENTILATION Valve PCV Valve

GENERAL INTRODUCTION/GLOSSARY1–32

SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS

PCV Valve POSITIVE CRANKCASE VENT Valve PCV Valve

PNP PARK/NEUTRAL POSITION Neutral position

PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch

RFP RAIL FUEL PRESSURE Common rail Pressure

RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor

SPARK PLUG SPARK PLUG Spark plug

SRI SERVICE REMINDER INDICATOR Check engine

ST SCAN TOOL Diagnostic tool

TC TURBOCHARGER Turbocharger

TCC TORQUE CONVERTER CLUTCH Torque Converter

TP Sensor THROTTLE POSITION Sensor Throttle Sensor

TSS Sensor TURBINE SHAFT SPEED Sensor Turbine Speed Sensor

VAF Sensor VOLUME AIR FLOW Sensor Air flow sensor

VLS VEHICLE LIMITING SPEED Speed Limiter Upper Limit

VSS VEHICLE SPEED SENSOR Vehicle Speed sensor

ENGINE (J05E) 2–1

ENGINE (J05E)

2-001

TROUBLESHOOTING..................................... 2-4

ENGINE ECU (J05E)....................................................2-4

PRECAUTIONS FOR DIAGNOSIS.........................2-4

ELECTRICAL ..........................................................2-6

PRECAUTIONS ......................................................2-7

COMPUTER (ECU) PIN ASSIGNMENT...............2-11

ENGINE ECU CONNECTOR................................2-15

INSPECTION ........................................................2-19

TROUBLE DIAGNOSIS USING THE COMPUTER

(HINO DX Ⅱ ) .......................................................2-20

DIAGNOSTIC TROUBLE CODE (DTC) TABLE....2-21

GROUP SHARING THE SENSOR SUPPLY

TERMINAL ............................................................2-43

GROUP SHARING THE SENSOR GND

TERMINAL ............................................................2-44

MALFUNCTION CODES IN CASE OF DISRUPTION

OF CAN COMMUNICATION.................................2-45

PRE-INSPECTION FOR ENGINE CAN

COMMUNICATION LINE (250 k) ..........................2-48

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k)

[DIESEL] ...............................................................2-53

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k)

[HYBRID]...............................................................2-62

PRE-INSPECTION FOR ENGINE CAN

COMMUNICATION LINE (500 k) [DIESEL] .......... 2-72

PRE-INSPECTION FOR ENGINE CAN

COMMUNICATION LINE (500 k) [HYBRID].......... 2-77

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k)

[DIESEL] ...............................................................2-83

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (500 k)

[HYBRID]...............................................................2-88

MALFUNCTION CODES FOR FAULTY ACTUATOR

POWER RELAY ....................................................2-93

ENG BASIC INSPECTION SHEET

(ENGINE INSPECTION CHECK SHEET) ............2-94

NO DTC ................................................................2-98

INSPECTION PROCEDURE FOR WHEN THE DEF

MIXED INTO THE ENGINE COOLANT ..............2-102

DTC: P0005 ........................................................2-104

DTC: P0006 and P0007 ......................................2-108

DTC: P0016 ........................................................2-113

DTC: P0027 ........................................................2-116

DTC: P003A ........................................................2-121

DTC: P0045 ........................................................2-126

DTC: P0047 ........................................................2-130

DTC: P0048 ........................................................2-134

DTC: P006E ........................................................2-138

DTC: P006F ........................................................2-142

DTC: P007B ........................................................2-146

DTC: P007C and P007D.....................................2-160

DTC: P0088 ........................................................2-168

DTC: P0096 ........................................................2-176

DTC: P0097 and P0098 ......................................2-187

DTC: P00AF........................................................2-195

DTC: P0101 ........................................................2-199

DTC: P0104 ........................................................2-208

DTC: P0106 ........................................................2-215

DTC: P0108 ........................................................2-221

DTC: P0112 and P0113 ......................................2-227

DTC: P0115 ........................................................2-235

DTC: P0117 and P0118 ......................................2-244

DTC: P011A ........................................................2-252

DTC: P011C........................................................2-261

DTC: P0122 and P0123 ......................................2-267

DTC: P0128 ........................................................2-276

DTC: P0148 ........................................................2-282

DTC: P016E and P016F .....................................2-294

DTC: P0182 and P0183 ......................................2-304

DTC: P0191 ........................................................2-312

DTC: P0192 and P0193 ......................................2-321

DTC: P01A5 ........................................................2-331

DTC: P01A6 ........................................................2-338

DTC: P0200 ........................................................2-345

DTC: P0201, P0202, P0203 and P0204 .............2-348

DTC: P0217 ........................................................2-353

DTC: P0219 ........................................................2-358

DTC: P0222 and P0223 ......................................2-366

DTC: P0234 ........................................................2-376

DTC: P0237 ........................................................2-382

DTC: P0263, P0266, P0269 and P0272 .............2-388

DTC: P026C and P026D.....................................2-399

DTC: P0299 ........................................................2-412

DTC: P0300 ........................................................2-418

DTC: P0301, P0302, P0303 and P0304 .............2-426

DTC: P0335 ........................................................2-435

DTC: P0336 ........................................................2-442

DTC: P0340 ........................................................2-449

ENGINE (J05E)2–2

033

833

080

856

892

898

904

933

955

960

982

990

033

055

063

DTC: P0341.........................................................2-453

DTC: P0381.........................................................2-461

DTC: P0401.........................................................2-467

DTC: P0402.........................................................2-483

DTC: P0404.........................................................2-494

DTC: P0405 and P0406 ......................................2-499

DTC: P041B ........................................................2-505

DTC: P041C and P041D .....................................2-518

DTC: P0420.........................................................2-526

DTC: P0421.........................................................2-528

DTC: P0422.........................................................2-531

DTC: P0489 and P0490 ......................................2-534

DTC: P049D ........................................................2-540

DTC: P04D5 and P04D6 .....................................2-545

DTC: P04DA........................................................2-553

DTC: P0500 and P0501 ......................................2-563

DTC: P0504.........................................................2-570

DTC: P0506.........................................................2-575

DTC: P0507.........................................................2-579

DTC: P0521.........................................................2-583

DTC: P0524.........................................................2-587

DTC: P0545 and P0546 ......................................2-592

DTC: P054E ........................................................2-600

DTC: P054F ........................................................2-604

DTC: P0562 and P0563 ......................................2-608

DTC: P05F1 ........................................................2-613

DTC: P0605.........................................................2-621

DTC: P0606.........................................................2-623

DTC: P0607.........................................................2-625

DTC: P0610.........................................................2-627

DTC: P0611.........................................................2-630

DTC: P0617.........................................................2-632

DTC: P0628 and P0629 ......................................2-636

DTC: P062F ........................................................2-644

DTC: P0630.........................................................2-648

DTC: P0642.........................................................2-652

DTC: P0643.........................................................2-658

DTC: P064C ........................................................2-666

DTC: P0652.........................................................2-671

DTC: P0653.........................................................2-677

DTC: P0671 and P0672 ......................................2-684

DTC: P0673 and P0674 ......................................2-690

DTC: P0683.........................................................2-696

DTC: P0686.........................................................2-702

DTC: P06D3 and P06D4 .....................................2-707

DTC: P073D ........................................................2-716

DTC: P081A ........................................................2-720

DTC: P081B ........................................................2-726

DTC: P0A7B........................................................2-730

DTC: P0AC4........................................................2-732

DTC: P0CA1........................................................2-734

DTC: P1133.........................................................2-736

DTC: P119F ........................................................2-742

DTC: P1426.........................................................2-748

DTC: P1427.........................................................2-755

DTC: P1428.........................................................2-762

DTC: P1458.........................................................2-770

DTC: P1459.........................................................2-775

DTC: P14B0 ........................................................2-780

DTC: P14B2 ........................................................2-784

DTC: P14B3 and P14B4 .....................................2-788

DTC: P14B7 and P14B8 .....................................2-794

DTC: P14BC and P14BD ....................................2-800

DTC: P14BF ........................................................2-806

DTC: P1515.........................................................2-811

DTC: P1530.........................................................2-816

DTC: P1601.........................................................2-820

DTC: P200C........................................................2-824

DTC: P200C ........................................................2-824

DTC: P2032 and P2

DTC: P2032 and P2033 ......................................2-833

DTC: P203F ........................................................2-841

DTC: P204F ........................................................2-845

DTC: P207F ........................................................2-848

DTC: P2

DTC: P2080.........................................................2-856

DTC: P2084.........................................................2-86

DTC: P2084.........................................................2-864

DTC: P20CD .......................................................2-87

DTC: P20CD .......................................................2-872

DTC: P20CE........................................................2-87

DTC: P20CE........................................................2-876

DTC: P20CF........................................................2-87

DTC: P20CF........................................................2-879

DTC: P20D8 ........................................................2-88

DTC: P20D8 ........................................................2-882

DTC: P20DE........................................................2-88

DTC: P20DE........................................................2-888

DTC: P20DF........................................................2-

DTC: P20DF........................................................2-892

DTC: P20E0........................................................2-

DTC: P20E0 ........................................................2-898

DTC: P20EE........................................................2-

DTC: P20EE........................................................2-904

DTC: P2100.........................................................2-91

DTC: P2100.........................................................2-912

DTC: P2101.........................................................2-91

DTC: P2101.........................................................2-917

DTC: P2103.........................................................2-92

DTC: P2103.........................................................2-924

DTC: P2120.........................................................2-92

DTC: P2120.........................................................2-929

DTC: P2122 and P2123......................................2-

DTC: P2122 and P2123 ......................................2-933

DTC: P2127 and P2128 ......................................2-94

DTC: P2127 and P2128 ......................................2-942

DTC: P2135.........................................................2-95

DTC: P2135.........................................................2-950

DTC: P2138.........................................................2-

DTC: P2138.........................................................2-955

DTC: P2146.........................................................2-

DTC: P2146.........................................................2-960

DTC: P2147 and P2148 ......................................2-96

DTC: P2147 and P2148 ......................................2-967

DTC: P2149.........................................................2-97

DTC: P2149.........................................................2-975

DTC: P2150 and P2151 ......................................2-

DTC: P2150 and P2151 ......................................2-982

DTC: P2184 and P2185......................................2-

DTC: P2184 and P2185 ......................................2-990

DTC: P2214.........................................................2-99

DTC: P2214.........................................................2-998

DTC: P2227.......................................................2-100

DTC: P2227.......................................................2-1009

DTC: P2228 and P2229....................................2-101

DTC: P2228 and P2229 ....................................2-1013

DTC: P2269.......................................................2-101

DTC: P2269.......................................................2-1018

DTC: P226C......................................................2-1023

DTC: P226C ......................................................2-1023

DTC: P22D3......................................................2-102

DTC: P22D3 ......................................................2-1029

DTC: P240F ......................................................2-1

DTC: P240F ......................................................2-1033

DTC: P2428.......................................................2-104

DTC: P2428.......................................................2-1043

DTC: P242B ......................................................2-1047

DTC: P242C and P242D ...................................2-1

DTC: P242C and P242D ...................................2-1055

DTC: P244A ......................................................2-1

DTC: P244A ......................................................2-1063

DTC: P244B ......................................................2-1083

DTC: P2457.......................................................2-11

DTC: P2457.......................................................2-1100

.........................................................2-

......................................2-

ENGINE (J05E) 2–3

635

696

U0073

U030

DTC: P2458 ......................................................2-1115

TC: P2458......................................................2-111

DTC: P2459 ......................................................2-1125

TC: P2459 ......................................................2-1125

TC: P2463 ......................................................2-1128

DTC: P2463 ......................................................2-1128

TC: P246F ......................................................2-1136

DTC: P246F ......................................................2-1136

TC: P2470 and P2471 ....................................2-114

DTC: P2470 and P2471 ....................................2-1144

TC: P24A0 ......................................................2-115

DTC: P24A0 ......................................................2-1152

TC: P24A1 ......................................................2-11

DTC: P24A1 ......................................................2-1155

TC: P24A2 ......................................................2-115

DTC: P24A2 ......................................................2-1157

TC: P2562 ......................................................2-1166

DTC: P2562 ......................................................2-1166

TC: P259E ......................................................2-1170

DTC: P259E ......................................................2-1170

TC: P259F ......................................................2-117

DTC: P259F ......................................................2-1176

TC: P2

DTC: P2635 ......................................................2-1181

TC: P268A and P2

DTC: P268A and P2696....................................2-1190

TC: P26C8......................................................2-119

DTC: P26C8......................................................2-1196

TC: P2BA9......................................................2-119

DTC: P2BA9......................................................2-1198

TC:

DTC: U0073 ......................................................2-1203

TC: U010A......................................................2-120

DTC: U010A......................................................2-1206

TC: U010C......................................................2-121

DTC: U010C......................................................2-1212

TC: U010E......................................................2-121

DTC: U010E......................................................2-1218

TC: U0293 ......................................................2-122

DTC: U0293 ......................................................2-1224

TC: U029D (DIESEL).....................................2-1229

DTC: U029D (DIESEL) .....................................2-1229

TC: U029D (HYBRID).....................................2-123

DTC: U029D (HYBRID).....................................2-1235

TC: U029E (DIESEL)......................................2-124

DTC: U029E (DIESEL)......................................2-1241

TC: U029E (HYBRID).....................................2-124

DTC: U029E (HYBRID).....................................2-1247

TC: U02A2......................................................2-125

DTC: U02A2......................................................2-1253

TC:

DTC: U0301 ......................................................2-1259

TC: U1001 ......................................................2-126

DTC: U1001 ......................................................2-1262

TC: U110A......................................................2-12

DTC: U110A......................................................2-1269

......................................................2-1181

.....................

......................................................2-12

1 ......................................................2-12

.............2-11

ENGINE (J05E)/TROUBLESHOOTING2–4

TROUBLESHOOTING

ENGINE ECU (J05E)

PRECAUTIONS FOR DIAGNOSIS

EN01H02127030602016001

• Ensure that individual connectors are certainly connected before start of checking works.

• Make sure to set the starter key to the "LOCK" position before disconnecting a connector.

• Replace the part or the component that have a failure or trouble. Do not fix and reuse it.

• Delete the past malfunction code after recording. Then conduct a diagnosis again to check for present failures.

• Delete the past failure memory after completion of a diagnostic analysis.

ENGINE (J05E)/TROUBLESHOOTING 2–5

SHTS021270300001

1. ILLUSTRATION OF CONNECTOR AND MEASUREMENT ON TERMINAL

LOCK

TO BE CONNECTED

MALE

CONNECTOR

213

546

CONNECTOR

MALE

CONNECTOR

INCORRECT

CORRECT

INCORRECT

WATERPROOF CONNECTOR

FEMALE

231

564

FEMALE

ILLUSTRATION OF CONNECTOR

The illustration of a connector contained in this document represents an image of a connector with its lock positioned on top as viewed from the connecting face.

NUMBERING OF CONNECTOR TERMINALS

The terminals are symmetrically numbered (symmetrically reversed numbering) as viewed on the connecting faces of a pair of connectors. The terminal #1 is located at the top right corner of a male connector and at the top left corner of a female connector respectively in this document.

PRECAUTIONS FOR TERMINAL MEASUREMENT

Unless otherwise specified in this document, the illustration of a connector represents an image of a connector as viewed from the connecting face. A test probe must access the back face of a connector. However, some types of connector do not allow a test probe to contact with the back face such as a waterproof connector. In such case, a test probe may be allowed to access the front face of a connector but a special care must be used to avoid a risk of damage in terminals.

As to a connector that is designed to use the signal check harness for terminal measurement, do not place a test probe directly onto the front or back face. Use a contact box of the connected signal check harness to take measurement on terminals.

ILLUSTRATION OF CONNECTOR AND MEASUREMENT SURFACE

VIEW A

VIEW B

The illustration of a connector contained in this document represents an image of a connector as viewed from the connecting face. For example, the terminal #1 of a female connector is located at the top left corner of a connector as viewed from the connecting face. In actual measurement on the terminal #1 of a female connector, a test probe must be placed onto the top right corner on the back face of a connector.

ENGINE (J05E)/TROUBLESHOOTING2–6

STARTER SWITCH

ACCELERATOR PEDAL POSITION SENSOR 1, 2

NEUTRAL SWITCH

STOP LIGHT SWITCH

DIAGNOSIS SWITCH

DPR REGENERATION SWITCH

PTO CUT RELAY

ENGINE STOP SWITCH

PTO SWITCH 2

PTO SWITCH 1

WATER LEVEL WARNING SWITCH

OIL PRESSURE SWITCH

VEHICLE SPEED SENSOR

SVS LIGHT

MALFUNCTION INDICATOR LIGHT (MIL)

GLOW LAMP (WAIT-TO-START LIGHT)

OUT PUT

INPUT

OTHERS

DPR INDICATOR LIGHT

STARTER CUT RELAY

EXHAUST BRAKE MAGNETIC VALVE

EXHAUST BRAKE DRIVE SIGNAL

DC MOTOR (FOR DIESEL THROTTLE VALVE) DRIVE SIGNAL

DIESEL THROTTLE VALVE POSITION SENSOR 1

DIESEL THROTTLE VALVE

DC MOTOR

DIESEL THROTTLE VALVE POSITION SENSOR 2

COMMON RAIL PRESSURE SENSOR (MAIN)

INTAKE TEMPERATURE SENSOR

(AFS BUILT-IN)

AIR FLOW SENSOR

(FREQUENCY TYPE )

COMMON RAIL PRESSURE SENSOR (SUB)

COMMON RAIL

SUCTION CONTROL VALVE FOR FUEL SUPPLY PUMP DRIVE POWER

SUCTION CONTROL VALVE FOR FUEL SUPPLY PUMP DRIVE SIGNAL

SUPPLY PUMP

S/P

GLOW PLUG DRIVE SIGNAL

PTO ACCELERATOR SENSOR

KEY SWITCH

BARMETRIC PRESSURE SENSOR (ECU BUILT-IN)

EXHAUST TEMPERATURE SENSOR (DPF OUTLET) EXHAUST TEMPERATURE SENSOR (DPF INLET) DPR DIFFERENTIAL PRESSURE SENSOR

EXHAUST TEMPERATURE SENSOR (DOC2 INLET)

EXHAUST TEMPERATURE SENSOR (DOC1 INLET)

INTAKE TEMPERATURE SENSOR (INTERCOOLER OUTLET)

INTAKE TEMPERATURE SENSOR (INTAKE MANIFOLD)

EGR TEMPERATURE SENSOR

COOLANT TEMPERATURE SENSOR 1

COOLANT TEMPERATURE SENSOR 2

CRANKSHAFT POSITION SENSOR

CAMSHAFT POSITION SENSOR

BOOST PRESSURE SENSOR

ENGINE

EGR VALVE CONTROLLER AND ACTUATOR

VARIABLE NOZZLE TURBOCHARGE (VNT) CONTROLLER AND ACTUATOR

TURBOCHARGER

FREQUENCY TYPE AFS

DC MOTOR

EGR VALVE

EGR COOLER

TTTT

PTT

ACTUATOR RELAY

POWER SOURCE

MAIN RELAY

VEHICLE CONTROL ECU

CAN COMMUNICATION (DIAGNOSIS,VEHICLE CONTROL ECU)

CAN COMMUNICATION (VARIABLE NOZZLE TURBO CHARGER, EGR VALVE DEF DOSING SYSTEM)

INJECTOR DRIVE SIGNAL

INJECTOR

AFTERTREATMENT FUEL INJECTOR DRIVE SIGNAL

AFTERTREATMENT FUEL CUTOFF VALVE DRIVE SIGNAL

AFTERTREATMENT FUEL PRESSURE

AFTERTREATMENT FUEL INJECTOR

DPR CLEANER

UREA SCR

DENOX ECU (DCU)SYSTEM

EXHAUST PIPE

AFTERTREATMENT FUEL PRESSURE SENSOR

AFTERTREATMENT FUEL CUTOFF VALVE

FUEL TEMPERATURE SENSOR

GLOW STATUS SIGNAL

GCU

FUSE

BATTERY

Troubleshooting

Troubleshooting tool

SHTS021270300002

ELECTRICAL

EN01H02127030602016002

ENGINE (J05E)/TROUBLESHOOTING 2–7

!WARNING

How to use tester probe

Incorrect

Correct

Incorrect

Correct

SHTS021270300003

PRECAUTIONS

EN01H02127030602016003

Approximately 110V is generated for the injector drive actuation system. For this reason, electrical shock may result if the injector drive circuit is touched directly by hand. Set the starter key to the LOCK position if it is necessary to check or repair the computer, harnesses, or connectors.

1. BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE ACTUATOR OR MAGNETIC VALVES.

2. HARNESS WIRE CONNECTOR.

(1) Multi-contact connectors suitable for the small electrical sig-

nals of electronic circuitry are used for wiring connections to the sensors, actuator and control unit. Be very careful when handling them.

• Before disconnecting any connectors, make sure that the

starter key is in the "LOCK" position.

• When disconnecting connectors, try to pull them out in a

straight line, disengaging the lock and holding onto the housing.

• Do not try to disconnect connectors by gripping the wires

or twisting them, as this could bend the contacts.

• Do not disconnect connectors unnecessarily.

• When using a circuit tester, apply the tester probe to the

harness wire side only. Never stick the tester probe into the holes on the connector terminal side, as this could cause poor contacts when the connector is reconnected.

• Do not let water, oil or dust get on the connector when it is

disconnected, as this could cause poor contacts when the connector is reconnected.

• Do not open the control unit cover. It could malfunction if

dust or water gets inside.

• Take care to ensure that water, oil or dust do not get on or

inside parts.

• When connecting in connectors, push them in all the way

and make sure that the lock engages.

3. ERASING THE MALFUNCTION MEMORY STORED IN THE PAST, CHECK THE CURRENT MALFUNCTION BY PERFORMING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.

ENGINE (J05E)/TROUBLESHOOTING2–8

10987654213 201918171615141211 13 302928272625242221 23 403938373635343231 33

(1 to 40)

Signal check harness (contact box)

V23

Example: V23 terminal

Computer (ECU) terminal signal

Computer (ECU) terminal No.

SHTS021270300004

4. AFTER COMPLETING THE MALFUNCTION ANALYSIS, ERASE THE MALFUNCTION MEMORY STORED IN THE PAST. OTHERWISE, THE MALFUNCTION LIGHT IN THE DISPLAY WILL REMAIN LIT.

5. CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE SEEN FROM THE CONNECTION SIDE, INSERT THE TESTING LEAD FROM THE BACKSIDE.

6. USING A CIRCUIT TESTER

• Use a circuit tester with an internal resistance of 100 k or

greater in the voltage measuring range.

7. USING A SIGNAL CHECK HARNESS

• To prevent breakage of the ECU connector, connect the signal

check harness and perform measuring by bringing the test lead into contact with the signal check harness side (contact box).

NOTICE The terminal numbers in the text and in the illustrations correspond to the table on the next page (computer pin assignment) as shown below.

Power supply 1

V1 VF V2 V3 MREL V4 EXB V5 PTOC V6

Neutral switch

V11 NSW V12 V13 IGSW V14 SP1 V15

Power supply 2

V21 VF2 V22 V23 MRL2 V24

PTO switch 1

V31 PTO V32 V33 IG V34 V35

Starter cut relay

Starter signal

Engine stop

switch

Main/

Actuator power

relay 1

Starter switch 1

Main/

Actuator power

relay 2

Starter switch 2 -

Exhaust brake

relay

Vehicle speed

pulse converter

Glow relay

TACHO Pulse

PTO cut relay -

SREL

V25

TAC

- - Diagno

CAN

communication

line

V16 CANL V17STA

V26

CAN

communication

line

V36 CANH V37ESTP

Glo (Indi

V7STCR

commu

V27

commu

ENGINE (J05E)/TROUBLESHOOTING 2–9

Test lead

Contact box

Connector (engine ECU side)

09843-E4020

09843-E4050

Signal check harness assembly

09843-E4060

Engine sub harness

Computer (engine ECU)

Signal check harness (engine side)

Signal check harness (vehicle side)

Engine side

Vehicle side

Black

Blue

Red

White

Terminal V01-V40

Terminal V41-V80

Terminal E01-E40

Terminal E41-E80

Connector

(engine ECU side)

Connector (engine sub harness side)

SHTS021270300005

8. CONNECT THE SIGNAL CHECK HARNESS.

(1) Set the starter key to the "LOCK" position and disconnect the

connectors from the engine ECU.

(2) Connect a signal check harness to the engine sub harness

and the engine ECU.

SST: 09843-E4050

Signal check harness

ENGINE (J05E)/TROUBLESHOOTING2–10

9. RADIO INSTALLATION

• There is a danger that the control unit might malfunction if a high

output radio transmitter (over 50W) is installed in the vehicle.

10. USING A QUICK CHARGER

• Disconnect both battery terminals before using a quick charger.

11. AIR CONDITIONER INSTALLATION

• Be careful not to scratch or damage the engine, chassis or the

harness inside the cab when installing an air conditioner. Also, make sure to reattach afterward any connectors that were disconnected during the installation process.

12. PERFORMING ELECTRIC WELDING

• Disconnect the negative terminal of the battery before perform-

ing any electric welding.

13. OTHER

• Make sure to check the other connectors before connecting

them in to prevent incorrect connections.

• Be careful not to allow the connectors to become soiled with

dust, water, fuel or oil when performing inspections or removing and replacing parts.

ENGINE (J05E)/TROUBLESHOOTING 2–11

V1 VF V2 V3 MREL V4 EXB V5 PTOC V6

V7 GIND V8 W2 V9 W V10

STCR

V11 NSW V12 V13 IGSW V14 SP1 V15

V16 CANL V17 CANN V18 +B V19 BATT V20 -STA

V21 VF2 V22 V23 MRL2 V24

SREL

V25

V26

V27 DG V28

V29

V30 TC

V31 PTO V32 V33 IG V34 V35

V36 CANH V37 CANP V38 +B1 V39 E01 V40 E11ESTP

TA C

Main/

Actuator power

relay 1

Exhaust brake

relay

PTO cut relay -

Glow pulg

(Indicator)

DPR refresh light

Check engine

warning light

Power supply 1

Starter cut relay

Starter switch 1

Vehicle speed

pulse converter

CAN

communication

line

CAN

communication

line

Power supply 1

(+B)

Back up power

supply

-Neutral switch

Glow relay

Starter signal

Main/

Actuator power

relay 2

- - Diagnosis light - Diagnosis switch

Power supply 2

Starter switch 2 -

CAN

communication

line

CAN

communication

line

Power supply 2

(+B)

Signal ground 1Power ground 1PTO switch 1

Engine stop

switch

TACHO Pulse

SHTS021270300006

COMPUTER (ECU) PIN ASSIGNMENT

EN01H02127030602016004

ENGINE (J05E)/TROUBLESHOOTING2–12

SHTS021270300007

Sensor power

Exhaust gas

temperature sensor

Accelerator

supply 3

(DOC2 inlet)

sensor 1

Power ground 2 Signal ground 2

(+B)

Power supply 3

(DPF outlet)

Exhaust gas

temperature sensor

switch

DPR refresh

V56 RGSW V57 57 V58 +B2 V59 E02 V60 E12

DPR differential

Exhaust gas

PTO

Accelerator

pressure sensor

temperature sensor

acceclerator

sensor 2

V70 70PTO2

(DOC2 outlet)

sensor

V67 VPA2 V68 VPA1 V69

Power ground 4Power ground 3

(+B)

Power supply 4

V78 +BM V79 E03 V80 E04

V77

- - Sensor ground 7 Sensor ground 9

- WIF signal

V45 EPA V46 46 V47 VPA V48 V49 49 V50 VCPA42

V44

V42 V43

V41

V55

V54

---

V65 EPA2 V66

V64

- Sensor ground 8 -

V75 ST1- V76

V74

- Stop light switch - -

V62 V63

- PTO switch 2

supply 4

Sensor power

V51 VCP2 V52 V53

V61

supply 5

Sensor power

V71 71 V72 V73

ENGINE (J05E)/TROUBLESHOOTING 2–13

SHTS021270300008

valve (Main)

Suction control

After treatment

E10 PCV-

E9 PCV+

valve (Main)

‑

fuel injector

E5 FIV

(Main)

No.2 Fuel injector

(Main)

No.3 Fuel injector

(Main)

No.2 Fuel injector

‑

(Main)

No.4 Fuel injector

(Main)

No.1 Fuel injector

E20 #4

E19 #2

E18 IJ2+

E17

E16 #3

E15 #1

valve (Sub)

Suction control

E30 PV-S

valve (Sub)

E29 PV+S

‑

E28

‑

E27

‑

E26

‑

E25

No.2 Fuel injector

No.3 Fuel injector

‑

No.4 Fuel injector

No.1 Fuel injector

(Sub)

E40 #40

(Sub)

E39 #20

(Sub)

E38 I2+S

(Sub)

E36 #30 E37

(Sub)

E35 #10

Intake throttle

‑

valve motor (+)

E1 M+ E2

(Main)

No.1 Fuel injector

Sensor power

Air flow sensor

E14 IJ1+

supply 1

E13 VC

VAF

(Power)

E12

‑

E11

Intake throttle

‑

E24

‑

E23

‑

E21 M- E22

valve motor (-)

(Sub)

No.4 Fuel injector

supply 2

Sensor power

After treatment

E33 VC2 E34 I1+S

‑

E31 FCV E32

fuel cutoff valve

ENGINE (J05E)/TROUBLESHOOTING2–14

SHTS021270300009

‑

line

communication

Sensor ground 5

Sensor ground 3

Sensor ground 1

‑

E60

E59 CAN+

E58 E5

E57 E3

E56 E1

‑

E50

CAN

E49 PCR1

sensor 1 (Main)

Fuel rail pressure

sensor

Fuel temperature

Intake air

E48 THF

(Air flow

E47 THA

sensor built-in)

temperature sensor

E46 -

‑‑

‑

E70

‑

E69

E68 PC1S

sensor 1 (Sub)

Fuel rail pressure

sensor

temperature

E67 PIM

sensor

E66 THW

Boost pressure

Coolant

‑

CAN

communication

Sensor ground 6

Sensor ground 4

Sensor ground 2

E80

line

E79 CAN-

E78 EVG

E76 E2 E77 E4

E45

‑

E44

THO1

Exhaust gus

(DOC1 outlet)

E43

temperature sensor

‑

Engine oil

pressure switch

E41 OSW E42

(ground)

G sensor

(Supply)

G sensor

NE sensor (+)

‑

E55

E54 G-

E53 VCG

NE+

E52

E51

sensor 2 (Sub)

Fuel rail pressure

sensor 2 (Main)

Fuel rail pressure

sensor

temperature

Intakemanifold

sensor 1

valve position

Intake throttle

Engine oil

pressure switch

E65 PC2S

E63 THIA E64 PCR2

VTA1

E61 DM E62

E75 SNE

NE sensor (SLD)

Air flow sensor

G sensor

E73 G+ E74 VG

NE-

E72

NE sensor (-)

‑

E71

ENGINE (J05E)/TROUBLESHOOTING 2–15

Lever

Sliding portion

SHTS021270300010

Hook

SHTS021270300011

ENGINE ECU CONNECTOR

EN01H02127030602016005

REMOVING THE ENGINE ECU CONNECTOR

NOTICE Before replacement, wait until the engine cools down as you may get burned. (Set the starter key to the "LOCK" position and leave it for more than 30 minutes to cool.)

1. CLEANING THE ENGINE ECU CONNECTOR

(1) Check that the engine ECU connector is completely con-

nected to the engine ECU.

(2) Directly spray water around the engine ECU connector by

using a small spray bottle.

NOTICE Do not remove the connector while at work.

HINT If it is much dirty, squirt water at the connector sliding portion and connector surface.

(3) Blow air around the engine ECU connector and engine ECU

surface to remove dirt and foreign matter.

NOTICE

• Do not remove the connector while at work.

• Blow off water with air as much as possible for drying.

(4) Using a small brush, carefully remove dirt and foreign matter

remaining at the sliding portion.

NOTICE Do not remove the connector while at work.

(5) Using a waste cloth, wipe off around the engine ECU con-

nector and engine ECU surface.

NOTICE

• Do not remove the connector while at work.

• Wipe up water thoroughly.

(6) If you feel the movement of the lever un-smooth, repeat steps

(1), (2), (3), (4) and (5).

(7) Disconnect the engine ECU connector and check it for depo-

sition of dirt and foreign matter.

a. Set the hook of the connector in the direction of the arrow

to release the lock.

ENGINE (J05E)/TROUBLESHOOTING2–16

Lever

Primary latch

SHTS021270300012

SHTS021270300013

Wipe off

Harness side connector

Do not wipe

SHTS021270300014

Wipe off

Engine ECU side connector

Do not wipe

SHTS021270300015

b. While pushing the primary latch of the connector, move the

lever in the direction of the arrow as shown in the figure until a "click" is heard and then detach the connector.

c. Pull out the connector straight.

NOTICE

• Do not insert and remove the connector more than necessary.

• Do not give shocks to the engine ECU.

• Never detach the harness by holding and pulling or prying as it

may result in wire or terminal deformation.

• Never insert a test lead from the rear of the connector.

• Do not paint or apply grease or oil to the connector to maintain

its function and durability.

HINT If it cannot be pulled out with a light force, check if the lever is fully open.

(8) If the side of the harness side connector is found dirty, wipe it

off with a moistened waste cloth while being careful not allowing dirt and foreign matter to drop.

NOTICE

• Use a thoroughly wrung waste cloth.

• Do not wipe off the terminal opening.

• Do not directly spray water.

(9) If the engine ECU side connector is found dirty, wipe off its

side with a moistened waste cloth.

NOTICE

• Use a thoroughly wrung waste cloth.

• Do not wipe off the terminal opening.

• Do not directly spray water.

(10) Blow air on the terminal part inside the engine ECU side con-

nector to remove dirt and foreign matter.

ENGINE (J05E)/TROUBLESHOOTING 2–17

Lever

SHTS021270300016

SHTS021270300017

SHTS021270300018

MOUNTING THE ENGINE ECU CONNECTOR

1. ATTACHING THE ENGINE ECU CONNECTOR

(1) Check that the harness side connector lever is fully open and

place it straight on the engine ECU side connector.

NOTICE At this time, check that the lever is fully open.

HINT Check that it is inserted along the wrong fitting prevention keyway.

Wrong fitting prevention keyway

Lever

(2) Press the upper part of the harness side connector and

insert the connector uniformly.

ENGINE (J05E)/TROUBLESHOOTING2–18

Lever

Sliding portion

SHTS021270300019

Hook

SHTS021270300020

(3) Move the lever in the direction of the arrow as shown in the

figure until a "click" is heard and attach the connector.

NOTICE If the lever cannot move smoothly, repeat steps (1) and (2). Also drop a few drops of water to the sliding portion to make it smooth.

(4) Move the hook in the direction of the arrow as shown in the

figure until a "click" is heard in order to lock the connector.

ENGINE (J05E)/TROUBLESHOOTING 2–19

MIL

SVS Light

SHTS021270300021

SHTS021270300022

INSPECTION

EN01H02127030602016006

1. PRIOR CHECK

(1) Set the starter key to the "ON" position (do not start the

engine) and confirm that the SVS (Service Vehicle Soon) light in the indicator area lights up.

HINT

• If the MIL (Malfunction Indicator Light) is lit, perform a system

check to see if the malfunction is of the past or present.

• In the case of the past malfunction, this light will turn off if a sta-

tus is judged to be normal in 3 times of driving.

• DTC must be cleared on the HINO DX Ⅱ , after MIL comes off.

(DEFINITION OF 1 TIME OF DRIVING) a. Begins with engine start and ends with engine shut off. b. Begins with engine start and ends after four hours of continu-

ous engine-on operation. c. Begins at end of the previous four hours of continuous

engine-on operation and ends after four hours of continuous

engine-on operation. d. Begins at the end of the previous four hours of continuous

engine-on operation and ends with engine shut off.

• Since the normal judgement method and time differ accord-

ing to the malfunction code, a proper definition will be selected from the above 4 definitions.

• If the malfunction indicator light does not go out, the system is

abnormal. Check the system according to diagnosis on the following page.

Starter

switch

Engine

Malfunction

indicator

light

MALFUNCTION INDICATOR LIGHT ILLUMINATION PATTERN

Start

Lock

Running

Stop

OFF

TIME

ENGINE (J05E)/TROUBLESHOOTING2–20

SHTS021270300023

Trouble diagnosis connector

SHTS021270300024

TROUBLE DIAGNOSIS USING THE COM-

PUTER (HINO DX Ⅱ )

EN01H02127030602016007

1. PREPARATION FOR CONNECTING HINO DX Ⅱ

(1) The "HINO DX Ⅱ " is a failure diagnosis tool for the common

rail fuel injection system and the chassis system. For connecting the computer to a vehicle, the "DST-i" and the dedicated cable will be required.

SPECIAL TOOL: Computer interface

Part name Part No.

DENSO DST-i Set (Without LCD)

DENSO DST-i Set (With LCD)

Without Bluetooth 95171-01021

With Bluetooth 95171-01041

Without Bluetooth 95171-01031

With Bluetooth 95171-01051

2. CONNECTION OF HINO DX Ⅱ

(1) Connect the DST-i to the trouble diagnosis connector located

in the electrical component box in the instrument panel or located in the electrical component box behind the rearmost seat.

(2) Connect the computer in which the HINO DX Ⅱ is installed, to

the DST-i. (3) Turn the starter key to "ON". (4) Turn on the power switch of the computer to start the HINO

DX Ⅱ .

ENGINE (J05E)/TROUBLESHOOTING 2–21

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

NOTICE A: Torque limit

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P0005 Fuel Cut Valve stuck closed

Light No Light P0006

Light No Light P0007

Light Light P0016

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Malfunction of fuel cutoff valve low

Malfunction of fuel cutoff valve high

Crankshaft position sensor and Camshaft position sensor - rationality

• Fuel cut valve —

• Fuel cut valve

• Wire harness

• ECU (ECU connector)

• Fuel cut valve

• Wire harness

• ECU (ECU connector)

• Camshaft gear

• Flywheel

• Engine speed main sensor

• Engine speed sub sensor

(crankshaft position sensor)

(camshaft position sensor)

EN01H02127030602016008

—

Light No Light P0027 Exhaust Brake Performance

Light No Light P003A

Light No Light P0045

Light No Light P0047

Light No Light P0048

Light No Light P006E

Light No Light P006F

Initialization failure (VNT actuator initialize error)

DC motor open circuit (VNT actuator motor open circuit)

DC motor terminal short circuit, DC motor short circuit (Short to Battery) (VNT actuator motor short to BATT)

DC motor terminal short circuit, DC motor short circuit (Short to GND) (VNT actuator motor short to GND)

Power supply failure (Out of range low) (VNT actuator power supply too low)

Power supply failure (Out of range high) (VNT actuator power supply too high)

• Exhaust brake valve —

• VNT controller A

• VNT actuator

• VNT controller

• VNT actuator

• VNT controller

• VNT actuator

• VNT controller

• VNT controller A

Light No Light P007B

Intake air temperature sensor (intercooler outlet) - rationality

• Intercooler outlet temperature sensor

• ECU (ECU connector)

• Intake air temperature sensor

• Boost pressure sensor

• Intake manifold temperature sensor

• Wire harness

—

ENGINE (J05E)/TROUBLESHOOTING2–22

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P007C

Light No Light P007D

No Light

SVS

Light

No Light P0088 Excessive common-rail pressure

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Intake air temperature sensor (intercooler outlet) - out of range (Out of range low)

Intake air temperature sensor (intercooler outlet) - out of range (Out of range high)

• Intercooler outlet temperature sensor

• ECU (ECU connector)

• Wire harness

• Intercooler outlet temperature sensor

• ECU (ECU connector)

• Wire harness

• Engine

• Supply pump

• SCV

• Engine ECU

• Pre fuel filter

• Fuel pipe

• Breather hose

• Fuel tank feed pipe

• Fuel tank

• Supply pump gauze filter

• Fuel high-pressure pipe

• Fuel filter

• Common rail pressure sensor

• Engine speed main sensor

(crankshaft position sensor)

• Fuel return pipe and hose

—

Light No Light P0096

Light No Light P0097

Light No Light P0098

Light No Light P00AF

Intake air temperature sensor (intake manifold) - rationality

Intake air temperature sensor (intake manifold) - out of range (Out of range low)

Intake air temperature sensor (intake manifold) - out of range (Out of range high)

Controller error (VNT actuator CPU malfunction)

• Intake air temperature sensor

(intake manifold)

• ECU (ECU connector)

• Intake air temperature sensor

(air flow sensor built-in)

• Intake air temperature sensor

(intercooler outlet)

• Boost pressure sensor

• Wire harness

• Intake air temperature sensor

(intake manifold)

• ECU (ECU connector)

• Wire harness

• Intake air temperature sensor

(intake manifold)

• ECU (ECU connector)

• Wire harness

• VNT controller A

—

ENGINE (J05E)/TROUBLESHOOTING 2–23

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P0101 Air flow sensor - rationality

Light No Light P0104 Air flow sensor - out of range

Light No Light P0106

Light No Light P0108

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Boost pressure sensor - rationality

Boost pressure sensor - out of range (Out of range high)

• Air cleaner element

• Intake system

• Air flow sensor

• ECU (ECU connector)

• Wire harness

• EGR valve

• Diesel throttle valve

• Intercooler

• Air flow sensor

• ECU (ECU connector)

• Wire harness

• Boost pressure sensor

• ECU (ECU connector)

• Wire harness

• Boost pressure sensor

• ECU (ECU connector)

• Wire harness

—

Light No Light P0112

Light No Light P0113

Light No Light P0115

Light No Light P0117

Light No Light P0118

Light No Light P011A

Intake air temperature sensor (air flow sensor built-in) - out of range (Out of range low)

Intake air temperature sensor (air flow sensor built-in) - out of range (Out of range high)

Malfunction of coolant temperature sensor and intake air temperature sensor

Engine coolant temperature sensor 1 - out of range (Out of range low)

Engine coolant temperature sensor 1 - out of range (Out of range high)

Engine coolant temperature sensor - rationality

• Intake air temperature sensor

• ECU (ECU connector)

• Wire harness

• Intake air temperature sensor

• ECU (ECU connector)

• Wire harness

• Engine coolant temperature sensor 1

• Engine coolant temperature sensor 2

• ECU (ECU connector)

• Wire harness

• Engine coolant temperature sensor

• ECU (ECU connector)

• Wire harness

• Engine coolant temperature sensor

• ECU (ECU connector)

• Wire harness

• Engine coolant temperature sensor 1

• Engine coolant temperature sensor 2

• ECU (ECU connector)

• Wire harness

—

Light No Light P011C

Intake air temperature sensor (air flow sensor built-in) - rationality

• Intake air temperature sensor

• ECU (ECU connector)

• Wire harness

—

ENGINE (J05E)/TROUBLESHOOTING2–24

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P0122

Light No Light P0123

Light No Light P0128

Light No Light P0148 Post injection failure

Light No Light P016E

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Intake throttle valve position sensor 1 - out of range (Out of range low)

Intake throttle valve position sensor 1 - out of range (Out of range high)

Thermostat - The coolant temperature does not reach a warmed-up temperature

Fuel system pressure control high

• Intake throttle valve position sensor 1

• ECU (ECU connector)

• Wire harness

• Intake throttle valve position sensor 1

• ECU (ECU connector)

• Wire harness

• Engine coolant temperature sensor

• Thermostat

• Fuel line

• Pre fuel filter

• Injector

• Engine speed main sensor

(Crankshaft position sensor)

• Engine

• Supply pump

• SCV

• Engine ECU

• Pre fuel filter

• Fuel pipe

• Breather hose

• Fuel tank feed pipe

• Fuel tank

• Supply pump gauze filter

• Fuel high-pressure pipe

• Fuel filter

• Common rail pressure sensor

• Engine speed main sensor

(crankshaft position sensor)

• Fuel return pipe and hose

—

ENGINE (J05E)/TROUBLESHOOTING 2–25

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P016F

No Light

SVS

Light

Light P0182 Fuel temperature sensor Low

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Fuel system pressure control low

• Engine

• Supply pump

• SCV

• Engine ECU

• Pre fuel filter

• Fuel pipe

• Breather hose

• Fuel tank feed pipe

• Fuel tank

• Supply pump gauze filter

• Fuel high-pressure pipe

• Fuel filter

• Common rail pressure sensor

• Engine speed main sensor

(crankshaft position sensor)

• Fuel return pipe and hose

• Fuel temperature sensor

• ECU (ECU connector)

• Wire harness

—

No Light

Light No Light P0191

Light No Light P0192

Light P0183 Fuel temperature sensor High

Fuel rail pressure sensor (main and sub) - out of range

Fuel rail pressure sensor (main) out of range (Out of range low)

• Fuel temperature sensor

• ECU (ECU connector)

• Wire harness

• Engine

• Supply pump

• SCV

• Engine ECU

• Pre fuel filter

• Fuel pipe

• Breather hose

• Fuel tank feed pipe

• Fuel tank

• Supply pump gauze filter

• Fuel high-pressure pipe

• Fuel filter

• Common rail pressure sensor

• Engine speed main sensor

(crankshaft position sensor)

• Fuel return pipe and hose

• Common rail pressure sensor

• Wire harness

• ECU (ECU connector)

—

Light No Light P0193

Fuel rail pressure sensor (main) out of range (Out of range high)

• Common rail pressure sensor

• Wire harness

• ECU (ECU connector)

—

ENGINE (J05E)/TROUBLESHOOTING2–26

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P01A5

Light No Light P01A6

Light No Light P0200

Light No Light P0201

Light No Light P0202

Light No Light P0203

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Fuel rail pressure sensor (sub)

- out of range (Out of range low)

Fuel rail pressure sensor (sub)

- out of range (Out of range high)

Fuel injector driver charge circuit (circuit high)

Fuel injector - disconnection (#1cyl)

Fuel injector - disconnection (#2cyl)

Fuel injector - disconnection (#3cyl)

• Common rail pressure sensor

• Wire harness

• ECU (ECU connector)

• Common rail pressure sensor

• Wire harness

• ECU (ECU connector)

• Engine ECU A

• ECU (ECU connector)

• Injector

• Engine ECU

• Injector harness

• ECU (ECU connector)

• Injector

• Engine ECU

• Injector harness

• ECU (ECU connector)

• Injector

• Engine ECU

• Injector harness

—

Light No Light P0204

No Light

Light No Light P0222

Light No Light P0223

Light P0217

No Light P0219 Engine overspeed condition

Fuel injector - disconnection (#4cyl)

Engine coolant over temperature condition

Intake throttle valve position sensor 2 - out of range (Out of range low)

Intake throttle valve position sensor 2 - out of range (Out of range high)

• ECU (ECU connector)

• Injector

• Engine ECU

• Injector harness

• Engine

• Cooling fan

• Fan clutch

• Engine coolant temperature sensor

• Engine oil level

• Engine speed main sensor

(Crankshaft position sensor)

• ECU (ECU connector)

• Wire harness

• Intake throttle valve position sensor 2

• ECU (ECU connector)

• Wire harness

• Intake throttle valve position sensor 2

• ECU (ECU connector)

• Wire harness

—

Light No Light P0234 Overboost

• Boost pressure sensor

• VNT controller

• EGR valve

—

ENGINE (J05E)/TROUBLESHOOTING 2–27

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P0237

Light No Light P0263 #1 Injection quantity and timing

Light No Light P0266 #2 Injection quantity and timing

Light No Light P0269 #3 Injection quantity and timing

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Boost pressure sensor - out of range (Out of range low)

• Boost pressure sensor

• ECU (ECU connector)

• Wire harness

• Fuel line

• Pre fuel filter

• Injector

• Engine speed main sensor

(Crankshaft position sensor)

• Fuel line

• Pre fuel filter

• Injector

• Engine speed main sensor

(Crankshaft position sensor)

• Fuel line

• Pre fuel filter

• Injector

• Engine speed main sensor

(Crankshaft position sensor)

—

Light No Light P026C

Light No Light P026D

Light No Light P0272 #4 Injection quantity and timing

Light No Light P0299 Underboost

Light No Light P0300 All injector (#1 – #4) Misfire

All injector (#1 – #4) Injection quantity and timing

• Fuel line

• Pre fuel filter

• Injector

• Engine speed main sensor

(Crankshaft position sensor)

• Fuel line

• Pre fuel filter

• Injector

• Engine speed main sensor

(Crankshaft position sensor)

• Fuel line

• Pre fuel filter

• Injector

• Engine speed main sensor

(Crankshaft position sensor)

• Boost pressure sensor

• Wire harness

• VNT controller

• EGR valve

• Fuel pipe

• Injector

—

Light No Light P0301 #1 Misfire

Light No Light P0302 #2 Misfire

• Fuel injection pipe

• Injector

• Fuel injection pipe

• Injector

—

ENGINE (J05E)/TROUBLESHOOTING2–28

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P0303 #3 Misfire

Light No Light P0304 #4 Misfire

Light Light P0335

Light No Light P0336

Light No Light P0340

Light No Light P0341

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Crankshaft position sensor

- disconnection

Crankshaft position sensor

- rationality

Camshaft position sensor

- disconnection

Camshaft position sensor - rationality

• Fuel injection pipe

• Injector

• Fuel injection pipe

• Injector

• Engine speed main sensor

(crankshaft position sensor)

• ECU (ECU connector)

• Wire harness

• Engine speed main sensor

(crankshaft position sensor)

• ECU (ECU connector)

• Wire harness

• Engine speed sub sensor

(camshaft position sensor)

• ECU (ECU connector)

• Wire harness

• Engine speed sub sensor

(camshaft position sensor)

• ECU (ECU connector)

• Wire harness

—

Light No Light P0381

Light No Light P0401 EGR low flow

Light No Light P0402 EGR high flow

Glow lamp (wait-to-start lamp)

- circuit

• Combination meter

• ECU (ECU connector)

• Wire harness

• Air cleaner element

• Air flow sensor

• Boost pressure sensor

• Intake air temperature sensor

(intake manifold)

• EGR valve

• EGR cooler

• SCV

• Injector

• EGR valve

• VNT controller

• Air cleaner element

• Air flow sensor

• Air intake system

• Boost pressure sensor

• Intake air temperature sensor

(intake manifold)

—

Light No Light P0404

Valve position control failure - DC motor out of range, functional (EGR valve stick failure)

• EGR valve A

ENGINE (J05E)/TROUBLESHOOTING 2–29

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P0405

Light No Light P0406

Light No Light P041B

Light No Light P041C

Light No Light P041D

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

EGR valve controller position sensor signal too low (EGR actuator position sensor signal too low)

Valve position sensor magnet lost (EGR actuator position sensor signal too high)

EGR gas temperature sensor

- rationality

EGR gas temperature sensor

- out of range (Out of range low)

EGR gas temperature sensor

- out of range (Out of range high)

• EGR valve A

• EGR cooler outlet temperature sensor

• ECU (ECU connector)

• Wire harness

• Intake air temperature sensor

(intake manifold)

• Intake air temperature sensor

(intercooler outlet)

• Boost pressure sensor

• EGR cooler outlet temperature sensor

• ECU (ECU connector)

• Wire harness

• EGR cooler outlet temperature sensor

• ECU (ECU connector)

• Wire harness

—

No Light

Light No Light P0421

Light No Light P0422 DOC deterioration

Light No Light P0489

Light No Light P0490

Light No Light P049D

Light No Light P04D5

Light No Light P04D6

No Light P0420

Tentative determination of ATC deterioration

Determination of ATC deterioration

EGR valve controller motor (open circuit) (EGR actuator motor open circuit)

EGR valve controller motor (short circuit) (EGR actuator motor short circuit)

Position failure (EGR actuator wiping fault)

Exhaust brake - circuit (Circuit low)

Exhaust brake - circuit (Circuit high)

——

• Fuel

• Exhaust gas temperature sensor

(DPF inlet)

• Fuel

• Exhaust gas temperature sensor

(DPF inlet)

• EGR valve A

• EGR valve

• EGR controller

• Exhaust brake magnetic valve

• Wire harness

• ECU (ECU connector)

• Exhaust brake magnetic valve

• Wire harness

• ECU (ECU connector)

—

ENGINE (J05E)/TROUBLESHOOTING2–30

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P04DA EGR feedback failure ——

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

• Combination meter

Light No Light P0500 Vehicle speed sensor - low

• Wire harness

—

• ECU (ECU connector)

• Combination meter

Light No Light P0501 Vehicle speed sensor - high

• Wire harness

—

• ECU (ECU connector)

• Brake switch

No Light

No Light P0504 Brake Switch Correlation

• Wire harness

—

• ECU (ECU connector)

Light No Light P0506 Idle speed abnormality (Low) ——

Light No Light P0507 Idle speed abnormality (High) ——

• Engine oil

No Light

Light P0521 Engine oil pressure rationality

• Oil pressure switch

• Wire harness

—

• ECU (ECU connector)

No Light

Light No Light P0545

Light No Light P0546

Light No Light P054E

Light No Light P054F

No Light

Light P0524 Engine oil pressure Too Low

Light P0562

Exhaust gas temperature sensor (DOC1 outlet)

- out of range (Out of range low)

Exhaust gas temperature sensor (DOC1 outlet)

- out of range (Out of range high)

Abnormality of injection rate during idling (Low)

Abnormality of injection rate during idling (High)

Battery voltage - out of range (Out of range low)

• Engine oil

• Oil pressure switch

• Wire harness

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DOC1 inlet)

• Wire harness

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DOC1 inlet)

• Wire harness

• ECU (ECU connector)

——

• Fuse

• Fusible link

• Battery cable

• Alternator

• Wire harness

• ECU (ECU connector)

—

ENGINE (J05E)/TROUBLESHOOTING 2–31

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

• Fuse

• Fusible link

No Light

Light P0563

Battery voltage - out of range (Out of range high)

• Battery cable

• Alternator

• Wire harness

• ECU (ECU connector)

• Air cleaner element

• Air intake system

• Air flow sensor

Light No Light P05F1

Crankcase ventilation system disconnection between the CV valve and the intake manifold

• Wire harness

• ECU (ECU connector)

• EGR valve

• Intake throttle valve

• Intercooler

Light No Light P0605 Flash ROM error — A

No Light

Light P0606 Control module processor ——

—

No Light

Light No Light P0611

Light No Light P0617 Starter key - rationality

Light No Light P0628

Light No Light P0629

Light No Light P062F

No Light

Light P0607 Control module performance — A

Light P0610 VIN data error ——

Fuel injector driver charge circuit

- circuit (circuit low)

Suction control valve for fuel supply pump - circuit (Circuit low)

Suction control valve for fuel supply pump - circuit (Circuit high)

Controller store data error (VNT actuator EEPROM error)

Light P0630

VIN Not Programmed or Mismatch

— A

• Starter key

• Wire harness

• ECU (ECU connector)

—

• Neutral start switch

• SCV

• Wire harness

—

• ECU (ECU connector)

• SCV

• Wire harness

• ECU (ECU connector)

• VNT controller A

• Vehicle control ECU. —

No Light

No Light P0642

ECU sensor power supply 1 failure (Out of range low)

• Wire harness

• ECU (ECU connector)

—

ENGINE (J05E)/TROUBLESHOOTING2–32

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

No Light

Light No Light P064C

No Light

SVS

Light

No Light P0643

No Light P0652

No Light P0653

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

ECU sensor power supply 1 failure (Out of range high)

Glow controller - Battery for glow plug open, GND short Glow controller - Over temperature

ECU sensor power supply 2 failure (Out of range low)

ECU sensor power supply 2 failure (Out of range high)

• Common rail pressure sensor 1

• Accelerator sensor 2

• Wire harness

• Boost pressure sensor

• Intake throttle valve position sensor

• Engine speed sub sensor

(camshaft position sensor)

• Wire harness

• ECU (ECU connector)

• Fuse

• Fusible link

• Glow control unit

• Wire harness

• ECU (ECU connector)

• Wire harness

• ECU (ECU connector)

• Common rail pressure sensor 2

• Wire harness

• Accelerator sensor 1

• DPR differential pressure sensor

• PTO accelerator sensor

• Aftertreatment fuel injection line pres-

sure sensor

• Wire harness

• ECU (ECU connector)

—

Light No Light P0671

Light No Light P0672

Light No Light P0673

Light No Light P0674

Glow plug (Circuit low) (#1cyl), Glow plug (Circuit high) (#1cyl)

Glow plug (Circuit low) (#2cyl), Glow plug (Circuit high) (#2cyl)

Glow plug (Circuit low) (#3cyl), Glow plug (Circuit high) (#3cyl)

Glow plug (Circuit low) (#4cyl), Glow plug (Circuit high) (#4cyl)

• Fusible link

• Glow control unit

• Wire harness

• Glow plug

• Fusible link

• Glow control unit

• Wire harness

• Glow plug

• Glow control unit

• Wire harness

• Glow plug

• Glow control unit

• Wire harness

• Glow plug

—

ENGINE (J05E)/TROUBLESHOOTING 2–33

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P0683

No Light

Light No Light P073D

No Light

SVS

Light

Light P0686

No Light P06D3

No Light P06D4

No Light P081A Starter Disable Circuit Low

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Glow controller - Battery for glow controller open, GND short Glow controller - Glow control signal Glow controller - Diagnosis signal

ECM/PCM Power Relay Control Circuit high

Air flow sensor power supply failure Short to GND

Air flow sensor power supply failure (High)

Transmission information (automatic transmission) - rationality

• Glow control unit

• Wire harness

—

• ECU (ECU connector)

• Main relay

• Wire harness

—

• ECU (ECU connector)

• Air flow sensor

• Wire harness

—

• ECU (ECU connector)

• Air flow sensor

• Wire harness

—

• ECU (ECU connector)

• Neutral switch —

• Starter cut relay

• Wire harness

—

• ECU (ECU connector)

No Light

Light No Light P0A7B HV BATTELY system failure ——

Light No Light P0AC4 HV system failure ——

Light No Light P0CA1 HV MOTOR system failure ——

No Light P081B Starter Disable Circuit High

• Wire harness

• ECU (ECU connector)

—

• PTO accelerator sensor

No Light

No Light P1133 PTO accelerator sensor (Hi)

• Wire harness

—

• ECU (ECU connector)

• Common rail pressure sensor

Light No Light P119F

Fuel rail pressure sensor - rationality

• Wire harness

—

• ECU (ECU connector)

• Differential pressure hose and pipe

Light No Light P1426

Differential pressure sensor rationality

• Differential pressure sensor

• Wire harness

—

• ECU (ECU connector)

• Differential pressure sensor

Light No Light P1427

Differential pressure sensor

- out of range (Out of range low)

• Wire harness

—

• ECU (ECU connector)

Light No Light P1428

Differential pressure sensor

- out of range (Out of range high)

• Differential pressure sensor

• Wire harness

• ECU (ECU connector)

—

ENGINE (J05E)/TROUBLESHOOTING2–34

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

No Light

Light No Light P1459

Light No Light P14B0

Light No Light P14B2

Light No Light P14B3

Light No Light P14B4

Light No Light P14B7

SVS

Light

No Light P1458

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Valve position control failure - DC motor out of range, functional (EGR actuator over temp warning level)

Controller high temperature (EGR actuator over temp severe level)

Controller store data error (EGR actuator abnormal information reading)

EGR controller power supply open circuit (EGR actuator power supply open circuit)

Battery voltage (high) (EGR actuator power supply too high)

Battery voltage (low) (EGR actuator power supply too low)

EGR valve controller temperature sensor 1 (Signal too low) (EGR actuator temp. sensor 1 signal too low)

• EGR valve A

EGR valve controller tempera-

Light No Light P14B8

Light No Light P14BC

Light No Light P14BD

Light No Light P14BF

Light No Light P1515 Charge air undercooling

ture sensor 1 (Signal too high) (EGR actuator temp. sensor 1 signal too high)

EGR valve controller temperature sensor 2 (Signal too low) (EGR actuator temp. sensor 2 signal too low)

EGR valve controller temperature sensor 2 (Signal too high) (EGR actuator temp. sensor 2 signal too high)

EGR valve controller temperature sensor 1, 2 - rationality (EGR actuator temp. sensor 1 performance invalid)

• EGR valve A

• Radiator curtain

• Air cleaner element

• Radiator fan

• Fan clutch

• Intercooler

• Intercooler tube

• Radiator

—

ENGINE (J05E)/TROUBLESHOOTING 2–35

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

No Light

Light No Light P1601

Light No Light P200C DPF over temperature

Light No Light P2032

Light No Light P2033

SVS

Light

No Light P1530 Engine stop switch malfunction

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Fuel injector adjustment data error

Exhaust gas temperature sensor (DOC2 inlet)

- out of range (Out of range low)

Exhaust gas temperature sensor (DOC2 inlet)

- out of range (Out of range high)

• Engine stop switch

• Wire harness

—

• ECU (ECU connector)

• Injector —

• Exhaust pipe

• Injector

• Engine

• Exhaust gas temperature sensor

(DPF inlet)

—

• Exhaust gas temperature sensor

(DPF outlet)

• Exhaust gas temperature sensor

(DOC2 inlet)

• Wire harness

—

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DOC2 inlet)

• Wire harness

—

• ECU (ECU connector)

No Light

Light or No Light

Light No Light P207F Improper reductant

Light No Light P2080

Light No Light P2084

No Light P203F Empty reductant tank

No Light or Light

P204F Reductant System Performance ——

Exhaust gas temperature sensor (DOC1outlet) - rationality

Exhaust gas temperature sensor (DOC2 inlet) - rationality

• DEF tank

• DEF tank level sensor

• DEF

• Engine

• Air flow sensor

• Exhaust gas temperature sensor

(SCR inlet)

• DEF pipe

• DEF injector

• NOx sensor

• SCR catalyst

• Exhaust gas temperature sensor

(DOC1 inlet)

• Wire harness

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DOC2 inlet)

• Wire harness

• ECU (ECU connector)

—

ENGINE (J05E)/TROUBLESHOOTING2–36

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P20CD

Light No Light P20CE

No Light

Light No Light P20D8

Light No Light P20DE

Light No Light P20DF

Light No Light P20E0

SVS

Light

Light P20CF

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Malfunction of fuel addition valve [Short-circuit]

Malfunction of fuel addition valve [+B short-circuit]

Malfunction of fuel addition valve [Leak] (Continuous injection)

Exhaust Fuel Doser open/close stuck

Aftertreatment Fuel Injection Line Pressure Sensor Performance Invalid

Aftertreatment Fuel Injection Line Pressure Sensor Signal Too Low

Aftertreatment Fuel Injection Line Pressure Sensor Signal Too High

• Fuel dosing valve

• Wire harness

—

• ECU (ECU connector)

• Fuel dosing valve —

——

• Fuel pipe (for aftertreatment)

• Fuel dosing valve

• Aftertreatment fuel pressure sensor

• Fuel pipe (for aftertreatment)

—

• Aftertreatment fuel injection line pres-

sure sensor

• Wire harness

—

• ECU (ECU connector)

• Aftertreatment fuel injection line pres-

sure sensor

• Wire harness

—

• ECU (ECU connector)

Light No Light P20EE

Light No Light P2100

Light No Light P2101 Intake throttle valve - functional

Light No Light P2103

NOx converting catalyst conversion efficiency

DC motor for intake throttle valve

- circuit (Open circuit (circuit low))

DC motor for intake throttle valve

- circuit (Short circuit (circuit high))

• DEF solution

• Engine

• Air flow sensor

• Exhaust gas temperature sensor

(SCR inlet)

• DEF pipe

• DEF injector

• Exhaust pipe

• NOx sensor

• SCR catalyst

• Diesel throttle

• Wire harness

• ECU (ECU connector)

• Air cleaner element

• Air hose

• Air pipe

• Exhaust muffler (exhaust pipe)

• Exhaust brake valve

• Diesel throttle

• Wire harness

• ECU (ECU connector)

—

ENGINE (J05E)/TROUBLESHOOTING 2–37

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

No Light

Light No Light P2122

Light No Light P2123

Light No Light P2127

Light No Light P2128

Light No Light P2135

SVS

Light

Light P2120

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Throttle/Pedal Position Sensor/ Switch "D" Circuit

Accelerator pedal position sensor 1

- out of range (Out of range low)

Accelerator pedal position sensor 1

- out of range (Out of range high)

Accelerator pedal position sensor 2

- out of range (Out of range low)

Accelerator pedal position sensor 2

- out of range (Out of range high)

Intake throttle valve position sensor

- rationality

——

• Accelerator sensor

• Wire harness

• ECU (ECU connector)

• Accelerator sensor

• Wire harness

• ECU (ECU connector)

• Accelerator sensor

• Wire harness

• ECU (ECU connector)

• Accelerator sensor

• Wire harness

• ECU (ECU connector)

• Intake throttle valve position sensor

• Wire harness

• ECU (ECU connector)

—

Light No Light P2138

Light No Light P2146

Light No Light P2147

Light No Light P2148

Light No Light P2149

Light No Light P2150

Light No Light P2151

Light No Light P2184

Accelerator pedal position sensor

- rationality

Fuel injector driver circuit 1

- circuit (circuit open)

Fuel injector driver circuit 1

- circuit (circuit low)

Fuel injector driver circuit 1

- circuit (circuit high)

Fuel injector driver circuit 2

- circuit (circuit open)

Fuel injector driver circuit 2

- circuit (circuit low)

Fuel injector driver circuit 2

- circuit (circuit high)

Engine coolant temperature sensor 2 - out of range (Out of range low)

• PTO accelerator sensor

• Accelerator sensor

• ECU (ECU connector)

• Injector

• Wire harness

• ECU (ECU connector)

• Injector

• Wire harness

• Injector

• Wire harness

• Injector

• Wire harness

• ECU (ECU connector)

• Injector

• Wire harness

• Injector

• Wire harness

• Engine coolant temperature sensor 2

• Wire harness

• ECU (ECU connector)

—

Light No Light P2185

Engine coolant temperature sensor 2 - out of range (Out of range high)

• Engine coolant temperature sensor 2

• Wire harness

• ECU (ECU connector)

—

ENGINE (J05E)/TROUBLESHOOTING2–38

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P2214

Light No Light P2227

Light No Light P2228

Light No Light P2229

No Light

SVS

Light

No Light P2269 Water in Fuel Condition

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

NOx sensor (SCR downstream)

- Performance and Monitoring capability

Barometric pressure sensor

- rationality

Barometric pressure sensor

- out of range (out of range low)

Barometric pressure sensor

- out of range (out of range high)

• DEF

• Exhaust pipe

• Air flow sensor

• Exhaust gas temperature sensor

(SCR inlet)

• Exhaust temperature sensor

(DPF outlet)

—

• Ambient air temperature sensor

• DEF injector

• NOx sensor

• Boost pressure sensor —

— A

• Fuel filter

• Fuel filter water level sensor

• Wire harness

—

• ECU (ECU connector)

Light No Light P226C Boost pressure slow response

Light No Light P22D3 Nozzle stuck (VNT stick failure)

Light No Light P240F EGR flow slow response

No Light

No Light P2428 Improper ATC temperature

• VNT controller

• EGR valve

• Air cleaner

• Air intake system

• Boost pressure sensor

• VNT actuator

• VNT controller A

• EGR valve

• VNT controller

• Air cleaner element

• Air flow sensor

• Intake system

• Boost pressure sensor

• Intake manifold temperature sensor

• Injector

• Pipe

• Hose

• AT C

• DPR

—

ENGINE (J05E)/TROUBLESHOOTING 2–39

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P242B

Light No Light P242C

Light No Light P242D

Light No Light P244A

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Exhaust gas temperature sensor (DOC inlet) - rationality

Exhaust gas temperature sensor (DOC inlet)

- out of range (Out of range low)

Exhaust gas temperature sensor (DOC inlet)

- out of range (Out of range high)

Filtering performance (missing substrate)

• Exhaust gas temperature sensor

(DPF inlet)

• Wire harness

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DPF inlet)

• Wire harness

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DPF inlet)

• Wire harness

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DPF inlet)

• Differential pressure sensor

• DPR filter

• Exhaust gas temperature sensor

(DPF outlet)

• EGR valve

• VNT controller

• Diesel throttle valve

• SCV

• Injector

—

Light No Light P244B Incomplete regeneration

Light No Light P2457 EGR cooler performance

• DPR

• Differential pressure sensor

• Engine

• Exhaust gas temperature sensor

(DPF inlet)

• Exhaust gas temperature sensor

(DPF outlet)

• DPF indicator light

• DPR switch

• Neutral switch

• Accelerator switch

• PTO signal

• External accelerator signal

• Injector

• EGR cooler outlet gas temperature

sensor

• EGR cooler

• EGR valve

• Diesel throttle valve

• SCV

• Injector

—

ENGINE (J05E)/TROUBLESHOOTING2–40

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

SVS

Light

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

• Exhaust pipe

• Exhaust brake valve

• Exhaust gas temperature sensor

No Light

Light P2458 DPR manual regeneration failure

(DPF inlet)

• Exhaust gas temperature sensor

(DOC1 inlet)

—

• DPR

• Coolant temperature sensor

• Engine

Light No Light P2459 Frequent regeneration ——

• DPF indicator light

• DPR switch

Light No Light P2463 DPF clogged

• Neutral switch

• Accelerator switch

• PTO signal

• External accelerator signal

• Exhaust gas temperature sensor

Light No Light P246F

Exhaust gas temperature sensor (DOC outlet) - rationality

(DPF outlet)

• Wire harness

—

• ECU (ECU connector)

Exhaust gas temperature sensor

Light No Light P2470

Light No Light P2471

Light No Light P24A0

Light No Light P24A1

Light No Light P24A2 Excessive DPR fuel addition rate

(DOC outlet)

- out of range (Out of range low)

Exhaust gas temperature sensor (DOC outlet)

- out of range (Out of range high)

Closed Loop DPF Regeneration Control At Limit

- Temperature Too Low

Closed Loop DPF Regeneration Control At Limit

- Temperature Too High

• Exhaust gas temperature sensor

(DPF outlet)

• Wire harness

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DPF outlet)

• Wire harness

• ECU (ECU connector)

• Exhaust gas temperature sensor

(DPF inlet)

——

• Engine oil

• Exhaust pipe

• Injector

• Exhaust brake valve

• EGR valve

• VNT controller

• Exhaust gas temperature sensor

(DPF inlet)

• DPR

—

ENGINE (J05E)/TROUBLESHOOTING 2–41

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light P2562

Light No Light P259E

Light No Light P259F

No Light

SVS

Light

No Light P2635

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Nozzle position sensor failure range (High level) (VNT actuator position sensor performance invalid)

Nozzle operating range failure NARROW (VNT actuator wiping error (too narrow range))

Nozzle operating range failure WIDE (VNT actuator wiping error (too wide range))

Fuel Pump Low Flow/Performance

• VNT controller

• VNT actuator

• VNT controller

• Turbocharger

• VNT controller A

• Engine

• Supply pump

• Pre fuel filter

• Engine ECU

• Fuel hose

• Fuel tank breather

• Fuel tank feed pipe

• Supply pump gauze filter

• Fuel high-pressure pipe

• Fuel filter

• SCV

• Common rail pressure sensor

• Engine speed main sensor

(crankshaft position sensor)

• Fuel return pipe and hose

• Fuel pipe

—

Light No Light P268A

Light No Light P2696

Light No Light P26C8 Vehicle system failure ——

Fuel injector adjustment data error

• Injector —

• DEF

No Light

No Light P2BA9 Insufficient Reagent Quality

• DEF tank

–

• DEF quality sensor

Engine ECU CAN communica-

Light No Light U0073

Light No Light U010A

tion bus for Emission control system - bus off

Engine ECU CAN communication (EGR valve control)

• Connector

• Wire harness

• EGR controller

— A

• Connector

Light No Light U010C

VNT actuator CAN communication error

• Wire harness

• VNT controller

ENGINE (J05E)/TROUBLESHOOTING2–42

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

MIL

Light No Light U010E

Light No Light U0293 CAN Bus-Line Open From HV

Light No Light U029D

Light No Light U029E

Light No Light U02A2

No Light

SVS

Light

No Light U0301

DTC

No.

DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM

Engine ECU CAN communication (DeNOx ECU)

Engine ECU CAN communication (NOx sensor (SCR upstream))

Engine ECU CAN communication (NOx sensor (SCR downstream))

Engine ECU CAN communication (DEF tank sensor)

Software Incompatibility With DeNOx ECU

• Connector

• Wire harness

• DCU

• Connector

• Wire harness

• HV system

• Connector

• NOx sensor 1

• Wire harness

• Connector

• NOx sensor 2

• Wire harness

• Connector

• DEF sensor

• Wire harness

—

——

• Connector

• Wire harness

• Vehicle control ECU

• Connector

• Wire harness

• Vehicle control ECU

—

Light No Light U1001

Light or No Light

NOTICE

No Light U110A

Engine ECU CAN communication bus for Vehicle control - bus off

Engine ECU CAN communication (Vehicle ECU)

• It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service

replacement. In addition, the ECU has a function enabling it to learn the performance of the supply pump at the time of ECU service replacement, so ensure sufficient time (several minutes) is available.

• When an injector is newly installed in a vehicle, it is necessary to enter the ID codes in the engine ECU using

the Diagnostic tool.

ENGINE (J05E)/TROUBLESHOOTING 2–43

GROUP SHARING THE SENSOR SUPPLY TERMINAL

EN01H02127030602016009

• If one of the sensor power supplies fails, more than one malfunction codes will occur for the sensors sharing the sensor

supply terminal. Check the sensors for short circuits and whether the sensor supply circuit is in normal condition.

ECU terminal Sensor DTC

Intake throttle valve position sensor 1 P0122

E33

V71

• If P0642 or P0652 has also occurred, the sensor supply of the ECU may be in abnormal condition or the GND may be

shorted somewhere in the following sensor group.

Group Sensor DTC

P0642

Common rail pressure sensor (Main) P0193

Boost pressure sensor P0237

PTO accelerator sensor —

Differential pressure sensor P1428

Accelerator pedal position sensor 1 P2122

P1198

Common rail pressure sensor (Sub)

P1197

P1428

Differential pressure sensor

P1427

P0652

PTO accelerator sensor P1133

Boost pressure sensor P0237

P0193

Common rail pressure sensor

P0192

Intake throttle valve position sensor 1 P0122

Accelerator pedal position sensor 1 P2127

Camshaft position sensor P0016

ENGINE (J05E)/TROUBLESHOOTING2–44

GROUP SHARING THE SENSOR GND TERMINAL

ECU terminal Sensor

Fuel temperature sensor

E76

E77 Boost sensor

E58

V46

V45

Intake air temperature sensor (intake manifold)

Common rail pressure sensor (Main)

Exhaust gas temperature sensor 1

Engine coolant temperature sensor

Intake air temperature sensor

Exhaust gas temperature sensor 2

Exhaust gas temperature sensor 3

Exhaust gas temperature sensor 4

Differential pressure sensor

Accelerator sensor 1

PTO accelerator sensor

EN01H02127030602016010

E57 Intake throttle valve position sensor 1

E56 Common rail pressure sensor (Sub)

E65 Accelerator sensor 2

ENGINE (J05E)/TROUBLESHOOTING 2–45

CAN-TMN2

(Terminator)

Engine

ECU

NOx

Sensor 2

NOx

Sensor 1

DEF

sensor

Engine peripherals/ Diesel aftertreatment system CAN line

VNT

Controller

EGR

Controller

DCU

(Terminator)

6 8 910 11

21 3 54

J/C_ENG_CAN J/C_DEF_SensorJ/C_CAN_DieselJ/C_ENG_CAN2

CAN-TMN2

(Terminator)

Engine

ECU

DEF

sensor

Engine peripherals/ Diesel aftertreatment system CAN line

VNT

Controller

EGR

Controller

DCU

(Terminator)

6 8 9 121110

21 5

J/C_ENG_CAN J/C_DEF_Sensor

NOx

Sensor 2

J/C_HV2

NOx

Sensor 1

J/C_HV1J/C_ENG_CAN2

SHTS021270300025

MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION

EN01H02127030602016011

Since the CAN communication line is configured as described below, more than one malfunction code may occur depending on the faulty area of the circuit.

For single failure

• The system itself is suspected of being faulty due to the broken harness or connector or supply circuit failure of the CAN

communication circuit for each actuator and controller.

ENGINE EQUIPMENT/EMISSION CONTROL DEVICE CAN LINE (250 k)

ENGINE (J05E)/TROUBLESHOOTING2–46

CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ENGINE ECU)

Malfunction Part Case

1 U010A

2 U010C

3 U029E

4 U029D

5 U02A2

6-12 U010A, U010C, U029D, U029E, U0073, U010E, U02A2

CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (DCU)

Malfunction Part Case

3 U029E

4 U029D

5 U02A2

6-12 U029D, U029E, U0029, U0100

ENGINE (J05E)/TROUBLESHOOTING 2–47

CAN-TMN2

(Terminator)

Engine control/ Diagnosis CAN Line

DCU

(Terminator)

VCS ECU

J/C_CAN2

Engine

ECU

J/C_CAN5

6 7 8

Engine control/ Diagnosis CAN Line

CAN-TMN2

(Terminator)

DCU

(Terminator)

VCS ECU

J/C_CAN2

Engine

ECU

J/C_CAN5

6 7 8

CAN-TMN2

(Terminator)

DCU

(Terminator)

VCS ECU

J/C_CAN2

Engine

ECU

J/C_CAN5

ABS ECU

J/C_CAN1 (10P)

6 7

ATM ECUDLC

J/C_CAN2 (22P)

J/C_CAN1 (10P)J/C_CAN1 (10P)

ABS ECU

J/C_CAN2 (22P)

ATM ECUDLC

SHTS021270300026

ENGINE CONTROL/DIAGNOSIS CAN LINE (500 k)

CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (ENGINE ECU)

Malfunction Part Case

4, 5, 6, 7, 8 U0293, U1001, U110A, Communication failure of the HINO DX Ⅱ

CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE (DCU)

Malfunction Part Case

4, 5, 6, 7, 8 U0038, Communication failure of the HINO DX Ⅱ

1, 3 Communication failure of the HINO DX Ⅱ

2 U1001, U110A Failure to communicate the VCU

1 Communication failure of the HINO DX Ⅱ

ENGINE (J05E)/TROUBLESHOOTING2–48

NOYES

SHTS021270300027

PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)

EN01H02127030602016012

Check the DTC detected [HINO DX Ⅱ ]

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

2. Connect the vehicle to HINO DX Ⅱ .

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

4. Check that the any DTC other than CAN communication system DTC (U****) has been detected.

Has a DTC other than CAN communication system DTC (U****) been detected?

Go to diagnosis procedure of a related DTC. Go to step 2.

ENGINE (J05E)/TROUBLESHOOTING 2–49

NOYES

TE1B LF2

TE1A LF1

TE2B LF4

TE2A LF3

ISGW

LES

CAH0 LEY

CAH1

LF5

GND1

LET

+24V

K9G

CAN-

KS4TCKS2

DSW

KPZ

ISOK

K9E

CAN+

KS3

SGND

K9H

CGFR

L30

KE4

GND4

LEW

+B2 LEP

GND2

LEU

GND5

LEX

+B3 LEQ

GND3

LEV

+B1 LEN

+B4 LER

CAL1

LF6

CAL0

LEZ

SHTS021270300028

Check for +B/GND short-circuit in CAN H-line

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

2. Disconnect the following sensors and controllers connected to the Engine peripherals and after-treatment CAN line.

• DCU(53P)

• EGR controller, VNT controller

• NOx sensors 1 and 2, DEF sensor

• CAN-TMN2 (terminating resistance)

3. Use the electrical tester to check the continuity between the following terminals. (1) Between the CAH0 terminal in the DCU (53P) vehicle side

connector and the 16th terminal in the DLC (16P).

(2) Between the CAH0 terminal in the DCU (53P) vehicle side

connector and the 4th terminal in the DLC (16P).

Measurement

conditions

Tester

connections

Standard values

DCU vehicle-side connector –

Starter key: LOCK

Diagnostic connector

No Continuity

CAH0 – 16th CAH0 – 4th

Do the measurements meet the standard value?

Go to step 3. Refer to "DISCONNECTION INSPECTION

FOR ENGINE CAN_H COMMUNICATION L LINE (250 k)" and check the CAN bus line.

ENGINE (J05E)/TROUBLESHOOTING2–50

NOYES

TE1B LF2

TE1A LF1

TE2B LF4

TE2A LF3

ISGW

LES

CAH0 LEY

CAH1

LF5

GND1

LET

+24V

K9G

CAN-

KS4TCKS2

DSW

KPZ

ISOK

K9E

CAN+

KS3

SGND

K9H

CGFR

L30

KE4

GND4

LEW

+B2 LEP

GND2

LEU

GND5

LEX

+B3 LEQ

GND3

LEV

+B1 LEN

+B4 LER

CAL1

LF6

CAL0

LEZ

SHTS021270300029

Check for +B/GND short-circuit in CAN L-line

1. Use the electrical tester to check the continuity between the following terminals.

(1) Between the CAL0 terminal in the DCU (53P) vehicle side

connector and the 16th terminal in the DLC(16P).

(2) Between the CAL0 terminal in the DCU (53P) vehicle side

connector and the 4th terminal in the DLC(16P).

Measurement

conditions

Tester

connections

Standard values

DCU vehicle-side connector –

Starter key: LOCK

Diagnostic connector

No Continuity

CAL0 – 16th CAL0 – 4th

Do the measurements meet the standard value?

Go to step 4. Refer to "DISCONNECTION INSPECTION

FOR ENGINE CAN_H COMMUNICATION L LINE (250 k)" and check the CAN bus line.

NOYES

Check the terminating resistance

CAH1

LF5

CAL1

LF6

CAH0

LEY

CAL0

LEZ

GND1

LET

GND4

LEW

+B2 LEP

GND2

LEU

GND5

LEX

+B3 LEQ

GND3

LEV

+B1 LEN

+B4 LER

TE1B

LF2

TE1A

LF1

TE2B

LF4

TE2A

LF3

ISGW

LES

CAL0

CANNCANP

CAH0

SHTS021270300030

ENGINE (J05E)/TROUBLESHOOTING 2–51

1. Use the electrical tester to check the continuity between the following terminals. (1) Between the CAH0 terminal and CAL0 terminal in the DCU

(53P).

(2) Between the CANP terminal and CANN terminal in CAN-

TMN2.

Measurement

conditions

Starter key: ON

Do the measurements meet the standard value?

Tester

connections

DCU (53P): CAH0 – CAL0 CAN-TMN2: CANP – CANN

Standard values

120  10 

Go to step 5. Replace the faulty part.

After replacing the part, confirm that no CAN communication system DTC is detected. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

NOYES

Check the resistance

CAL0

CAH0

SHTS021270300031

ENGINE (J05E)/TROUBLESHOOTING2–52

1. Use the electrical tester to check the continuity between the following terminals. (1) Between the CAH0 terminal and CAL0 terminal in the DCU

(53P).

ISGW

LES

TE2A

LF3

TE2B

LF4

TE1A

LF1

TE1B

LF2

CAH0

LEY

CAL0

LEZ

CAL1

LF6

CAH1

LF5

GND3

+B1

+B4

LEV

LEN

LER

GND2

GND5

+B3

LEU

LEX

LEQ

GND1

GND4

+B2

LET

LEW

LEP

Measurement

conditions

Starter key: ON

Tester

connections

DCU (53P): CAH0 – CAL0

Standard values

45 – 75 

Do the measurements meet the standard value?

Procedure completed. CAN bus line (main line and trunk lines) between terminating resistances is normal. Go to the diagnostic procedure for the detected DTC.

Refer to "DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L LINE (250 k)" and check the CAN bus line.

ENGINE (J05E)/TROUBLESHOOTING 2–53

NOYES

SHTS021270300032

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L

LINE (250 k) [DIESEL]

Check harness in CAN bus line between J/C DEF SSR and DCU (Failure Site 11)

EN01H02127030602016013

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

2. Disconnect the following sensors and controllers connected to the Engine peripherals and aftertreatment CAN line. (Leave the DCU, engine ECU, and CAN-TMN2 connected.)

• EGR controller, VNT controller

• NOx sensor 1 and 2, DEF sensor

3. Disconnect the J/C DEF SSR connector.

4. Use electrical tester to measure the resistance between No.5 (CANH) terminal and No.10 (CANL) terminal at the J/C DEF SSR connector.

Measurement

conditions

Starter key: LOCK

Tester

connections

J/C DEF SSR connector No.5 (CANH) – No.10 (CANL)

Standard values

110 – 130 

Do the measurements meet the standard value?

Connect the J/C DEF SSR connector, and go to step 2.

CAN bus line disconnection between J/C DEF SSR and the DCU Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING2–54

YES

SHTS021270300033

Check harness in CAN bus line between J/C_CAN_Diesel and J/C DEF SSR (Failure Site 10)

1. Disconnect the J/C_CAN_Diesel connector.

2. Use electrical tester to measure the resistance between No.5 (CANH) terminal and No.8 (CANL) terminal at the J/ C_CAN_Diesel connector.

Measurement

conditions

Starter key: LOCK

Do the measurements meet the standard value?

Connect the J/C_CAN_Diesel connector, and go to step 3.

Tester

connections

J/C_CAN_Diesel connector No.5 (CANH) – No.8 (CANL)

Standard values

110 – 130 

CAN bus line disconnection between J/ C_CAN_Diesel and the J/C DEF SSR Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING 2–55

YES

SHTS021270300034

Check harness in CAN bus line between J/C_ENG_CAN and J/C_CAN_Diesel (Failure Site 9)

1. Disconnect the J/C_ENG_CAN connector.

2. Use electrical tester to measure the resistance between No.6 (CANH) terminal and No.8 (CANL) terminal at the J/C_ENG_CAN connector.

Measurement

conditions

Starter key: LOCK

Do the measurements meet the standard value?

Connect the J/C_ENG_CAN connector, and go to step 4.

Tester

connections

J/C_ENG_CAN connector No.6 (CANH) – No.8 (CANL)

Standard values

110 – 130 

CAN bus line disconnection between J/ C_ENG_CAN and the J/C_CAN_Diesel Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING2–56

YES

%KG

%KE

%KH2%KF

%KM

%KL

SHTS021270300035

Check harness in CAN bus line between J/C_ENG_CAN2 and J/C_ENG_CAN (Failure Site 8)

1. Disconnect the J/C_ENG_CAN2 connector.

2. Use electrical tester to measure the resistance between No.5 (CANH) terminal and No.8 (CANL) terminal at the J/ C_ENG_CAN2 connector.

Measurement

conditions

Starter key: LOCK

Do the measurements meet the standard value?

Connect the J/C_ENG_CAN2 connector, and go to step 5.

Tester

connections

Standard values

J/C_ENG_CAN2 connector No.5 (CANH) –

110 – 130 

No.8 (CANL)

CAN bus line disconnection between J/ C_ENG_CAN2 and the J/C_ENG_CAN Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING 2–57

NOYES

E79

E59

SHTS021270300036

Check harness in CAN bus line between engine ECU and J/C_ENG_CAN2 (Failure Site 7)

1. Disconnect the engine ECU connector (both 2 connectors).

2. Connect the signal check harness to the engine ECU vehicle-side connector. (Do not connect harness to the ECU)

3. Use electrical tester to measure the resistance between (CANH) terminal and (CANL) terminal at the ECU check harness. These circuits are identified as terminal E59 and terminal E79 on the ECU check harness D.

Measurement

conditions

Starter key: LOCK

Tester

connections

Signal check harness (Engine ECU) E59 (CANH) – E79 (CANL)

Standard values

110 – 130 

Do the measurements meet the standard value?

Go to step 6. CAN bus line disconnection between engine

ECU and J/C_ENG_CAN2 Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING2–58

NOYES

V37

V17

SHTS021270300037

Check harness in CAN bus line between engine ECU and CAN-TMN2 (terminating resistance)

(Failure Site 6)

1. Use electrical tester to measure the resistance between (CANN) terminal and (CANH) terminal at the ECU check harness. These circuits are identified as terminal V17 and terminal V37 on the ECU check harness A.

Measurement

conditions

Starter key: LOCK

Do the measurements meet the standard value?

Disconnect ECU Check Harness. Go to step 7.

Tester

connections

Signal check harness (Engine ECU) V17 (CANN) – V37 (CANP)

Standard values

110 – 130 

CAN bus line disconnection between engine ECU and CAN-TMN2 (terminating resistance) Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING 2–59

NOYES

SHTS021270300038

Inspect the EGR controller [HINO DX Ⅱ ]

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

2. Connect the connector of the engine ECU.

3. Connect the vehicle to HINO DX Ⅱ .

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

5. Erase the malfunction history and set the starter key to the "LOCK" position.

6. Connect the EGR controller connector.

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

8. Check that the EGR controller communication failure (U010A) is not detected.

Did the EGR controller communication failure (U010A) disappear?

Go to step 8. Replace the EGR controller.

Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING2–60

NOYES

SHTS021270300039

SHTS021270300040

Inspect the VNT controller [HINO DX Ⅱ ]

1. Erase the trouble history and set the starter key to the "LOCK" position.

2. Connect the VNT controller connector.

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

4. Check that the VNT controller communication failure (U010C) is not detected.

Did the VNT controller communication failure (U010C) disappear?

Go to step 9. Replace the VNT controller.

Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

NOx sensor 1 [HINO DX Ⅱ ]

1. Erase the trouble history and set the starter key to the "LOCK" position.

2. Connect the NOx sensor 1 connector.

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

4. Check that the NOx sensor 1 communication failure (U029D) is not detected.

Did the NOx sensor 1 communication failure (U029D) disappear?

Go to step 10. Replace the NOx sensor 1.

Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING 2–61

NOYES

SHTS021270300041

SHTS021270300042

Inspect the NOx sensor 2 [HINO DX Ⅱ ]

1. Erase the trouble history and set the starter key to the "LOCK" position.

2. Connect the NOx sensor 2 connector.

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

4. Check that the NOx sensor 2 communication failure (U029E) is not detected.

Did the NOx sensor 2 communication failure (U029E) disappear?

Go to step 11. Replace the NOx sensor 2.

Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

Check the DEF sensor [HINO DX Ⅱ ]

1. Erase the trouble history and set the starter key to the "LOCK" position.

2. Disconnect the DEF sensor connector.

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

4. Check that the DEF sensor communication failure (U02A2) is not detected.

Did the DEF sensor communication failure (U02A2) disappear?

Procedure completed. If another CAN communication system DTC is detected, go to the diagnostic procedure for the detected DTC.

Replace the DEF sensor. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test

drive.) Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING2–62

NOYES

SHTS021270300043

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L

LINE (250 k) [HYBRID]

Check harness in CAN bus line between J/C DEF SSR and DCU (Failure Site 12)

EN01H02127030602016014

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

2. Disconnect the following sensors and controllers connected to the Engine peripherals and after-treatment CAN line. (Leave the DCU, engine ECU, and CAN-TMN2 connected.)

• EGR controller, VNT controller

• NOx sensor 1 and 2, DEF sensor

3. Disconnect the J/C DEF SSR connector.

4. Use electrical tester to measure the resistance between No.5 (CANH) terminal and No.10 (CANL) terminal at the J/C DEF SSR connector.

Measurement

conditions

Starter key: LOCK

Tester

connections

J/C DEF SSR connector No.5 (CANH) – No.10 (CANL)

Standard values

110 – 130 

Do the measurements meet the standard value?

Connect the J/C DEF SSR connector, and go to step 2.

CAN bus line disconnection between J/C DEF SSR and the DCU Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING 2–63

YES

SHTS021270300044

Check harness in CAN bus line between J/C_HV1 and J/C DEF SSR (Failure Site 11)

1. Disconnect the J/C_HV1 connector.

2. Use electrical tester to measure the resistance between No.4 (CANH) terminal and No.9 (CANL) terminal at the J/C_HV1 connector.

Measurement

conditions

Starter key: LOCK

Do the measurements meet the standard value?

Connect the J/C_HV1 connector, and go to step 3.

Tester

connections

J/C_HV1 connector No.4 (CANH) – No.9 (CANL)

Standard values

110 – 130 

CAN bus line disconnection between J/ C_HV1 and the J/C DEF SSR Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

ENGINE (J05E)/TROUBLESHOOTING2–64

YES

SHTS021270300045

Check harness in CAN bus line between J/C_HV2 and J/C_HV1 (Failure Site 10)

1. Disconnect the J/C_HV2 connector.

2. Use electrical tester to measure the resistance between No.3 (CANH) terminal and No.8 (CANL) terminal at the J/C_HV2 connector.

Measurement

conditions

Starter key: LOCK

Do the measurements meet the standard value?

Connect the J/C_HV2 connector, and go to step 4.

Tester

connections

J/C_HV2 connector No.3 (CANH) – No.8 (CANL)

Standard values

110 – 130 

CAN bus line disconnection between J/ C_HV2 and the J/C_HV1 Repair or replace the harness. Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test drive.)

Hino Motors HINO 155, HINO 195h, HINO 155h, HINO 195 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

GENERAL INTRODUCTION

HOW TO IDENTIFY VEHICLE TYPE

HOW TO IDENTIFY VEHICLE TYPE

VEHICLE TYPE

VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE

APPEARANCE OF VEHICLE

APPEARANCE

APPEARANCE OF VEHICLE

SAFETY INSTRUCTIONS AND READINESS TO WORK

WARNING

GENERAL PRECAUTIONS

IDENTIFICATION INFORMATION

SAFETY INSTRUCTIONS FOR WORK

PRECAUTIONS

INTRODUCTION TO WORKSHOP MANUAL

GENERAL

INTRODUCTION TO DESCRIPTIONS

DEFINITION OF TERM

TROUBLE SHOOTING

TROUBLESHOOTING WITH DIAGNOSIS MONITOR

TROUBLESHOOTING PROCEDURE

APPARATUS FOR TROUBLE SHOOTING

TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DX Ⅱ )

STEP OF TROUBLE DIAGNOSIS

APPARATUS FOR TROUBLE DIAGNOSIS

GLOSSARY

DEFINITION OF ABBREVIATION

LIST OF ABBREVIATION

GLOSSARY OF SAE AND HINO TERMS

ENGINE (J05E)

TROUBLESHOOTING

ENGINE ECU (J05E)

PRECAUTIONS FOR DIAGNOSIS

ELECTRICAL

PRECAUTIONS

COMPUTER (ECU) PIN ASSIGNMENT

ENGINE ECU CONNECTOR

INSPECTION

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

GROUP SHARING THE SENSOR SUPPLY TERMINAL

GROUP SHARING THE SENSOR GND TERMINAL

MALFUNCTION CODES IN CASE OF DISRUPTION OF CAN COMMUNICATION

PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)