Hino 195h Series Workshop Manual
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Hino 195h Series Workshop Manual

Hino trucks equipped with j05e engine
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Table of Contents

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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 sys-
tems in these vehicles.
Chassis Workshop Manual
J05E Engine Workshop Manual
Trouble shooting Workshop Manual
MENU
FOREWORD
'
s Manual.
Manual Name
Pub. No.
S1-LXJE03A
S1-LXJE03A EWD
S5-LJ05E04A
S7-LXJE03C 1/7
S7-LXJE03C 2/7
S7-LXJE03C 3/7
S7-LXJE03C 5/7
S7-LXJE03C 6/7
S7-LXJE03C 7/7

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Summary of Contents for Hino 195h Series

  • Page 1 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 sys- tems in these vehicles.
  • Page 2 CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. MANUAL No. S7-LXJE03C 4/7 (U.S.A.), S7-LXJE04C 4/7 (CANADA) MODELS HINO 155, 155h, 195, 195h CHAPTER Production Code XFC710, XFC720, XFC740, XJC700, XJC710, XJC720, XJC740 HYBRID...
  • Page 3 BODY CONSTRUCTION BODY INSIDE ACCESSORY BODY OUTSIDE ACCESSORY AIR BAG AND SEAT BELT All rights reserved. This manual may not be reproduced or copied in whole in part, with- HEATER AND AIR CONDITIONER out the written consent of Hino Motors, Ltd.
  • Page 4 INDEX: TROUBLE SHOOTING GROUP 2/2 ELECTRICAL CONTROL SYSTEM...

  • Page 5: Table Of Contents

    HYBRID 3–1 HYBRID 3-001 TROUBLE SHOOTING ........3-4 DTC: P3001 (TC44) ..........3-249 DTC: P3001 (TC45) ..........3-252 HYBRID CONTROL SYSTEM........3-4 DTC: P3001 (TC46) ..........3-255 TROUBLE SHOOTING STEPS DTC: P3001 (TC47) ..........3-259 FOR HYBRID SYSTEM ..........3-4 DTC: P3001 (TC4A)..........3-263 SAFETY MEASURES DTC: P3001 (TC4B)..........3-267 FOR HIGH-VOLTAGE WORK .......3-12 DTC: P3001 (TC4C)..........3-270 LIST OF CONNECTOR SYMBOLS ......3-15...
  • Page 6 3–2 HYBRID DTC: P0A1B (TC92)..........3-472 DTC: P0BEF (TC9C) ...........3-764 DTC: P0A1B (TC97)..........3-474 DTC: P0BF0 (TC9D) ...........3-767 DTC: P0A1B (TC3F) ...........3-476 DTC: P3126 (TC12) ..........3-770 DTC: P0A1B (TCA1) ...........3-478 DTC: U0073 (TC91) ..........3-783 DTC: P0A1B (TCA2) ...........3-480 DTC: U0074 (TC3E) ..........3-788 DTC: P0A1B (TCA3) ...........3-482 DTC: U0293 (TC31) ..........3-792 DTC: P0A1B (TCA4) ...........3-484...

  • Page 7: Hybrid

    HYBRID 3–3 DTC: P0B92 ............3-1010 DTC: P0B97 ............3-1015 DTC: P0B9C ............. 3-1020 DTC: P0BA1............3-1025 DTC: P0C30............3-1030 DTC: P3004 ............3-1036 DTC: P3011 ............3-1039 DTC: P3012 ............3-1044 DTC: P3013 ............3-1049 DTC: P3014 ............3-1054 DTC: P3015 ............

  • Page 8: Trouble Shooting

    3–4 HYBRID/TROUBLE SHOOTING TROUBLE SHOOTING HYBRID CONTROL SYSTEM TROUBLE SHOOTING STEPS FOR HYBRID SYSTEM EN01H03ZZZ030602002001 CONFIGURATION DIAGRAM OF HYBRID TROUBLE SHOOTING SYSTEM HYBRID CONTROL SYSTEM: CAN: HV BATTERY ECU SIGNAL LINE: READ CODE AND DIAGNOSE ENGINE ECU MALFUNCTION INFORMATION MIL ON REQUEST MIL ON REQUEST READ CODE AND DIAGNOSE...
  • Page 9 HYBRID/TROUBLE SHOOTING 3–5 HV WARNING LIGHT LIGHTING PROCESS The HV ECU controls the HV warning light. The HV warning light turns on in case of malfunction of the HV ECU, the HV battery ECU, the inverter, or the clutch ECU. The HV ECU receives information regarding malfunction of the HV battery ECU, the inverter, and the clutch ECU via CAN.
  • Page 10 3–6 HYBRID/TROUBLE SHOOTING DEFINITION OF MALFUNCTION Driving cycle The driving cycle (hereinafter referred to as "DCY") is confirmed when the engine revolution becomes equal to or more than the value calculated using the following formula [idling speed minus 150 r/min] after the starter key is turned to the "ON"...
  • Page 11 HYBRID/TROUBLE SHOOTING 3–7 Pending diagnosis code Represents the diagnosis code in which the malfunction is confirmed by detecting the malfunction in 2DCY or more. The following table shows examples in which the malfunction is confirmed in 2DCY. COMPLETION OF COMPLETION OF DCY#1 DCY#2 DETECTION OF...
  • Page 12 3–8 HYBRID/TROUBLE SHOOTING Permanent diagnosis code Permanent malfunction is confirmed by confirming the Confirmed malfunction. COMPLETION OF COMPLETION OF DCY#1 DCY#2 DETECTION OF MALFUNCTION VEHICLE CONDITION CONFIRMATION CONFIRMED MALFUNCTION CONFIRMATION PERMANENT MALFUNCTION LIGHT ON HV WARNING LIGHT LIGHT ON SHTS03ZZZ0300007 Deletion of diagnosis code Code name Deletion from vehicle condition...
  • Page 13 HYBRID/TROUBLE SHOOTING 3–9 • The following figure shows deletion of the Pending diagnosis code and deletion of the Permanent diagnosis code in 3DCY. COMPLETION OF COMPLETION OF COMPLETION OF COMPLETION OF COMPLETION OF DCY#1 DCY#2 DCY#3 DCY#4 DCY#5 DETECTION OF DETECTION OF NORMAL JUDGMENT #1 NORMAL JUDGMENT #2...
  • Page 14 3–10 HYBRID/TROUBLE SHOOTING PROCEDURE FOR DELETING THE PERMANENT MALFUNCTION There are two procedures for deleting the Permanent diagnosis code. Confirmed diagnosis code Permanent diagnosis code Deletion procedure None Present Deletion using the procedure (1) Present Present Deletion using the procedure (1) or (2) —...
  • Page 15 • There may be irregular contact or temporary noise due to partial fitting of the connector if parts are returned to normal without repairing or replacing parts using the diagnostic chart. • The service tool or trouble shooting tool described in the trouble shooting chart indicates the genuine Hino ser- vice tool.

  • Page 16: Safety Measures For High-Voltage Work

    3–12 HYBRID/TROUBLE SHOOTING SAFETY MEASURES FOR HIGH-VOLTAGE WORK EN01H03ZZZ030602002002 CAUTIONS ON INSPECTION OF HYBRID CONTROL SYSTEM To inspect the high-voltage system or disconnect the low- voltage connector in the PCU box, be sure to take actions to prevent electric shocks, i.e. wearing insulated gloves and dis- connection of service plug.
  • Page 17 HYBRID/TROUBLE SHOOTING 3–13 Check the insulated gloves for damage such as cracks and break before use. Also, do not use wet insulated gloves. Do not carry on any metal product such as a pen and scale which may fall to cause short circuit while working. INCORRECT Be sure to wear insulated gloves when it is necessary to touch any high-voltage terminal without insulating coating.
  • Page 18 3–14 HYBRID/TROUBLE SHOOTING SHTS03ZZZ0300012...

  • Page 19: List Of Connector Symbols

    HYBRID/TROUBLE SHOOTING 3–15 LIST OF CONNECTOR SYMBOLS EN01H03ZZZ030602002003 BATTERY ECU (CAN) INVERTER COOLING WATER PUMP WHITE BLACK 4 5 6 7 8 9 J/C DIAG CAN BATTERY ECU (TEMPERATURE MONITORING) WHITE DARK GRAY 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BATTERY ECU (VOLTAGE MONITORING) HV ECU1...
  • Page 20 3–16 HYBRID/TROUBLE SHOOTING COOLANT TEMPERATURE SENSOR HV BATTERY COOLING FAN GRAY BLACK INVERTER START RELAY SMR DRIVE WHITE (COMPONENT SIDE) (RELAY BLOCK SIDE) HV BATTERY START RELAY SERVICE PLUG SWITCH WHITE (COMPONENT SIDE) (RELAY BLOCK SIDE) J/C CTRL CAN PCU HARNESS 24-PIN WHITE BLACK BLACK...
  • Page 21 HYBRID/TROUBLE SHOOTING 3–17 A’ RESOLVER STARTER SWITCH BLACK WHITE B’ ROTATION MACHINE TEMPERATURE SENSOR AT ECU BLACK WHITE 3 4 5 6 9 10 11 12 13 14 15 22 23 24 C’ D’ E’ F’ HIGH VOLTAGE J/B (IN BATTERY PACK) VEHICLE CONTROL ECU WHITE C’: BATT OUT(-)
  • Page 22 3–18 HYBRID/TROUBLE SHOOTING CLUTCH ECU NEUTRAL SWITCH BLACK BLACK 29 30 ABS ECU BLACK 6 7 8 9 101112 1314 151617181920 212223 25262728293031323334 DLC3 BLACK HIGH VOLTAGE J/B (IN ECU-BOX) k, l, m, n, p, q h: BATT(-) k: DDC(-) I: DDC(+) m: BATT(+) p: INV(+)

  • Page 23: Hv System Wiring Diagram

    HYBRID/TROUBLE SHOOTING 3–19 HV SYSTEM WIRING DIAGRAM EN01H03ZZZ030602002004 KEY CYLINDER INVERTER START RELAY W/TEMP_SSR HOUSING GND A 19 BATTERY ECU SMR1 HIGH VOLTAGE J/B J/B (+) J/B (-) (IN ECU BOX) SERVICE PLUG SMR2 HV BATTERY CURRENT 288V SMR3 SENSOR HIGH VOLTAGE J/B (IN BATTERY PACK) SMR: System Main Relay...
  • Page 24 3–20 HYBRID/TROUBLE SHOOTING WHEEL SPEED SENSOR IG1-1 VEHICLE ENGINE CONTROL CLUTCH METER METER DLC3 TURN SW 21 20 20 19 15 25 HAZ SW NSSW 24 21 22 20 8 9 x x x VCM WARN SW A/C WARN SW HYD WARN SW 2 7 8 CAN J/C...

  • Page 25: Hearing Sheet

    HYBRID/TROUBLE SHOOTING 3–21 HEARING SHEET EN01H03ZZZ030602002005 HEARING OF REQUESTS FROM CUSTOMER As the steps of trouble shooting are advanced, hear requests from customer without fault by referring this hear- ing sheet. Vehicle type Date of occurrence Travel distance Warehousing date Frame No.

  • Page 26: Hybrid Ecu

    3–22 HYBRID/TROUBLE SHOOTING HYBRID ECU DIAGNOSIS CODE TABLE EN01H03ZZZ030602003001 Symbol Lighting pattern ☆ Light is turned on when any fault occurs, and off when the fault is resolved Number of mal- Diagnosis code Description of Vehicle behavior for occur- function Warning name malfunction...
  • Page 27 HYBRID/TROUBLE SHOOTING 3–23 Number of mal- Diagnosis code Description of Vehicle behavior for occur- function Warning name malfunction rence of malfunction confir- Light mation Abnormality in Abnormality in clutch system the clutch ECU ☆ P0810 Idling stop may not work. (idling stop (idling stop is available)
  • Page 28 3–24 HYBRID/TROUBLE SHOOTING Number of mal- Diagnosis code Description of Vehicle behavior for occur- function Warning name malfunction rence of malfunction confir- Light mation Idling stop is not working. Lowering the speed during Abnormality in Sticking of the deceleration may decrease ☆...
  • Page 29 HYBRID/TROUBLE SHOOTING 3–25 Number of mal- Diagnosis code Description of Vehicle behavior for occur- function Warning name malfunction rence of malfunction confir- Light mation The engine may not start running. However, the engine starts up by the starter for starter-equipped Abnormality in Abnormality in vehicles.
  • Page 30 3–26 HYBRID/TROUBLE SHOOTING Number of mal- Diagnosis code Description of Vehicle behavior for occur- function Warning name malfunction rence of malfunction confir- Light mation The engine may not start running. However, the engine starts up by the starter for starter-equipped Abnormality in Abnormality in vehicles.
  • Page 31 HYBRID/TROUBLE SHOOTING 3–27 Number of mal- Diagnosis code Description of Vehicle behavior for occur- function Warning name malfunction rence of malfunction confir- Light mation The engine may not start running. However, the engine starts up by the Abnormal starter for starter-equipped Abnormality in external over- vehicles.
  • Page 32 3–28 HYBRID/TROUBLE SHOOTING Number of mal- Diagnosis code Description of Vehicle behavior for occur- function Warning name malfunction rence of malfunction confir- Light mation Disconnection Abnormality in of the HV water HV water pump Behavior of vehicle does not ☆ ☆...
  • Page 33 HYBRID/TROUBLE SHOOTING 3–29 Number of mal- Diagnosis code Description of Vehicle behavior for occur- function Warning name malfunction rence of malfunction confir- Light mation Idling stop is not working. Engine ECU Engine ECU Lowering the speed during ☆ ☆ U0100 CAN communi- CAN communi- deceleration may decrease...

  • Page 34: Freeze Frame Data List

    3–30 HYBRID/TROUBLE SHOOTING FREEZE FRAME DATA LIST EN01H03ZZZ030602003002 Item Description Display range Unit — TC No. Detailed code of DTC No. 00 - $FF Represents brake pedal communication input — Stop light switch (CAN reception) 0 - 1 status. Pedal ON = 1 / Pedal OFF = 0 DPR regenerating signal Received from the engine during DPR regenerat- —...
  • Page 35 HYBRID/TROUBLE SHOOTING 3–31 Item Description Display range Unit HV battery charge limit value Represents the HV battery charge limit value. 0 - 200 Represents the judged value of gear position. Neutral= 0 / 1st gear = 1 / 2nd gear = 2 / —...
  • Page 36 3–32 HYBRID/TROUBLE SHOOTING Item Description Display range Unit Select lever position Select lever position — AT-P = 0 / AT-RL = 1 / AT-N = 2 / AT-D = 3 / 0 - 255 (CAN reception) AT-4 range = 4 / AT-3 range = 5 / AT-Others = 6 Clutch state Engaged = 0 / partial clutch = 1 / —...

  • Page 37: List Of Data Monitor Items

    HYBRID/TROUBLE SHOOTING 3–33 LIST OF DATA MONITOR ITEMS EN01H03ZZZ030602003003 Display Item Description Unit range Number of diagnosis codes Number of recorded diagnosis codes 0 - 255 Codes Represents the brake pedal communication — Stop light switch (CAN reception) 0 - 1 input status.
  • Page 38 3–34 HYBRID/TROUBLE SHOOTING Display Item Description Unit range Represents the idling stop cancel switch signal Idling stop cancel switch — input status. Idling stop cancel status ON = ON. 0 - 1 (CAN reception) ON = 1 / OFF = 0 ABS activation signal Represents the ABS activation signal input sta- —...
  • Page 39 HYBRID/TROUBLE SHOOTING 3–35 Display Item Description Unit range HV radiator fan revolution HV radiator fan revolution 0 - 10,000 r/min HV water pump drive request duty HV water pump drive request duty 0 - 100 HV water pump drive request revo- HV water pump drive request revolution 0 - 10,000 r/min...

  • Page 40: Common Inspection Chart

    3–36 HYBRID/TROUBLE SHOOTING COMMON INSPECTION CHART EN01H03ZZZ030602003004 • If common inspection requirements are described in the trouble shooting chart, conduct inspection using the common inspection chart. 1. Chart for inspection of the signal line at the PCU lower side wire harness for short circuit 2.
  • Page 41 HYBRID/TROUBLE SHOOTING 3–37 Inspection of the signal line to the PCU harness 12-pin connector at the PCU lower side wire harness for short circuit Set the starter key to the "LOCK" position and remove the PCU harness 12-pin connector. TARGET Measure resistance between the connector terminal specified in CONNECTORS the trouble shooting chart and the PCU harness 12-pin connector...
  • Page 42 3–38 HYBRID/TROUBLE SHOOTING Measure resistance between the connector terminal specified in the trouble shooting chart and the HV battery start relay (relay block side). TARGET Target connectors  1st to 5th (except 4th) CONNECTORS SHTS03ZZZ0300024 Measure resistance between the connector terminal specified in the trouble shooting chart and the inverter start relay (relay block side).
  • Page 43 HYBRID/TROUBLE SHOOTING 3–39 Measure resistance between the connector terminal specified in the trouble shooting chart and the coolant temperature sensor connector (PCU lower harness side). TARGET Target connectors  1st and 2nd CONNECTORS SHTS03ZZZ0300028 Measure resistance between the connector terminal specified in the trouble shooting chart and the inverter connector (PCU lower harness side).
  • Page 44 3–40 HYBRID/TROUBLE SHOOTING (2) CHART FOR INSPECTION OF THE SIGNAL LINE AT THE PCU UPPER SIDE WIRE HARNESS FOR SHORT CIR- CUIT Inspection of the signal line to the PCU harness 16-pin connector at the PCU upper side wire harness for short circuit Set the starter key to the "LOCK"...

  • Page 45: Dtc: P0500 (Tc51)

    HYBRID/TROUBLE SHOOTING 3–41 DTC: P0500 (TC51) EN01H03ZZZ030602003005 DTC: P0500 (TC51) Abnormality in vehicle speed sensor INFORMATION Wheel speed sensor Combination meter HV ECU Speed pulse ABS ECU SHTS03ZZZ0300031 Technical description • – <Description of malfunction> • The signal from the vehicle speed sensor cannot be detected. DTC set condition DTC detection condition •...
  • Page 46 3–42 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of vehicle speed sensor •...
  • Page 47 INSPECTION PROCEDURE: P0500 (TC51) Inspecting the ABS ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Select [Brake] on the diagnosis tool screen.
  • Page 48 3–44 HYBRID/TROUBLE SHOOTING Inspecting the continuity of vehicle wire harness (between the combination meter and the PCU harness vehicle-side connector) Disconnect the PCU harness (24P) connector. Using the electrical tester, measure the resistance between the vehicle-side connector of combination meter (40P) and the vehi- cle-side connector terminal of PCU harness (24P).
  • Page 49 HYBRID/TROUBLE SHOOTING 3–45 Inspecting the continuity of PCU wire harness (lower side) Disconnect the HV ECU3 connector. Using the electrical tester, measure the resistance between the lower-side connector of PCU harness (24P) and the HV ECU3 connector terminal. Measurement Tester Standard values conditions connections...
  • Page 50 3–46 HYBRID/TROUBLE SHOOTING Inspecting the engine ECU [HINO-DX] Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Select [Engine] on the diagnosis tool screen. In [Fault Information], check if any DTC related to the vehicle speed signal system is detected.
  • Page 51 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (For 1 minutes at the vehicle speed of 10 km/h...
  • Page 52 (Yes/No) 1. Set the starter key to the "LOCK" position. DTC is 2. Connect the diagnosis tool detected from (HINO-DX) to the vehicle. the ABS: Go to Perform trou- 3. Set the starter key to the "ON" Inspecting the YES.
  • Page 53 18th terminal – GND <Standard values> 10 k or more DTC is 1. Connect the diagnosis tool detected from (HINO-DX) to the vehicle. the engine 2. Set the starter key to the "ON" ECU: Go to position. Inspecting the YES.
  • Page 54 The inspec- tion is com- 2. Connect the diagnosis tool DTC P0500- pleted.(If no (HINO-DX) to the vehicle. 51 is detected: repair or parts 3. Set the starter key to the "ON" Reproduction Go to replacement is position.

  • Page 55: Dtc: P0501 (Tc5B)

    HYBRID/TROUBLE SHOOTING 3–51 DTC: P0501 (TC5B) EN01H03ZZZ030602003006 DTC: P0501 (TC5B) Abnormality in characteristics of vehicle speed sensor INFORMATION Wheel speed sensor Combination meter HV ECU Speed pulse ABS ECU SHTS03ZZZ0300039 Technical description • – <Description of malfunction> • Detected the abnormality in the vehicle speed sensor. (Abnormality in characteristics of vehicle speed sensor) DTC set condition DTC detection condition •...
  • Page 56 3–52 HYBRID/TROUBLE SHOOTING Estimated failure factors • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of vehicle speed sensor • Malfunction of HV ECU • Malfunction of ABS ECU • Malfunction of meter ECU...
  • Page 57 INSPECTION PROCEDURE: P0501 (TC5B) Inspecting the ABS ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Select [Brake] on the diagnosis tool screen.
  • Page 58 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (For 1 minutes at the vehicle speed of 10 km/h...
  • Page 59 (Yes/No) 1. Set the starter key to the "LOCK" position. DTC is 2. Connect the diagnosis tool detected from (HINO-DX) to the vehicle. the ABS: Go to Perform trou- 3. Set the starter key to the "ON" Inspecting the YES.
  • Page 60 The inspec- tion is com- 2. Connect the diagnosis tool DTC P0501- pleted.(If no (HINO-DX) to the vehicle. 5B is detected: repair or parts 3. Set the starter key to the "ON" Reproduction Go to replacement is position.

  • Page 61: Dtc: P0562 (Tc71)

    HYBRID/TROUBLE SHOOTING 3–57 DTC: P0562 (TC71) EN01H03ZZZ030602003007 DTC: P0562 (TC71) Abnormality in power supply voltage INFORMATION F_HV_10A HV ECU SHTS03ZZZ0300043 Technical description • – <Description of malfunction> • Detected a reduction in 12 V line battery voltage (control power supply voltage). DTC set condition DTC detection condition •...
  • Page 62 3–58 HYBRID/TROUBLE SHOOTING Estimated failure factors • Capacity reduction of 12 V battery • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of HV ECU...
  • Page 63 INSPECTION PROCEDURE: P0562 (TC71) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if DTC P060B-B2 other than P0562-71 is detected.
  • Page 64 3–60 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) Connect the PCU harness (24P) connector. Disconnect the HV ECU3 connector. Using the electrical tester, measure the voltage between the HV ECU3 connector terminals. Measurement Tester Standard values conditions connections HV ECU3 connec- 10 –...
  • Page 65 Is any defect found? Replace the PCU wire harness (upper side). Go to step 6. Inspecting the HV ECU [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position.
  • Page 66 3–62 HYBRID/TROUBLE SHOOTING Reproduction check [HINO-DX] Clear the malfunction history. Set the starter key to the "ON" position and wait for 1 minute. In [Fault Information] on the diagnosis tool screen, check if DTC P0562-71 is detected. SHTS03ZZZ0300048 Is DTC P0562-71 detected? Re-inspect the 12 V battery and power supply The inspection is completed.
  • Page 67 1. Set the starter key to the "LOCK" position. DTC P060B- 2. Connect the diagnosis tool B2 is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Reading the bleshooting for 3. Set the starter key to the "ON"...
  • Page 68 YES. diagnosis tool screen and mon- Replace the HV ECU Go to step 7. itor [Power supply voltage] of HV ECU. [HINO-DX] The mea- HV ECU. sured value is <Measurement conditions> not within the Starter key: ON range of stan- <Measured item>...
  • Page 69 Re-inspect the 2. Set the starter key to the "ON" Reproduction The inspec- 12 V battery position and wait for 1 minute. check [HINO- tion is com- DTC P0562- and power 3. In [Fault Information] on the pleted. 71 is not supply circuit.

  • Page 70: Dtc: P060B (Tcb2)

    3–66 HYBRID/TROUBLE SHOOTING DTC: P060B (TCB2) EN01H03ZZZ030602003008 DTC: P060B (TCB2) Abnormality in A/D converter INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality of A/D converter in the HV ECU. DTC set condition DTC detection condition • The starter key is set to the ON position. Judgement criteria •...
  • Page 71 INSPECTION PROCEDURE: P060B (TCB2) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Start the engine and keep it idling for 1 minute.
  • Page 72 1. Set the starter key to the "LOCK" position. The inspec- 2. Connect the diagnosis tool DTC P060B- tion is com- (HINO-DX) to the vehicle. B2 is detected: pleted.(The 3. Set the starter key to the "ON" Go to YES. Reproduction abnormality position.

  • Page 73: Dtc: P0617 (Tc59)

    HYBRID/TROUBLE SHOOTING 3–69 DTC: P0617 (TC59) EN01H03ZZZ030602003009 DTC: P0617 (TC59) Malfunction of starter switch INFORMATION Starter key Neutral switch HV ECU SHTS03ZZZ0300050 Technical description • – <Description of malfunction> • Detected an abnormality in the starter key (starter signal circuit is stuck to High). DTC set condition DTC detection condition •...
  • Page 74 3–70 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of starter key •...
  • Page 75 HYBRID/TROUBLE SHOOTING 3–71 INSPECTION PROCEDURE: P0617 (TC59) Inspecting the neutral switch 1 Set the starter key to the "LOCK" position. Disconnect the neutral switch connector. Set the starter key to the "ON" position. Set the shift lever to the N position. Using the electrical tester, measure the resistance between the neutral switch connector terminals.
  • Page 76 3–72 HYBRID/TROUBLE SHOOTING Inspecting the vehicle wire harness for short circuit 1 (starter key signal circuit) Set the starter key to the "LOCK" position. VEHICLE GND Disconnect the connectors of starter key and PCU harness (24P). Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the 6th terminal of starter key vehicle-side connector and the ground.
  • Page 77 HYBRID/TROUBLE SHOOTING 3–73 Inspecting the vehicle wire harness for short circuit 2 (starter key signal circuit) Using the electrical tester, measure the voltage between the 12th terminal of PCU harness (24P) vehicle-side connector and the ground. VEHICLE GND Measurement Tester Standard values conditions connections...
  • Page 78 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (The vehicle speed and the engine speed remain at 25 km/h or more and 1500 r/min or more, respectively, for 30 seconds or more.)
  • Page 79 HYBRID/TROUBLE SHOOTING 3–75 CHECKLIST: P0617 (TC59) P0617 (TC59) Malfunction of starter switch Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the neutral switch connector. The mea- 3. Set the starter key to the "ON" sured value is position.
  • Page 80 3–76 HYBRID/TROUBLE SHOOTING P0617 (TC59) Malfunction of starter switch Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connectors of The mea- starter key and PCU harness (24P). sured value is within the 3.
  • Page 81 1. Connect all the connectors that have been disconnected to restore the system. The inspec- 2. Connect the diagnosis tool tion is com- (HINO-DX) to the vehicle. DTC P0617- pleted. 3. Set the starter key to the "ON" 59 is detected: (If no repair or position.

  • Page 82: Dtc: P062F (Tcb3)

    3–78 HYBRID/TROUBLE SHOOTING DTC: P062F (TCB3) EN01H03ZZZ030602003010 DTC: P062F (TCB3) Abnormality in EEPROM INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality of EEPROM in the HV ECU. DTC set condition DTC detection condition • The starter key is set to the ON position. •...
  • Page 83 INSPECTION PROCEDURE: P062F (TCB3) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if DTC P0562-71 other than P062F-B3 is detected.
  • Page 84 1. Set the starter key to the "LOCK" position. DTC P0562- 2. Connect the diagnosis tool 71 is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Reading the bleshooting for 3. Set the starter key to the "ON"...

  • Page 85: Dtc: P0810 (Tc9C)

    HYBRID/TROUBLE SHOOTING 3–81 DTC: P0810 (TC9C) EN01H03ZZZ030602003011 DTC: P0810 (TC9C) Abnormality in clutch system (idling stop inhibited) INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4)
  • Page 86 3–82 HYBRID/TROUBLE SHOOTING Reset condition • When the notification that there is none of the following abnormality is received from the clutch ECU: - Notification of power supply abnormality - Notification of oil temperature sensor abnormality - Notification of solenoid abnormality - Notification that receiving from AT ECU is unavailable and that the communication has been disrupted - Notification of abnormality in electric oil pump for the clutch - Notification of clutch disengagement abnormality...
  • Page 87 INSPECTION PROCEDURE: P0810 (TC9C) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC other than P0810-9C is detected.
  • Page 88 (Yes/No) 1. Set the starter key to the DTC other "LOCK" position. than P0810- 2. Connect the diagnosis tool 9C is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Perform trou- Reading the bleshooting for bleshooting of 3. Set the starter key to the "ON"...

  • Page 89: Dtc: P0810 (Tc9D)

    HYBRID/TROUBLE SHOOTING 3–85 DTC: P0810 (TC9D) EN01H03ZZZ030602003012 DTC: P0810 (TC9D) Abnormality in clutch system (idling stop available) INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4)
  • Page 90 3–86 HYBRID/TROUBLE SHOOTING Indication, warning or system control regulation when the DTC is set. • MIL: OFF • HV warning light: ON Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> •...
  • Page 91 INSPECTION PROCEDURE: P0810 (TC9D) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC other than P0810-9D is detected.
  • Page 92 (Yes/No) 1. Set the starter key to the DTC other "LOCK" position. than P0810- 2. Connect the diagnosis tool 9D is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Perform trou- Reading the bleshooting for bleshooting of 3. Set the starter key to the "ON"...

  • Page 93: Dtc: P0A01 (Tc7B)

    HYBRID/TROUBLE SHOOTING 3–89 DTC: P0A01 (TC7B) EN01H03ZZZ030602003013 DTC: P0A01 (TC7B) Abnormality in characteristics of inverter coolant temperature sensor INFORMATION Coolant temperature sensor HV ECU SHTS03ZZZ0300064 Technical description • – <Description of malfunction> • Detected an abnormality in the inverter cooling circuit (abnormality in the characteristics of inverter coolant temper- ature sensor).
  • Page 94 3–90 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Malfunction of inverter cooling circuit • Malfunction of inverter coolant temperature sensor •...
  • Page 95 HYBRID/TROUBLE SHOOTING 3–91 INSPECTION PROCEDURE: P0A01 (TC7B) Inspecting the coolant line route Check the coolant line route (radiator, inverter, and hose) for any damage or water leakage. Is any defect found? Repair or replace the defective part. Go to step 2. After repair/replacement, perform the inspec- tion again.
  • Page 96 HYBRID/TROUBLE SHOOTING Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any other coolant temperature sensor system DTC (listed below) is detected.
  • Page 97 HYBRID/TROUBLE SHOOTING 3–93 Inspecting the signal line of PCU wire harness (lower side) for short circuit Set the starter key to the "LOCK" position. For the 2nd terminal of coolant temperature sensor connector, inspect the signal line of PCU wire harness (lower side) for short circuit.
  • Page 98 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. In [Data Monitor] on the diagnosis tool screen, measure [HV sys- tem coolant temperature].
  • Page 99 Go to NO. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC other than P0A01- 3. Set the starter key to the "ON" 7B is detected: position.
  • Page 100 3–96 HYBRID/TROUBLE SHOOTING Abnormality in characteristics of inverter P0A01 (TC7B) Inspection Procedure coolant temperature sensor Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connector of The mea- coolant temperature sensor. sured value is 3.
  • Page 101 The mea- 2. Connect the diagnosis tool The inspec- sured value is (HINO-DX) to the vehicle. tion is com- within the pleted. 3. Set the starter key to the "ON" range of stan- (If no repair or position.

  • Page 102: Dtc: P0A02 (Tc78)

    3–98 HYBRID/TROUBLE SHOOTING DTC: P0A02 (TC78) EN01H03ZZZ030602003014 DTC: P0A02 (TC78) Coolant temperature sensor Low abnormality INFORMATION Coolant temperature sensor HV ECU SHTS03ZZZ0300068 Technical description • – <Description of malfunction> • Detected a GND short circuit in the inverter coolant temperature sensor. DTC set condition DTC detection condition •...
  • Page 103 HYBRID/TROUBLE SHOOTING 3–99 Estimated failure factors • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of inverter coolant temperature sensor • Malfunction of HV ECU...
  • Page 104 3–100 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A02 (TC78) Inspecting the continuity of PCU wire harness (lower side) Set the starter key to the "LOCK" position. Disconnect the connectors of coolant temperature sensor and HV ECU1. Using the electrical tester, measure the resistance between the coolant temperature sensor connector and the HV ECU1 connec- tor terminal.
  • Page 105 HYBRID/TROUBLE SHOOTING 3–101 Inspecting the PCU wire harness (lower side) for short circuit 1 Using the electrical tester, measure the resistance between each terminal of coolant temperature sensor connector and the ground. VEHICLE GND Measurement Tester Standard values conditions connections Coolant tempera- ture sensor con- nector...
  • Page 106 3–102 HYBRID/TROUBLE SHOOTING Inspecting the coolant temperature sensor Using the electrical tester, measure the resistance of coolant tem- perature sensor. Measurement Tester Standard values conditions connections 0 C {32 F}: Coolant tempera- 5.3 k – 6.2 k ture sensor 20 C {68 F}: connector (sen- Starter key: LOCK 2.3 k –...
  • Page 107 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. In [Data Monitor] on the diagnosis tool screen, measure [HV sys- tem coolant temperature].
  • Page 108 3–104 HYBRID/TROUBLE SHOOTING CHECKLIST: P0A02 (TC78) P0A02 (TC78) Coolant temperature sensor Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connectors of The mea- coolant temperature sensor sured value is and HV ECU1.
  • Page 109 The mea- 2. Connect the diagnosis tool The inspec- sured value is (HINO-DX) to the vehicle. tion is com- within the pleted. 3. Set the starter key to the "ON" range of stan- (If no repair or position.

  • Page 110: Dtc: P0A03 (Tc79)

    3–106 HYBRID/TROUBLE SHOOTING DTC: P0A03 (TC79) EN01H03ZZZ030602003015 DTC: P0A03 (TC79) Coolant temperature sensor High abnormality INFORMATION Coolant temperature sensor HV ECU SHTS03ZZZ0300074 Technical description • – <Description of malfunction> • Detected the disconnection or power supply (positive side) short circuit in the inverter coolant temperature sensor. DTC set condition DTC detection condition •...
  • Page 111 HYBRID/TROUBLE SHOOTING 3–107 After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of inverter coolant temperature sensor •...
  • Page 112 3–108 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A03 (TC79) Inspecting the continuity of PCU wire harness (lower side) Set the starter key to the "LOCK" position. Disconnect the connectors of coolant temperature sensor and HV ECU1. Using the electrical tester, measure the resistance between the coolant temperature sensor connector and the HV ECU1 connec- tor terminal.
  • Page 113 HYBRID/TROUBLE SHOOTING 3–109 Inspecting the coolant temperature sensor Using the electrical tester, measure the resistance of coolant tem- perature sensor. Measurement Tester Standard values conditions connections 0 C {32F}: Coolant tempera- 5.3 k – 6.2 k ture sensor con- 20 C {68 F}: nector (sensor Starter key: LOCK 2.3 k –...
  • Page 114 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. In [Data Monitor] on the diagnosis tool screen, measure [HV sys- tem coolant temperature].
  • Page 115 HYBRID/TROUBLE SHOOTING 3–111 CHECKLIST: P0A03 (TC79) P0A03 (TC79) Coolant temperature sensor High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connectors of The mea- coolant temperature sensor sured value is and HV ECU1.
  • Page 116 The mea- 2. Connect the diagnosis tool The inspec- sured value is (HINO-DX) to the vehicle. tion is com- within the pleted. 3. Set the starter key to the "ON" range of stan- (If no repair or position.

  • Page 117: Dtc: P0A06 (Tc7F)

    HYBRID/TROUBLE SHOOTING 3–113 DTC: P0A06 (TC7F) EN01H03ZZZ030602003016 DTC: P0A06 (TC7F) HV water pump drive signal Low abnormality INFORMATION Inverter Inverter coolant pump starter relay PCI_B_2 20 HV ECU SHTS03ZZZ0300078 Technical description • – <Description of malfunction> • Detected a disconnection or GND short circuit in the HV water pump drive signal circuit. DTC set condition DTC detection condition •...
  • Page 118 3–114 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper connector contact or fitting • Malfunction of HV water pump •...
  • Page 119 INSPECTION PROCEDURE: P0A06 (TC7F) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if DTC P324B-62 or P324C-61 is detected.
  • Page 120 3–116 HYBRID/TROUBLE SHOOTING Inspecting the voltage of vehicle wire harness Set the starter key to the "LOCK" position. VEHICLE GND Disconnect the PCU harness (24P) connector. Using the electrical tester, measure the voltage between the 3rd terminal of PCU harness (24P) vehicle-side connector and the ground.
  • Page 121 HYBRID/TROUBLE SHOOTING 3–117 Inspecting the inverter start relay Set the starter key to the "LOCK" position. Remove the inverter start relay. Using the electrical tester, measure the resistance between the 3rd and 5th terminals of inverter start relay. (With no voltage applied) Apply the voltage of 12 V between the 1st and 2nd terminals of inverter start relay and measure the resistance between the 3rd...
  • Page 122 3–118 HYBRID/TROUBLE SHOOTING Inspecting the voltage of PCU wire harness (lower side) Set the starter key to the "LOCK" position. Connect the PCU harness (24P) connector and the inverter start relay. Disconnect the inverter cooling pump connector. Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the con- nector terminals of inverter cooling pump.
  • Page 123 HYBRID/TROUBLE SHOOTING 3–119 Inspecting the continuity of PCU wire harness (lower side) Set the starter key to the "LOCK" position. Disconnect the HV ECU2 connector. Using the electrical tester, measure the resistance between the inverter cooling pump connector and the HV ECU2 connector ter- minal.
  • Page 124 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "ON" position and wait for 1 minute.
  • Page 125 1. Set the starter key to the DTC P324B- "LOCK" position. 62 or P324C- 2. Connect the diagnosis tool 61 is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Reading the bleshooting for 3. Set the starter key to the "ON"...
  • Page 126 3–122 HYBRID/TROUBLE SHOOTING P0A06 (TC7F) HV water pump drive signal Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Remove the inverter start relay. 3. Using the electrical tester, mea- sure the resistance between The mea- the 3rd and 5th terminals of...
  • Page 127 HYBRID/TROUBLE SHOOTING 3–123 P0A06 (TC7F) HV water pump drive signal Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. The mea- 2. Disconnect the HV ECU2 con- sured value is nector.
  • Page 128 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0A06- (HINO-DX) to the vehicle. 7F is detected: 3. Set the starter key to the "ON" Go to YES. Reproduction The inspec- position.

  • Page 129: Dtc: P0A07 (Tc7E)

    HYBRID/TROUBLE SHOOTING 3–125 DTC: P0A07 (TC7E) EN01H03ZZZ030602003017 DTC: P0A07 (TC7E) HV water pump drive signal High abnormality INFORMATION Inverter Inverter coolant pump starter relay PCI_B_2 20 HV ECU SHTS03ZZZ0300087 Technical description • – <Description of malfunction> • Detected a disconnection or power supply (positive side) short circuit in the HV water pump drive signal circuit. DTC set condition DTC detection condition <Condition 1>...
  • Page 130 3–126 HYBRID/TROUBLE SHOOTING Reset condition • When the following conditions are met: <Condition 1> - Input signal for monitoring HV water pump drive signal remains 4.6 V or less for 0.1 second or more. <Condition 2> - Input signal for monitoring HV water pump drive signal remains at 1 Hz or more for 5 second or more. Indication, warning or system control regulation when the DTC is set.
  • Page 131 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "LOCK" position and wait for 1 minute.
  • Page 132 10 k or more 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0A07- 3. Set the starter key to the "ON" 7E is detected: position.

  • Page 133: Dtc: P0A0F (Tc31)

    HYBRID/TROUBLE SHOOTING 3–129 DTC: P0A0F (TC31) EN01H03ZZZ030602003018 DTC: P0A0F (TC31) Engine system abnormality INFORMATION Technical description • – <Description of malfunction> • Cranking was performed but the engine did not start. (Engine misfire) DTC set condition DTC detection condition • The starter key is set to the ON position. •...
  • Page 134 Inspecting the engine ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any engine system DTC is detected.
  • Page 135 HYBRID/TROUBLE SHOOTING 3–131 Reproduction check [HINO-DX] In the [Data Monitor] on the diagnosis tool screen, select [HV bat- tery minimum temperature] to read the HV battery temperature. Continue cranking for 5 seconds if [HV battery minimum tempera- ture] is -10 C {14 F} or more and for 8 seconds if below -10 C {14 F} to check that the engine starts.
  • Page 136 1. Set the starter key to the detected from "LOCK" position. the engine 2. Connect the diagnosis tool ECU: Go to (HINO-DX) to the vehicle. Perform trou- Inspecting the YES. bleshooting for 3. Set the starter key to the "ON"...

  • Page 137: Dtc: P0A1D (Tc12)

    HYBRID/TROUBLE SHOOTING 3–133 DTC: P0A1D (TC12) EN01H03ZZZ030602003019 DTC: P0A1D (TC12) Abnormality in HV ECU function INFORMATION Technical description • – <Description of malfunction> • Detected the abnormality in the CAN communication circuit in the HV ECU. (Control CAN register stuck) DTC set condition DTC detection condition •...
  • Page 138 INSPECTION PROCEDURE: P0A1D (TC12) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "LOCK" position and wait for 1 minute.
  • Page 139 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0A1D- The inspec- 3. Set the starter key to the "ON" 12 is detected: tion is com- position.

  • Page 140: Dtc: P0A1D (Tc17)

    3–136 HYBRID/TROUBLE SHOOTING DTC: P0A1D (TC17) EN01H03ZZZ030602003020 DTC: P0A1D (TC17) Abnormality in HV ECU function INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the CAN communication circuit in the HV ECU. (DIAG CAN register stuck) DTC set condition DTC detection condition •...
  • Page 141 INSPECTION PROCEDURE: P0A1D (TC17) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "LOCK" position and wait for 1 minute.
  • Page 142 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. Replace the DTC P0A1D- The inspec- 3. Set the starter key to the "ON" HV ECU. 17 is detected: tion is com- position.

  • Page 143: Dtc: P0A78 (Tc21)

    HYBRID/TROUBLE SHOOTING 3–139 DTC: P0A78 (TC21) EN01H03ZZZ030602003021 DTC: P0A78 (TC21) Abnormality in the inverter INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter or HV motor (critical abnormality of inverter). DTC set condition DTC detection condition •...
  • Page 144 INSPECTION PROCEDURE: P0A78 (TC21) Inspecting the inverter [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the inverter line is detected.
  • Page 145 1. Set the starter key to the the inverter "LOCK" position. line is 2. Connect the diagnosis tool detected: Go (HINO-DX) to the vehicle. Perform trou- Inspecting the to YES. bleshooting for 3. Set the starter key to the "ON"...

  • Page 146: Dtc: P0A78 (Tc22)

    3–142 HYBRID/TROUBLE SHOOTING DTC: P0A78 (TC22) EN01H03ZZZ030602003022 DTC: P0A78 (TC22) Abnormality in the inverter INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter or HV motor (minor abnormality of inverter). DTC set condition DTC detection condition •...
  • Page 147 INSPECTION PROCEDURE: P0A78 (TC22) Inspecting the inverter [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the inverter line is detected.
  • Page 148 1. Set the starter key to the the inverter "LOCK" position. line is 2. Connect the diagnosis tool detected: Go (HINO-DX) to the vehicle. Perform trou- Inspecting the to YES. bleshooting for 3. Set the starter key to the "ON"...

  • Page 149: Dtc: P0A7E (Tc48)

    HYBRID/TROUBLE SHOOTING 3–145 DTC: P0A7E (TC48) EN01H03ZZZ030602003023 DTC: P0A7E (TC48) Abnormality in high temperature of HV battery INFORMATION Technical description • – <Description of malfunction> • Detected the high temperature abnormality in the HV battery. DTC set condition DTC detection condition •...
  • Page 150 Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any of the following DTC related to malfunction of HV battery cooling fan is detected.
  • Page 151 Perform troubleshooting for each of related Go to step 4. DTC. Inspecting the operation of HV battery cooling fan [HINO-DX] In [Activation Test] on the diagnosis tool screen, select [HV battery cooling fan duty value]. Run the HV battery cooling fan at the duty value of 90% to check that the cooling fan is rotating.
  • Page 152 3–148 HYBRID/TROUBLE SHOOTING Inspecting the HV battery temperature sensor [HINO-DX] Set the starter key to the "LOCK" position. Leave (cool) the vehicle for approximately 1 hour. Start and then idle the engine. In [Data Monitor] on the diagnosis tool screen, monitor [Maximum temperature of HV battery].
  • Page 153 1. Set the starter key to the "LOCK" position. DTC other 2. Connect the diagnosis tool than P0A7E- (HINO-DX) to the vehicle. 48 is detected: 3. Set the starter key to the "ON" Go to YES. Perform trou- Reading the position.
  • Page 154 HV battery to YES. mum temperature of HV ECU. temperature Go to step 6. battery]. After replace- sensor [HINO- The mea- <Measurement conditions> ment, go to sured value is Starter key: ON step 6. not within the After cooling, idling state range of stan- <Measured item>...

  • Page 155: Dtc: P0A82 (Tc67)

    HYBRID/TROUBLE SHOOTING 3–151 DTC: P0A82 (TC67) EN01H03ZZZ030602003024 DTC: P0A82 (TC67) Abnormality in function of HV battery cooling fan INFORMATION PCI_B_20A HV battery starter relay HV battery cooling fan HV ECU SHTS03ZZZ0300102 Technical description • – <Description of malfunction> • Detected an abnormality in the function of HV battery cooling fan. DTC set condition DTC detection condition •...
  • Page 156 3–152 HYBRID/TROUBLE SHOOTING <Upper limit> HV battery cooling fan drive duty of 20%: 1416.7 r/min HV battery cooling fan drive duty of 30%: 1886.3 r/min HV battery cooling fan drive duty of 40%: 2317.8 r/min HV battery cooling fan drive duty of 50%: 2697.9 r/min HV battery cooling fan drive duty of 60%: 3014.0 r/min HV battery cooling fan drive duty of 70%: 3291.9 r/min HV battery cooling fan drive duty of 80%: 3522.8 r/min...
  • Page 157 HYBRID/TROUBLE SHOOTING 3–153 Estimated failure factors • Disconnection or short circuit of harness • Improper connector connection or fitting • Malfunction of HV battery cooling fan • Malfunction of HV ECU...
  • Page 158 Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any of the following DTC related to malfunction of HV battery cooling fan is detected.
  • Page 159 Go to step 4. Replace the HV battery cooling fan. Checking the number of revolutions of HV battery cooling fan [HINO-DX] In [Activation Test] on the diagnosis tool screen, change the opera- tion duty value of HV battery cooling fan to 20 and 90%.
  • Page 160 3–156 HYBRID/TROUBLE SHOOTING Inspecting the continuity of PCU wire harness (lower side) Set the starter key to the "LOCK" position. Disconnect the connectors of HV ECU1 and PCU harness (16P). Using the electrical tester, measure the resistance between the HV ECU1 connector and the lower-side connector terminal of PCU harness (16P).
  • Page 161 HYBRID/TROUBLE SHOOTING 3–157 Inspecting the signal line of PCU wire harness (lower side) for short circuit For the 12th terminal of PCU harness (16P) lower-side connector, inspect the signal line of PCU wire harness (lower side) for short circuit. (See "Inspecting the PCU harness signal line for short cir- cuit.") Measurement Tester...
  • Page 162 3–158 HYBRID/TROUBLE SHOOTING Inspecting the signal line of PCU wire harness (upper side) for short circuit For the 12th terminal of PCU harness (16P) upper-side connector, inspect the signal line of PCU wire harness (upper side) for short circuit. (See "Inspecting the PCU harness signal line for short cir- cuit.") Measurement Tester...
  • Page 163 HYBRID/TROUBLE SHOOTING 3–159 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position. Clear the malfunction history. In [Activation Test] on the diagnosis tool screen, select [HV battery cooling fan duty value].
  • Page 164 1. Set the starter key to the "LOCK" position. DTC other 2. Connect the diagnosis tool than P0A82- (HINO-DX) to the vehicle. 67 is detected: 3. Set the starter key to the "ON" Go to YES. Perform trou- Reading the position.
  • Page 165 Go to step 5. HV battery battery cool- <Measurement conditions> The mea- cooling fan. ing fan [HINO- Starter key: ON sured value is <Measured item> not within the Number of revolutions of HV bat- range of stan-...
  • Page 166 3–162 HYBRID/TROUBLE SHOOTING Abnormality in function of P0A82 (TC67) Inspection Procedure HV battery cooling fan Check Step Action Description Judgement (Yes/No) 1. For the 12th terminal of PCU harness (16P) lower-side con- nector, inspect the signal line of PCU wire harness (lower side) Defect is for short circuit.
  • Page 167 6. Run the HV battery cooling fan Go to YES. Reproduction The inspec- at the duty value of 90% for 1 Replace the check [HINO- tion is com- minute. DTC P0A82- HV ECU. pleted. 7. Set the starter key to the 67 is not "LOCK"...

  • Page 168: Dtc: P0A84 (Tc66)

    3–164 HYBRID/TROUBLE SHOOTING DTC: P0A84 (TC66) EN01H03ZZZ030602003025 DTC: P0A84 (TC66) Abnormality in HV battery cooling fan drive signal Low INFORMATION PCI_B_20A HV battery starter relay HV battery cooling fan HV ECU SHTS03ZZZ0300110 Technical description • – <Description of malfunction> • Detected a disconnection or GND short circuit in the HV battery cooling fan drive signal circuit. DTC set condition DTC detection condition •...
  • Page 169 HYBRID/TROUBLE SHOOTING 3–165 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check the battery voltage to make sure that there is no abnormality. After-inspection work •...
  • Page 170 Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any of the following DTC related to malfunction of HV battery start relay is detected.
  • Page 171 HYBRID/TROUBLE SHOOTING 3–167 Inspecting the HV battery start relay Set the starter key to the "LOCK" position. Remove the HV battery start relay. Using the electrical tester, measure the resistance between the 3rd and 5th terminals of HV battery start relay. (With no voltage applied) Apply the voltage of 12 V between the 1st and 2nd terminals of HV battery start relay and measure the resistance between the 3rd...
  • Page 172 3–168 HYBRID/TROUBLE SHOOTING Inspecting the voltage of PCU wire harness (lower side) Connect the PCU harness (24P) connector and the HV battery start relay. Disconnect the PCU harness (16P) connector. Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the lower- side connector terminals of PCU harness (16P).
  • Page 173 HYBRID/TROUBLE SHOOTING 3–169 Inspecting the continuity of PCU wire harness (lower side) Set the starter key to the "LOCK" position. Disconnect the HV ECU2 connector. Using the electrical tester, measure the resistance between the lower-side connector terminal of PCU harness (16P) and the HV ECU2 connector terminal.
  • Page 174 3–170 HYBRID/TROUBLE SHOOTING Inspecting the signal line of PCU wire harness (lower side) for short circuit For the 11th terminal of PCU harness (16P) lower-side connector, inspect the signal line of PCU wire harness (lower side) for short circuit. (See "Inspecting the PCU harness signal line for short cir- cuit.") Measurement Tester...
  • Page 175 Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history.
  • Page 176 1. Set the starter key to the "LOCK" position. DTC other 2. Connect the diagnosis tool than P0A84- (HINO-DX) to the vehicle. 66 is detected: Go to YES. Perform trou- 3. Set the starter key to the "ON" Reading the bleshooting for position.
  • Page 177 HYBRID/TROUBLE SHOOTING 3–173 Abnormality in HV battery cooling fan P0A84 (TC66) Inspection Procedure drive signal Low Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Remove the HV battery start relay. 3. Using the electrical tester, mea- The mea- sure the resistance between sured value is...
  • Page 178 3–174 HYBRID/TROUBLE SHOOTING Abnormality in HV battery cooling fan P0A84 (TC66) Inspection Procedure drive signal Low Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the HV ECU2 con- The mea- nector. sured value is 3.
  • Page 179 HYBRID/TROUBLE SHOOTING 3–175 Abnormality in HV battery cooling fan P0A84 (TC66) Inspection Procedure drive signal Low Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect all the connectors that have been disconnected. The mea- sured value is 3.
  • Page 180 2. Set the starter key to the "LOCK" position. 3. Connect the diagnosis tool DTC P0A84- (HINO-DX) to the vehicle. 66 is detected: 4. Set the starter key to the "ON" Go to YES. Reproduction The inspec- position.

  • Page 181: Dtc: P0A85 (Tc65)

    HYBRID/TROUBLE SHOOTING 3–177 DTC: P0A85 (TC65) EN01H03ZZZ030602003026 DTC: P0A85 (TC65) Abnormality in HV battery cooling fan drive signal High INFORMATION PCI_B_20A HV battery starter relay HV battery cooling fan HV ECU SHTS03ZZZ0300119 Technical description • – <Description of malfunction> • Detected a power supply (positive side) short circuit in the HV battery cooling fan drive signal circuit. DTC set condition DTC detection condition <Condition A>...
  • Page 182 3–178 HYBRID/TROUBLE SHOOTING Reset condition • When the following conditions are met: <Condition A> Input signal for monitoring HV battery cooling fan drive signal remains at 3.6 V or less for 0.1 second or more. <Condition B> Input signal for monitoring HV battery cooling fan drive signal remains at 1 Hz or more for 0.5 second or more. Indication, warning or system control regulation when the DTC is set.
  • Page 183 HYBRID/TROUBLE SHOOTING 3–179 INSPECTION PROCEDURE: P0A85 (TC65) Inspecting the signal line of PCU wire harness (lower side) for short circuit Set the starter key to the "LOCK" position. Disconnect the PCU harness (16P) connector and the HV ECU2 connector. For the 11th terminal of PCU harness (16P) lower-side connector, inspect the signal line of PCU wire harness (lower side) for short circuit.
  • Page 184 Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history.
  • Page 185 HYBRID/TROUBLE SHOOTING 3–181 CHECKLIST: P0A85 (TC65) Abnormality in HV battery cooling fan P0A85 (TC65) Inspection Procedure drive signal High Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the PCU harness (16P) connector and the HV ECU2 connector.
  • Page 186 2. Set the starter key to the "LOCK" position. 3. Connect the diagnosis tool DTC P0A85- (HINO-DX) to the vehicle. 65 is detected: 4. Set the starter key to the "ON" Go to YES. Reproduction The inspec- position.

  • Page 187: Dtc: P0A90 (Tc2A)

    HYBRID/TROUBLE SHOOTING 3–183 DTC: P0A90 (TC2A) EN01H03ZZZ030602003027 DTC: P0A90 (TC2A) Abnormality in motor function INFORMATION Inverter Motor SHTS03ZZZ0300121 Technical description • – <Description of malfunction> • Detected the functional abnormality in the inverter or HV motor. DTC set condition DTC detection condition •...
  • Page 188 3–184 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 189 INSPECTION PROCEDURE: P0A90 (TC2A) Inspecting the inverter [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the inverter line is detected.
  • Page 190 3–186 HYBRID/TROUBLE SHOOTING Inspecting the continuity of three-phase cable 1 Disconnect the three-phase cable (U, V, and W terminals) from the inverter and HV motor. Using the electrical tester, measure the resistance between the terminals of both ends of the three-phase cable. Measurement Tester Standard values...
  • Page 191 HYBRID/TROUBLE SHOOTING 3–187 Inspecting the insulation resistance of three-phase cable 1 Using the megohm tester (500 V range), measure the insulation resistance between the terminals of three-phase cable. ! CAUTION Terminals must be insulated to avoid contact. Measurement Tester Standard values conditions connections Three-phase cable...
  • Page 192 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. (Insert the service plug last.) Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history.
  • Page 193 HYBRID/TROUBLE SHOOTING 3–189 Inspecting the continuity of three-phase cable 2 Disconnect the three-phase cable (U, V, and W terminals) from the relay terminal block. Using the electrical tester, measure the resistance between the terminals of both ends of the three-phase cable on the HV motor side.
  • Page 194 3–190 HYBRID/TROUBLE SHOOTING Inspecting the insulation resistance of three-phase cable 2 Disconnect the three-phase cable (U, V, and W terminals) from the relay terminal block. Using the megohm tester (500 V range), measure the insulation resistance between the terminals of three-phase cable. ! CAUTION Terminals must be insulated to avoid contact.
  • Page 195 1. Set the starter key to the the inverter "LOCK" position. line is 2. Connect the diagnosis tool detected: Go (HINO-DX) to the vehicle. Perform trou- Inspecting the to YES. bleshooting for 3. Set the starter key to the "ON"...
  • Page 196 3–192 HYBRID/TROUBLE SHOOTING P0A90 (TC2A) Abnormality in motor function Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Using the megohm tester (500 V range), measure the insula- • When the The mea- tion resistance between the ter- central ter- sured value is minals of three-phase cable.
  • Page 197 1. Connect all the connectors that have been disconnected to restore the system. (Insert the service plug last.) 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0A90- 3. Set the starter key to the "ON" 2A is detected: position.
  • Page 198 3–194 HYBRID/TROUBLE SHOOTING P0A90 (TC2A) Abnormality in motor function Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the three-phase cable (U, V, and W terminals) from the relay terminal block. 2. Using the megohm tester (500 V range), measure the insula- The mea- tion resistance between the ter- sured value is...

  • Page 199: Dtc: P0A92 (Tc29)

    HYBRID/TROUBLE SHOOTING 3–195 DTC: P0A92 (TC29) EN01H03ZZZ030602003028 DTC: P0A92 (TC29) Abnormality in charging performance INFORMATION Connector B High volatage J/B (inside the battery pack) Battery ECU Relay Motor Resistor SMR1 Inverter terminal terminal Connector C High volatage J/B block block Color: Orange (Inside the ECU-box) Voltage monitoring cable...
  • Page 200 3–196 HYBRID/TROUBLE SHOOTING Reset condition • The following conditions are met continuously for 3 seconds or more: - Charging power/generated power is 0.50 or more. - Charging power/generated power is 1.50 or less. Indication, warning or system control regulation when the DTC is set. •...
  • Page 201 INSPECTION PROCEDURE: P0A92 (TC29) Inspecting the inverter [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the inverter line is detected.
  • Page 202 3–198 HYBRID/TROUBLE SHOOTING Preparation for inspection Set the starter key to the "LOCK" position. Disconnect the service plug and wait for 7 minutes or more. Disconnect the 16 P and 22 P connectors of HV battery ECU. Is the inspection preparation completed? Go to step 4.
  • Page 203 HYBRID/TROUBLE SHOOTING 3–199 Inspecting the service plug 1 Disconnect the 1st and 2nd terminals from the HV battery and then remove the frame wire. Using the electrical tester, measure the insulation resistance between each terminal of frame wire and the ground. (Do not install the service plug.) Measurement Tester...
  • Page 204 3–200 HYBRID/TROUBLE SHOOTING Inspecting the insulation resistance of high-voltage J/B (in the battery pack) Disconnect the BATT OUT (+) [5] and BATT OUT (-) [6] terminals from the high-voltage J/B (in the battery pack), and then remove the frame wire. BATT OUT(-)[6] BATT IN(-)[4] Using the electrical tester, measure the insulation resistance...
  • Page 205 HYBRID/TROUBLE SHOOTING 3–201 Inspecting the insulation resistance of frame wire (to the high-voltage J/B) Disconnect the 9th and 10th terminals from the high-voltage J/B (in the ECU box), and then remove the frame wire. [10] Using the electrical tester, measure the insulation resistance between the terminals of frame wire and the ground.
  • Page 206 3–202 HYBRID/TROUBLE SHOOTING Inspecting the insulation resistance of high-voltage J/B (in the ECU box) Disconnect the 13th and 14th terminals from the high-voltage J/B (in the ECU box), and then remove the frame wire. 9 (BATT+) Using the electrical tester, measure the insulation resistance between the terminals of high-voltage J/B (in the ECU box) and 10 (BATT-) the ground.
  • Page 207 HYBRID/TROUBLE SHOOTING 3–203 Inspecting the insulation resistance of frame wire (between the high-voltage J/B (in the ECU box) and the inverter) Disconnect the 15th and 16th terminals from the inverter and then remove the frame wire. [16] Using the electrical tester, measure the insulation resistance between the terminals of frame wire and the ground.
  • Page 208 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. (Insert the service plug last.) Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history.
  • Page 209 1. Set the starter key to the the inverter "LOCK" position. line is 2. Connect the diagnosis tool detected: Go (HINO-DX) to the vehicle. Perform trou- Inspecting the to YES. bleshooting for 3. Set the starter key to the "ON"...
  • Page 210 3–206 HYBRID/TROUBLE SHOOTING P0A92 (TC29) Abnormality in charging performance Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the 1st and 2nd ter- minals from the HV battery and The mea- then remove the frame wire. sured value is 2.
  • Page 211 HYBRID/TROUBLE SHOOTING 3–207 P0A92 (TC29) Abnormality in charging performance Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the BATT OUT (+) [5] and BATT OUT (-) [6] termi- nals from the high-voltage J/B (in the battery pack), and then remove the frame wire.
  • Page 212 3–208 HYBRID/TROUBLE SHOOTING P0A92 (TC29) Abnormality in charging performance Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the 13th and 14th terminals from the high-voltage J/B (in the ECU box), and then The mea- remove the frame wire. sured value is 2.
  • Page 213 (Insert the service plug last.) 2. Connect the diagnosis tool (HINO-DX) to the vehicle. 3. Set the starter key to the "ON" position. 4. Clear the malfunction history. 5. Perform a test run. (Repeat the...

  • Page 214: Dtc: P0A93 (Tc7A)

    3–210 HYBRID/TROUBLE SHOOTING DTC: P0A93 (TC7A) EN01H03ZZZ030602003029 DTC: P0A93 (TC7A) Abnormality in inverter cooling system INFORMATION Coolant temperature sensor HV ECU SHTS03ZZZ0300140 Technical description • – <Description of malfunction> • Detected an abnormality in high temperature of inverter coolant. DTC set condition DTC detection condition •...
  • Page 215 HYBRID/TROUBLE SHOOTING 3–211 Estimated failure factors • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of inverter cooling circuit • Malfunction of inverter coolant temperature sensor • Malfunction of HV water pump • Malfunction of HV radiator fan •...
  • Page 216 3–212 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A93 (TC7A) Inspecting the coolant system route Check the coolant system route (radiator, inverter, and hose) for any damage or water leakage. Is any defect found? Repair or replace the defective part. Go to step 2. After repair/replacement, perform the inspec- tion again.
  • Page 217 3–213 Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any other coolant temperature sensor system DTC (listed below) is detected.
  • Page 218 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run for approximately 30 minutes.
  • Page 219 Go to NO. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC other than P0A93- 3. Set the starter key to the "ON" 7A is detected: position.
  • Page 220 1. Connect all the connectors that have been disconnected to restore the system. DTC P0A93- 2. Connect the diagnosis tool 7A is detected: (HINO-DX) to the vehicle. Go to YES. Reproduction The inspec- 3. Set the starter key to the "ON" Replace the check [HINO- position.

  • Page 221: Dtc: P0Afd (Tc6B)

    HYBRID/TROUBLE SHOOTING 3–217 DTC: P0AFD (TC6B) EN01H03ZZZ030602003030 DTC: P0AFD (TC6B) Abnormality in low temperature of HV battery INFORMATION Technical description • – <Description of malfunction> • Detected the low temperature abnormality in the HV battery. DTC set condition DTC detection condition •...
  • Page 222 INSPECTION PROCEDURE: P0AFD (TC6B) Inspecting the inverter [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the inverter line is detected.
  • Page 223 HYBRID/TROUBLE SHOOTING 3–219 Inspecting the HV battery temperature [HINO-DX] Select [Data Monitor] on the diagnosis tool screen and monitor [HV battery minimum temperature]. Measurement Tester Standard values conditions connections HV battery mini- HV battery mini- mum temperature: Starter key: ON -30 C {-22 F} or...
  • Page 224 1. Set the starter key to the the inverter "LOCK" position. line is 2. Connect the diagnosis tool detected: Go (HINO-DX) to the vehicle. Perform trou- Inspecting the to YES. bleshooting for 3. Set the starter key to the "ON"...

  • Page 225: Dtc: P0Bca (Tc68)

    HYBRID/TROUBLE SHOOTING 3–221 DTC: P0BCA (TC68) EN01H03ZZZ030602003031 DTC: P0BCA (TC68) Abnormality in HV battery cooling fan revolving number signal High INFORMATION PCI_B_20A HV battery starter relay HV battery cooling fan HV ECU SHTS03ZZZ0300147 Technical description • – <Description of malfunction> •...
  • Page 226 3–222 HYBRID/TROUBLE SHOOTING Pre-inspection work • Check the battery voltage to make sure that there is no abnormality. After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness •...
  • Page 227 INSPECTION PROCEDURE: P0BCA (TC68) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if P060B- B2 is detected.
  • Page 228 Replace the PCU wire harness (upper side). Replace the HV battery cooling fan. After replacement, go to step 4. Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position.
  • Page 229 "LOCK" position. B2 is detected: 2. Connect the diagnosis tool Go to YES. Perform trou- Reading the (HINO-DX) to the vehicle. bleshooting for DTC [HINO- Go to step 2. 3. Set the starter key to the "ON" DTC P060B- each of related position.
  • Page 230 68 is detected: 3. Clear the malfunction history. Go to YES. Reproduction The inspec- Replace the 4. Set the starter key to the check [HINO- tion is com- DTC P0BCA- HV ECU. "LOCK" position and wait for 1 pleted. 68 is not minute.

  • Page 231: Dtc: P0C73 (Tc80)

    HYBRID/TROUBLE SHOOTING 3–227 DTC: P0C73 (TC80) EN01H03ZZZ030602003032 DTC: P0C73 (TC80) Abnormality in HV water pump function INFORMATION PCI_B_2 20A Inverter starter relay Inverter coolant pump SHTS03ZZZ0300150 Technical description • – <Description of malfunction> • Detected an abnormality in the HV water pump function. DTC set condition DTC detection condition •...
  • Page 232 3–228 HYBRID/TROUBLE SHOOTING Judgement criteria • One of the conditions below is met continuously for 10 seconds or more. - The number of revolutions of the HV water pump is higher than the upper limit. - The number of revolutions of the HV water pump is lower than the lower limit. (For upper and lower limits, see below.) <Lower limit>...
  • Page 233 Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any of the following DTC is detected.
  • Page 234 3–230 HYBRID/TROUBLE SHOOTING Inspecting the coolant level Remove the radiator cap and check the height from the coolant level to the filling port. Is the coolant level about 10 mm from the filling port? Go to step 4. Add coolant. (See "Adding coolant.") After adding coolant, perform the inspection again.
  • Page 235 Replace the PCU wire harness (lower side). Replace the inverter cooling pump. After replacement, go to step 6. Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position.
  • Page 236 1. Set the starter key to the "LOCK" position. DTC other 2. Connect the diagnosis tool than P0C73- (HINO-DX) to the vehicle. 80 is detected: 3. Set the starter key to the "ON" Go to YES. Perform trou- Reading the position.
  • Page 237 80 is detected: km/h or more) Go to YES. Reproduction The inspec- Replace the 5. Set the starter key to the check [HINO- tion is com- DTC P0C73- HV ECU. "LOCK" position and wait for 1 pleted. 80 is not minute.

  • Page 238: Dtc: P3000 (Tc42)

    3–234 HYBRID/TROUBLE SHOOTING DTC: P3000 (TC42) EN01H03ZZZ030602003033 DTC: P3000 (TC42) Abnormality in status of HV battery ECU IG signal INFORMATION PCI_B_20A HV battery starter relay HV ECU Battery ECU SHTS03ZZZ0300153 Technical description • – <Description of malfunction> • Detected an abnormality in the HV battery IG signal circuit (status abnormality). DTC set condition DTC detection condition •...
  • Page 239 HYBRID/TROUBLE SHOOTING 3–235 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, reducing the feeling of deceleration during deceleration. Pre-inspection work •...
  • Page 240 INSPECTION PROCEDURE: P3000 (TC42) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if DTC P33B1-64 or P33B2-63 related to malfunctioning of HV battery ECU start relay circuit is detected.
  • Page 241 HYBRID/TROUBLE SHOOTING 3–237 Inspecting the HV battery start relay Set the starter key to the "LOCK" position. Remove the HV battery start relay. Using the electrical tester, measure the resistance between the 3rd and 5th terminals of HV battery start relay. (With no voltage applied) Apply the voltage of 12 V between the 1st and 2nd terminals of HV battery start relay and measure the resistance between the 3rd...
  • Page 242 3–238 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) Connect the HV battery start relay and PCU harness (24P) con- nectors. Disconnect the PCU harness (16P) connector. Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the lower- side connector terminals of PCU harness (16P).
  • Page 243 HYBRID/TROUBLE SHOOTING 3–239 Inspecting the PCU wire harness (upper side) Set the starter key to the "LOCK" position. Connect the PCU harness (16P) connector. Disconnect the PCU harness (26P) connector. Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the bat- tery ECU (26P) connector terminals.
  • Page 244 1. Set the starter key to the "LOCK" position. DTC P33B1- 2. Connect the diagnosis tool 64 or P33B2- (HINO-DX) to the vehicle. 63 is detected: Go to YES. Perform trou- 3. Set the starter key to the "ON" Reading the bleshooting for position.
  • Page 245 HYBRID/TROUBLE SHOOTING 3–241 Abnormality in status of P3000 (TC42) Inspection Procedure HV battery ECU IG signal Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Remove the HV battery start relay. 3. Using the electrical tester, mea- The mea- sure the resistance between sured value is...
  • Page 246 3–242 HYBRID/TROUBLE SHOOTING Abnormality in status of P3000 (TC42) Inspection Procedure HV battery ECU IG signal Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the PCU harness (16P) connector. The mea- 3.

  • Page 247: Dtc: P3001 (Tc41)

    HYBRID/TROUBLE SHOOTING 3–243 DTC: P3001 (TC41) EN01H03ZZZ030602003034 DTC: P3001 (TC41) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (abnormality in ECU memory line) in the HV battery. DTC set condition DTC detection condition •...
  • Page 248 Inspecting the HV battery ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected.
  • Page 249 "LOCK" position. line is DTC. 2. Connect the diagnosis tool detected: Go (If communica- Inspecting the (HINO-DX) to the vehicle. to YES. tion between HV battery 3. Set the starter key to the "ON" the diagnosis Go to step 2.

  • Page 250: Dtc: P3001 (Tc43)

    3–246 HYBRID/TROUBLE SHOOTING DTC: P3001 (TC43) EN01H03ZZZ030602003035 DTC: P3001 (TC43) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the HV battery. DTC set condition DTC detection condition • The output of HV battery ECU start relay is ON. •...
  • Page 251 Inspecting the HV battery ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected.
  • Page 252 "LOCK" position. line is DTC. 2. Connect the diagnosis tool detected: Go (If communica- Inspecting the (HINO-DX) to the vehicle. to YES. tion between HV battery 3. Set the starter key to the "ON" the diagnosis Go to step 2.

  • Page 253: Dtc: P3001 (Tc44)

    HYBRID/TROUBLE SHOOTING 3–249 DTC: P3001 (TC44) EN01H03ZZZ030602003036 DTC: P3001 (TC44) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the HV battery system. DTC set condition DTC detection condition • The output of HV battery ECU start relay is ON. Judgement criteria •...
  • Page 254 Inspecting the HV battery ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected.
  • Page 255 "LOCK" position. line is DTC. 2. Connect the diagnosis tool detected: Go (If communica- Inspecting the (HINO-DX) to the vehicle. to YES. tion between HV battery 3. Set the starter key to the "ON" the diagnosis Go to step 2.

  • Page 256: Dtc: P3001 (Tc45)

    3–252 HYBRID/TROUBLE SHOOTING DTC: P3001 (TC45) EN01H03ZZZ030602003037 DTC: P3001 (TC45) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (disconnection of high-voltage fuse) in the HV battery. DTC set condition DTC detection condition •...
  • Page 257 Inspecting the HV battery ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected.
  • Page 258 "LOCK" position. line is DTC. 2. Connect the diagnosis tool detected: Go (If communica- Inspecting the (HINO-DX) to the vehicle. to YES. tion between HV battery 3. Set the starter key to the "ON" the diagnosis Go to step 2.

  • Page 259: Dtc: P3001 (Tc46)

    HYBRID/TROUBLE SHOOTING 3–255 DTC: P3001 (TC46) EN01H03ZZZ030602003038 DTC: P3001 (TC46) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (request for stopping discharge) in the HV battery. DTC set condition DTC detection condition •...
  • Page 260 INSPECTION PROCEDURE: P3001 (TC46) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC other than the following is detected: •...
  • Page 261 HYBRID/TROUBLE SHOOTING 3–257 Inspecting the HV battery ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected. SHTS03ZZZ0300169 Is any DTC related to the HV battery line detected? Perform troubleshooting for each of related Go to step 4.
  • Page 262 1. Set the starter key to the than P3001- "LOCK" position. 46, P3001-47, 2. Connect the diagnosis tool or P3001-4A is (HINO-DX) to the vehicle. detected: Go Perform trou- 3. Set the starter key to the "ON" Reading the to YES.

  • Page 263: Dtc: P3001 (Tc47)

    HYBRID/TROUBLE SHOOTING 3–259 DTC: P3001 (TC47) EN01H03ZZZ030602003039 DTC: P3001 (TC47) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (auxiliary charge request) in the HV battery. DTC set condition DTC detection condition •...
  • Page 264 INSPECTION PROCEDURE: P3001 (TC47) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC other than the following is detected: •...
  • Page 265 HYBRID/TROUBLE SHOOTING 3–261 Inspecting the HV battery ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected. SHTS03ZZZ0300173 Is any DTC related to the HV battery line detected? Perform troubleshooting for each of related Go to step 4.
  • Page 266 1. Set the starter key to the than P3001- "LOCK" position. 46, P3001-47, 2. Connect the diagnosis tool or P3001-4A is (HINO-DX) to the vehicle. detected: Go Perform trou- 3. Set the starter key to the "ON" Reading the to YES.

  • Page 267: Dtc: P3001 (Tc4A)

    HYBRID/TROUBLE SHOOTING 3–263 DTC: P3001 (TC4A) EN01H03ZZZ030602003040 DTC: P3001 (TC4A) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an external overload abnormality in the HV battery. DTC set condition DTC detection condition • The output of HV battery ECU start relay is ON. Judgement criteria •...
  • Page 268 INSPECTION PROCEDURE: P3001 (TC4A) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC other than the following is detected.
  • Page 269 HYBRID/TROUBLE SHOOTING 3–265 Inspecting the HV battery ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected. SHTS03ZZZ0300177 Is any DTC related to the HV battery line detected? Perform troubleshooting for each of related Go to step 4.
  • Page 270 1. Set the starter key to the than P3001- "LOCK" position. 46, P3001-47, 2. Connect the diagnosis tool or P3001-4A is (HINO-DX) to the vehicle. detected: Go Perform trou- 3. Set the starter key to the "ON" Reading the to YES.

  • Page 271: Dtc: P3001 (Tc4B)

    HYBRID/TROUBLE SHOOTING 3–267 DTC: P3001 (TC4B) EN01H03ZZZ030602003041 DTC: P3001 (TC4B) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the HV battery voltage detection circuit. DTC set condition DTC detection condition •...
  • Page 272 Inspecting the HV battery ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected.
  • Page 273 "LOCK" position. line is DTC. 2. Connect the diagnosis tool detected: Go (If communica- Inspecting the (HINO-DX) to the vehicle. to YES. tion between HV battery 3. Set the starter key to the "ON" the diagnosis Go to step 2.

  • Page 274: Dtc: P3001 (Tc4C)

    3–270 HYBRID/TROUBLE SHOOTING DTC: P3001 (TC4C) EN01H03ZZZ030602003042 DTC: P3001 (TC4C) Abnormality in HV battery line INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (request for stopping charge) in the HV battery. DTC set condition DTC detection condition •...
  • Page 275 Inspecting the HV battery ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected.
  • Page 276 "LOCK" position. line is DTC. 2. Connect the diagnosis tool detected: Go (If communica- Inspecting the (HINO-DX) to the vehicle. to YES. tion between HV battery 3. Set the starter key to the "ON" the diagnosis Go to step 2.

  • Page 277: Dtc: P3009 (Tc49)

    HYBRID/TROUBLE SHOOTING 3–273 DTC: P3009 (TC49) EN01H03ZZZ030602003043 DTC: P3009 (TC49) Abnormality in leakage INFORMATION Connector B High volatage J/B (Inside the battery pack) Battery ECU Relay Motor Resistor SMR1 Inverter terminal terminal Connector C High volatage J/B block block color: Orange (Inside the ECU-box) Voltage monitoring cable SMR2...
  • Page 278 3–274 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper connector connection or fitting • Malfunction of high-voltage circuit •...
  • Page 279 HYBRID/TROUBLE SHOOTING 3–275 INSPECTION PROCEDURE: P3009 (TC49) Preparation for inspection Set the starter key to the "LOCK" position. Disconnect the service plug and wait for 7 minutes or more. Disconnect the 16P and 22 P connectors of battery ECU. Is the inspection preparation completed? Go to step 2.
  • Page 280 3–276 HYBRID/TROUBLE SHOOTING Inspecting the service plug 1 Disconnect the 1st and 2nd terminals from the HV battery and then remove the frame wire. Using the electrical tester, measure the insulation resistance between the terminals of frame wire and the ground. (Do not install the service plug.) Measurement Tester...
  • Page 281 HYBRID/TROUBLE SHOOTING 3–277 Inspecting the insulation resistance of high-voltage J/B (in the battery pack) Disconnect the BATT OUT (+) [5] and BATT OUT (-) [6] terminals from the high-voltage J/B (in the battery pack), and then remove the frame wire. BATT OUT(-)[6] BATT IN(-)[4] Using the electrical tester, measure the insulation resistance...
  • Page 282 3–278 HYBRID/TROUBLE SHOOTING Inspecting the insulation resistance of frame wire (to the high-voltage J/B) Disconnect the 9th and 10th terminals from the high-voltage J/B (in the ECU box), and then remove the frame wire. [10] Using the electrical tester, measure the insulation resistance between the terminals of frame wire and the ground.
  • Page 283 HYBRID/TROUBLE SHOOTING 3–279 Inspecting the insulation resistance of frame wire (between the high-voltage J/B (in the ECU box) and the inverter) Disconnect the 15th and 16th terminals from the inverter and then remove the frame wire. [16] Using the electrical tester, measure the insulation resistance between the terminals of frame wire and the ground.
  • Page 284 3–280 HYBRID/TROUBLE SHOOTING Inspecting the insulation resistance of inverter Disconnect the 17th, 18th, and 19th terminals from the inverter and then remove the frame wire. VEHICLE GND Using the electrical tester, measure the insulation resistance between the terminals of inverter and the ground. 15 16 Measurement Tester...
  • Page 285 HYBRID/TROUBLE SHOOTING 3–281 Inspecting the insulation resistance of frame wire (between the inverter and the relay terminal block) Disconnect the frame wires of 20th, 21st, and 22nd terminals from the relay terminal block. [22] [21] Using the electrical tester, measure the insulation resistance between the terminals of frame wire and the ground.
  • Page 286 3–282 HYBRID/TROUBLE SHOOTING Inspecting the insulation resistance of relay terminal block Using the electrical tester, measure the insulation resistance between the relay terminal block side terminals and the ground. Measurement Tester Standard values conditions connections Relay terminal block 20th terminal – Starter key: LOCK 10 M...
  • Page 287 Connect all the cables and connectors that have been discon- nected to restore the system. Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history.
  • Page 288 3–284 HYBRID/TROUBLE SHOOTING CHECKLIST: P3009 (TC49) P3009 (TC49) Abnormality in leakage Inspection Procedure Check Step Action Description Judgement (Yes/No) Inspection preparation is 1. Set the starter key to the completed: Go "LOCK" position. to YES. Perform the Preparation for inspection 2.
  • Page 289 HYBRID/TROUBLE SHOOTING 3–285 P3009 (TC49) Abnormality in leakage Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Install a service plug to the The mea- frame wire. sured value is 2. Using the electrical tester, mea- within the sure the insulation resistance range of stan- between the terminals of frame dard value: Go...
  • Page 290 3–286 HYBRID/TROUBLE SHOOTING P3009 (TC49) Abnormality in leakage Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the 13th and 14th terminals from the high-voltage J/B (in the ECU box), and then The mea- remove the frame wire. sured value is within the 2.
  • Page 291 HYBRID/TROUBLE SHOOTING 3–287 P3009 (TC49) Abnormality in leakage Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the frame wires of 20th, 21st, and 22nd terminals The mea- from the relay terminal block. sured value is 2. Using the electrical tester, mea- within the Inspecting the sure the insulation resistance...
  • Page 292 2. Set the starter key to the DTC P3009- "LOCK" position. 49 is detected: 3. Connect the diagnosis tool Go to YES. (HINO-DX) to the vehicle. Reproduction Replace the The inspec- check [HINO- HV battery tion is com- 4.

  • Page 293: Dtc: P3128 (Tc7D)

    HYBRID/TROUBLE SHOOTING 3–289 DTC: P3128 (TC7D) EN01H03ZZZ030602003044 DTC: P3128 (TC7D) Abnormality in HV radiator fan revolution number Low INFORMATION Inverter cooling Inverter radiator fan starter relay PCI_B_2 20A HV ECU Inverter SHTS03ZZZ0300196 Technical description • – <Description of malfunction> • Detected an abnormality in low number of revolutions of HV radiator fan. DTC set condition DTC detection condition •...
  • Page 294 3–290 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper connector connection or fitting • Malfunction of HV radiator fan •...
  • Page 295 INSPECTION PROCEDURE: P3128 (TC7D) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Select [Hybrid] on the diagnosis tool screen. In [Fault Information] on the diagnosis tool screen, check if any of...
  • Page 296 3–292 HYBRID/TROUBLE SHOOTING Inspecting the voltage of vehicle wire harness Set the starter key to the "LOCK" position. VEHICLE GND Disconnect the PCU harness (24P) connector. Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the 3rd terminal of PCU harness (24P) vehicle-side connector and the ground.
  • Page 297 HYBRID/TROUBLE SHOOTING 3–293 Inspecting the inverter start relay Set the starter key to the "LOCK" position. Remove the inverter start relay. Using the electrical tester, measure the resistance between the 3rd and 5th terminals of inverter start relay. (With no voltage applied) Apply the voltage of 12 V between the 1st and 2nd terminals of inverter start relay and measure the resistance between the 3rd...
  • Page 298 3–294 HYBRID/TROUBLE SHOOTING Inspecting the voltage of PCU wire harness (lower side) Connect the PCU harness (24P) connector and the inverter start relay. Disconnect the connector of inverter cooling radiator fan. Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the con- nector terminals of inverter cooling radiator fan.
  • Page 299 HYBRID/TROUBLE SHOOTING 3–295 Inspecting the continuity of PCU wire harness (lower side) Set the starter key to the "LOCK" position. Disconnect the HV ECU1 connector. Using the electrical tester, measure the resistance between the connector terminal of inverter cooling radiator fan and the HV ECU1 connector terminal.
  • Page 300 Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history.
  • Page 301 Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool DTC P324B- (HINO-DX) to the vehicle. 62 or P324C- 3. Set the starter key to the "ON" 61 is detected: position. Go to YES.
  • Page 302 3–298 HYBRID/TROUBLE SHOOTING Abnormality in HV radiator fan revolution P3128 (TC7D) Inspection Procedure number Low Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Remove the inverter start relay. 3. Using the electrical tester, mea- sure the resistance between The mea- the 3rd and 5th terminals of...
  • Page 303 HYBRID/TROUBLE SHOOTING 3–299 Abnormality in HV radiator fan revolution P3128 (TC7D) Inspection Procedure number Low Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the HV ECU1 con- The mea- nector. sured value is 3.
  • Page 304 2. Set the starter key to the "LOCK" position. 3. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P3128- 4. Set the starter key to the "ON" 7D is detected: position. Go to YES.

  • Page 305: Dtc: P3129 (Tc7C)

    HYBRID/TROUBLE SHOOTING 3–301 DTC: P3129 (TC7C) EN01H03ZZZ030602003045 DTC: P3129 (TC7C) Abnormality in HV radiator fan revolution number High INFORMATION Inverter cooling Inverter radiator fan starter relay PCI_B_2 20A HV ECU Inverter SHTS03ZZZ0300204 Technical description • – <Description of malfunction> • Detected an abnormally high number of revolutions of the HV radiator fan. DTC set condition DTC detection condition •...
  • Page 306 3–302 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper connector connection or fitting • Malfunction of HV radiator fan •...
  • Page 307 HYBRID/TROUBLE SHOOTING 3–303 INSPECTION PROCEDURE: P3129 (TC7C) Inspecting the inverter cooling radiator fan Check that the inverter cooling radiator fan is free from damage. Is any defect found? Replace the inverter cooling radiator fan. Go to step 2. Inspecting the signal line of PCU wire harness (lower side) for short circuit Set the starter key to the "LOCK"...
  • Page 308 Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history.
  • Page 309 2. Set the starter key to the "LOCK" position. 3. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P3129- 4. Set the starter key to the "ON" 7C is detected: position. Go to YES.

  • Page 310: Dtc: P314C (Tc82)

    3–306 HYBRID/TROUBLE SHOOTING DTC: P314C (TC82) EN01H03ZZZ030602003046 DTC: P314C (TC82) Abnormality in HV water pump revolution number signal Low INFORMATION Inverter Inverter coolant pump starter relay PCI_B_2 20 HV ECU SHTS03ZZZ0300206 Technical description • – <Description of malfunction> • Detected a GND short circuit in the HV water pump revolution number signal circuit. DTC set condition DTC detection condition •...
  • Page 311 HYBRID/TROUBLE SHOOTING 3–307 After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of HV water pump •...
  • Page 312 3–308 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P314C (TC82) Inspecting the PCU wire harness (lower side) for short circuit Set the starter key to the "LOCK" position. VEHICLE GND Disconnect the inverter cooling pump and the HV ECU1 connec- tor. Using the electrical tester, measure the resistance between the 2nd terminal of inverter cooling pump connector and the ground.
  • Page 313 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "ON" position and wait for 1 minute.
  • Page 314 1. Connect all the connectors that have been disconnected to restore the system. DTC P314C- 2. Connect the diagnosis tool 82 is detected: (HINO-DX) to the vehicle. Go to YES. Reproduction 3. Set the starter key to the "ON" The inspec- Replace the check [HINO- position.

  • Page 315: Dtc: P314D (Tc81)

    HYBRID/TROUBLE SHOOTING 3–311 DTC: P314D (TC81) EN01H03ZZZ030602003047 DTC: P314D (TC81) Abnormality in HV water pump revolution number signal High INFORMATION Inverter Inverter coolant pump starter relay PCI_B_2 20 HV ECU SHTS03ZZZ0300209 Technical description • – <Description of malfunction> • Detected a disconnection in the HV water pump revolution number signal circuit. DTC set condition DTC detection condition •...
  • Page 316 3–312 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Disconnection or short circuit of harness • Improper contact or fitting of connector • Malfunction of HV water pump •...
  • Page 317 INSPECTION PROCEDURE: P314D (TC81) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if DTC P324B-62 or P324C-61 is detected.
  • Page 318 3–314 HYBRID/TROUBLE SHOOTING Checking the activation of inverter cooling pump [HINO-DX] In [Activation Test] on the diagnosis tool screen, select [HV water pump drive duty value]. Activate the HV water pump at the duty value of 60% and feel the hose to make sure that the water pump is running.
  • Page 319 HYBRID/TROUBLE SHOOTING 3–315 Inspecting the inverter start relay Set the starter key to the "LOCK" position. Remove the inverter start relay. Using the electrical tester, measure the resistance between the 3rd and 5th terminals of inverter start relay. (With no voltage applied) Apply the voltage of 12 V between the 1st and 2nd terminals of inverter start relay and measure the resistance between the 3rd...
  • Page 320 3–316 HYBRID/TROUBLE SHOOTING Inspecting the voltage of PCU wire harness (lower side) Connect the inverter start relay and PCU harness (24P) connec- tors. Disconnect the inverter cooling pump connector. Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the con- nector terminals of inverter cooling pump.
  • Page 321 HYBRID/TROUBLE SHOOTING 3–317 Inspecting the continuity of PCU wire harness (lower side) Set the starter key to the "LOCK" position. Disconnect the HV ECU1 connector. Using the electrical tester, measure the resistance between the inverter cooling pump connector and the HV ECU1 connector ter- minal.
  • Page 322 3–318 HYBRID/TROUBLE SHOOTING Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "ON" position and wait for 1 minute.
  • Page 323 1. Set the starter key to the DTC P324B- "LOCK" position. 62 or P324C- 2. Connect the diagnosis tool 61 is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Reading the bleshooting for 3. Set the starter key to the "ON"...
  • Page 324 3–320 HYBRID/TROUBLE SHOOTING Abnormality in HV water pump revolution P314D (TC81) Inspection Procedure number signal High Check Step Action Description Judgement (Yes/No) 1. Disconnect the PCU harness The mea- (24P) connector. sured value is 2. Using the electrical tester, mea- within the sure the voltage between the range of stan-...
  • Page 325 HYBRID/TROUBLE SHOOTING 3–321 Abnormality in HV water pump revolution P314D (TC81) Inspection Procedure number signal High Check Step Action Description Judgement (Yes/No) 1. Connect the inverter start relay and PCU harness (24P) con- nectors. The mea- 2. Disconnect the inverter cooling sured value is pump connector.
  • Page 326 2. Set the starter key to the "ON" Go to YES. position. Reproduction The inspec- Replace the check [HINO- tion is com- 3. Clear the malfunction history. DTC P314D- HV ECU. pleted. 4. Set the starter key to the "ON"...

  • Page 327: Dtc: P324B (Tc62)

    HYBRID/TROUBLE SHOOTING 3–323 DTC: P324B (TC62) EN01H03ZZZ030602003048 DTC: P324B (TC62) Abnormality in inverter start relay Low INFORMATION PCI_B_20A Inverter starter relay Inverter Inverter cooling HV ECU radiator fan Inverter coolant pump SHTS03ZZZ0300217 Technical description • – <Description of malfunction> • Detected a GND short circuit in the inverter start relay energized circuit. DTC set condition DTC detection condition •...
  • Page 328 3–324 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine cannot be started. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 329 HYBRID/TROUBLE SHOOTING 3–325 INSPECTION PROCEDURE: P324B (TC62) Inspecting the inverter start relay Set the starter key to the "LOCK" position. Remove the inverter start relay from the relay block. Using the electrical tester, measure the resistance between the inverter start relay terminals. Measurement Tester Standard values...
  • Page 330 3–326 HYBRID/TROUBLE SHOOTING Inspecting the signal line of PCU wire harness (lower side) for short circuit For the 1st terminal of inverter start relay connector (relay block), inspect the signal line of PCU wire harness (lower side) for short circuit. (See "Inspecting the PCU harness signal line for short cir- cuit.") Measurement Tester...
  • Page 331 HYBRID/TROUBLE SHOOTING 3–327 CHECKLIST: P324B (TC62) P324B (TC62) Abnormality in inverter start relay Low Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. The mea- sured value is 2. Remove the inverter start relay within the from the relay block.

  • Page 332: Dtc: P324C (Tc61)

    3–328 HYBRID/TROUBLE SHOOTING DTC: P324C (TC61) EN01H03ZZZ030602003049 DTC: P324C (TC61) Abnormality in inverter start relay High INFORMATION PCI_B_20A Inverter starter relay Inverter Inverter cooling HV ECU radiator fan Inverter coolant pump SHTS03ZZZ0300220 Technical description • – <Description of malfunction> • Detected a disconnection or power supply (positive side) short circuit in the inverter start relay energized circuit. DTC set condition DTC detection condition •...
  • Page 333 HYBRID/TROUBLE SHOOTING 3–329 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine cannot be started. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 334 3–330 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P324C (TC61) Inspecting the inverter start relay Set the starter key to the "LOCK" position. Remove the inverter start relay from the relay block. Using an electrical tester, measure the resistance between the inverter start relay terminals. Measurement Tester Standard values...
  • Page 335 HYBRID/TROUBLE SHOOTING 3–331 Inspecting the continuity of PCU wire harness (lower side) Disconnect the HV ECU2 and inverter connectors. Using an electrical tester, measure the resistance from the inverter start relay connector (relay block) to the HV ECU2 connector ter- minal and to the ground.
  • Page 336 3–332 HYBRID/TROUBLE SHOOTING Inspecting the signal line of PCU wire harness (lower side) for short circuit For the 1st terminal of inverter start relay connector (relay block), inspect the signal line of PCU wire harness (lower side) for short circuit. (See "Inspecting the PCU harness signal line for short cir- cuit.") Measurement Tester...
  • Page 337 HYBRID/TROUBLE SHOOTING 3–333 CHECKLIST: P324C (TC61) P324C (TC61) Abnormality in inverter start relay High Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. The mea- sured value is 2. Remove the inverter start relay within the from the relay block.

  • Page 338: Dtc: P33B1 (Tc64)

    3–334 HYBRID/TROUBLE SHOOTING DTC: P33B1 (TC64) EN01H03ZZZ030602003050 DTC: P33B1 (TC64) Abnormality in HV battery ECU start relay Low INFORMATION PCI_B_20A HV battery starter relay HV battery cooling fan HV ECU SHTS03ZZZ0300223 Technical description • – <Description of malfunction> • Detected a GND short circuit in the energized circuit of HV battery ECU start relay. DTC set condition DTC detection condition •...
  • Page 339 HYBRID/TROUBLE SHOOTING 3–335 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, which may reduce the feeling of deceleration during deceleration. Pre-inspection work •...
  • Page 340 3–336 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P33B1 (TC64) Inspecting the HV battery start relay Set the starter key to the "LOCK" position. Remove the HV battery start relay from the relay block. Using the electrical tester, measure the resistance between the HV battery start relay terminals.
  • Page 341 HYBRID/TROUBLE SHOOTING 3–337 Inspecting the signal line of PCU wire harness (lower side) for short circuit Disconnect the HV ECU2 connector. For the 1st terminal of HV battery start relay connector (relay block), inspect the signal line of PCU wire harness (lower side) for short circuit.
  • Page 342 3–338 HYBRID/TROUBLE SHOOTING CHECKLIST: P33B1 (TC64) P33B1 (TC64) Abnormality in HV battery ECU start relay Low Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. The mea- sured value is 2. Remove the HV battery start within the relay from the relay block.

  • Page 343: Dtc: P33B2 (Tc63)

    HYBRID/TROUBLE SHOOTING 3–339 DTC: P33B2 (TC63) EN01H03ZZZ030602003051 DTC: P33B2 (TC63) Abnormality in HV battery ECU start relay High INFORMATION PCI_B_20A HV battery starter relay HV battery cooling fan HV ECU SHTS03ZZZ0300226 Technical description • – <Description of malfunction> • Detected a disconnection or power supply (positive side) short circuit in the energized circuit of HV battery ECU start relay.
  • Page 344 3–340 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, which may reduce the feeling of deceleration during deceleration. Pre-inspection work •...
  • Page 345 HYBRID/TROUBLE SHOOTING 3–341 INSPECTION PROCEDURE: P33B2 (TC63) Inspecting the HV battery start relay Set the starter key to the "LOCK" position. Remove the HV battery start relay from the relay block. Using the electrical tester, measure the resistance between the HV battery start relay terminals.
  • Page 346 3–342 HYBRID/TROUBLE SHOOTING Inspecting the continuity of PCU wire harness (lower side) Disconnect the HV ECU2 connector. Using the electrical tester, measure the resistance from the HV battery start relay connector (relay block) to the HV ECU2 connec- tor terminal and to the ground. Measurement Tester Standard values...
  • Page 347 HYBRID/TROUBLE SHOOTING 3–343 Inspecting the signal line of PCU wire harness (lower side) for short circuit For the 1st terminal of HV battery start relay connector (relay block), inspect the signal line of PCU wire harness (lower side) for short circuit. (See "Inspecting the PCU harness signal line for short circuit.") Measurement Tester...
  • Page 348 3–344 HYBRID/TROUBLE SHOOTING CHECKLIST: P33B2 (TC63) P33B2 (TC63) Abnormality in HV battery ECU start relay High Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. The mea- sured value is 2. Remove the HV battery start within the relay from the relay block.

  • Page 349: Dtc: U0073 (Tc11)

    HYBRID/TROUBLE SHOOTING 3–345 DTC: U0073 (TC11) EN01H03ZZZ030602003052 DTC: U0073 (TC11) Abnormality in CAN communication with HV ECU (control CAN) INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1...
  • Page 350 3–346 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, which may reduce the feeling of deceleration during deceleration. •...
  • Page 351 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU and inverter.
  • Page 352 3–348 HYBRID/TROUBLE SHOOTING Inspecting the inverter [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-91 is detected in the inverter. SHTS03ZZZ0300231 Is DTC U0073-91 detected? Refer to the "CONTROL CAN COMMUNICA- Replace the HV ECU. TION LINE (HYBRID)" in the chapter "CON-...
  • Page 353 SYSTEM". items. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U0073- pleted. position. 11 is detected: (Temporary Go to YES.

  • Page 354: Dtc: U0074 (Tc16)

    3–350 HYBRID/TROUBLE SHOOTING DTC: U0074 (TC16) EN01H03ZZZ030602003053 DTC: U0074 (TC16) Abnormality in CAN communication with HV ECU (DIAG CAN) INFORMATION Engine ECU VCS ECU (CANN) (CANP) (CANL) (CANH) J/C CAN1(22P) J/C CAN 2 INST PANEL INST PANEL J/C CAN5 ENGINE No.1 W/H No.1 W/H No.2 W/H J/C CAN1(10P)
  • Page 355 HYBRID/TROUBLE SHOOTING 3–351 Indication, warning or system control regulation when the DTC is set. • MIL: ON • HV warning light: ON Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> •...
  • Page 356 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "LOCK" position and wait for approxi- mately 1 minute.
  • Page 357 1. Set the starter key to the "LOCK" position. The inspec- 2. Connect the diagnosis tool tion is com- (HINO-DX) to the vehicle. Refer to the DTC U0074- pleted. 3. Set the starter key to the "ON" "DIAGNOSIS 16 is detected: (Temporary position.

  • Page 358: Dtc: U0100 (Tc13)

    3–354 HYBRID/TROUBLE SHOOTING DTC: U0100 (TC13) EN01H03ZZZ030602003054 DTC: U0100 (TC13) Engine ECU CAN communication blackout INFORMATION Engine ECU VCS ECU (CANN) (CANP) (CANL) (CANH) J/C CAN1(22P) J/C CAN 2 INST PANEL INST PANEL J/C CAN5 ENGINE No.1 W/H No.1 W/H No.2 W/H J/C CAN1(10P) HV PCU...
  • Page 359 HYBRID/TROUBLE SHOOTING 3–355 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, which may reduce the feeling of deceleration during deceleration. Pre-inspection work •...
  • Page 360 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "LOCK" position and wait for approxi- mately 1 minute.
  • Page 361 1. Set the starter key to the "LOCK" position. The inspec- 2. Connect the diagnosis tool tion is com- (HINO-DX) to the vehicle. Refer to the DTC U0100- pleted. 3. Set the starter key to the "ON" "DIAGNOSIS 13 is detected: (Temporary position.

  • Page 362: Dtc: U0101 (Tc18)

    3–358 HYBRID/TROUBLE SHOOTING DTC: U0101 (TC18) EN01H03ZZZ030602003055 DTC: U0101 (TC18) TCM ECU CAN communication blackout INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4) X-21 (CA2+)
  • Page 363 HYBRID/TROUBLE SHOOTING 3–359 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, which may reduce the feeling of deceleration during deceleration. Pre-inspection work •...
  • Page 364 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU and vehicle control ECU.
  • Page 365 HYBRID/TROUBLE SHOOTING 3–361 Inspecting the HV ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-11 is detected in the HV ECU. SHTS03ZZZ0300238 Is DTC U0073-11 detected? Perform troubleshooting for each of related Go to step 4.
  • Page 366 3–362 HYBRID/TROUBLE SHOOTING Inspecting the vehicle control ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0101 (AT ECU communication blackout) is detected in the vehi- cle control ECU. SHTS03ZZZ0300239 Is DTC U0101 detected? Refer to the "CONTROL CAN COMMUNICA- Replace the HV ECU.
  • Page 367 SYSTEM". items. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U0101- pleted. position. 18 is detected: (Temporary 4.
  • Page 368 • [U110A] Vehicle control ECU detected: Go CAN COMMU- (All communi- CAN communication black- Reading the to YES. NICATION cation black- DTC [HINO- LINE outs have • [U1136] Clutch ECU CAN All communi- (HYBRID)" in been gener- communication blackout cation blackout the chapter ated.)

  • Page 369: Dtc: U0110 (Tc14)

    HYBRID/TROUBLE SHOOTING 3–365 DTC: U0110 (TC14) EN01H03ZZZ030602003056 DTC: U0110 (TC14) Inverter CAN communication blackout INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4) X-21 (CA2+) Combination meter...
  • Page 370 3–366 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, which may reduce the feeling of deceleration during deceleration. Pre-inspection work •...
  • Page 371 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU, inverter, and vehicle control ECU.
  • Page 372 3–368 HYBRID/TROUBLE SHOOTING Inspecting the HV ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-11 is detected in the HV ECU. SHTS03ZZZ0300242 Is DTC U0073-11 detected? Perform troubleshooting for each of related Go to step 4.
  • Page 373 HYBRID/TROUBLE SHOOTING 3–369 Inspecting the inverter 2 [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC P0A1B-92 (Stuck control CAN register) is detected in the inverter. SHTS03ZZZ0300244 Is DTC P0A1B-92 detected? Replace the inverter. Go to step 6.
  • Page 374 3–370 HYBRID/TROUBLE SHOOTING Inspecting the vehicle control ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0155 (Meter CAN communication blackout) is detected in the vehicle control ECU. SHTS03ZZZ0300246 Is DTC U0155 detected? Refer to the "CONTROL CAN COMMUNICA- Replace the HV ECU.
  • Page 375 SYSTEM". items. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U0110- pleted. position. 14 is detected: (Temporary 4.
  • Page 376 • [U110A] Vehicle control ECU detected: Go (All communi- CAN communication black- Reading the to YES. cation black- DTC 1 [HINO- Go to step 8. outs have • [U0101] AT ECU CAN com- All communi- been gener- munication blackout cation blackout ated.)

  • Page 377: Dtc: U0111 (Tc15)

    HYBRID/TROUBLE SHOOTING 3–373 DTC: U0111 (TC15) EN01H03ZZZ030602003057 DTC: U0111 (TC15) HV battery ECU CAN communication blackout INFORMATION Engine ECU VCS ECU (CANN) (CANP) (CANL) (CANH) J/C CAN1(22P) J/C CAN 2 INST PANEL INST PANEL J/C CAN5 ENGINE No.1 W/H No.1 W/H No.2 W/H J/C CAN1(10P) HV PCU...
  • Page 378 3–374 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, which may reduce the feeling of deceleration during deceleration. Pre-inspection work •...
  • Page 379 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU and vehicle control ECU.
  • Page 380 Go to step 4. DTC. (Perform troubleshooting of U0073-11 Step 2 and onward.) Inspecting the HV battery ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0074 (CAN transmission abnormality) is detected in the HV bat- tery ECU.
  • Page 381 Go to step 6. Go to step 7. (All communication blackouts have been generated.) Inspecting the vehicle control ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0105 (Engine ECU communication blackout) is detected in the vehicle control ECU.
  • Page 382 3–378 HYBRID/TROUBLE SHOOTING Reading the DTC 2 [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if any control CAN system ECU communication blackout is detected other than U0111-15 in the HV ECU. • [U0100] Engine ECU CAN communication blackout •...
  • Page 383 SYSTEM". items. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U0111- pleted. position. 15 is detected: (Temporary 4.
  • Page 384 Go (All communi- detected other than U0111-15 Reading the to YES. cation black- in the HV ECU. DTC 1 [HINO- Go to step 7. outs have All communi- • [U0100] Engine ECU CAN been gener- cation blackout communication blackout ated.)

  • Page 385: Dtc: U0121 (Tc24)

    HYBRID/TROUBLE SHOOTING 3–381 DTC: U0121 (TC24) EN01H03ZZZ030602003058 DTC: U0121 (TC24) ABS ECU CAN communication blackout INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4) X-21 (CA2+)
  • Page 386 3–382 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. Pre-inspection work •...
  • Page 387 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU and vehicle control ECU.
  • Page 388 3–384 HYBRID/TROUBLE SHOOTING Inspecting the HV ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-11 is detected in the HV ECU. SHTS03ZZZ0300257 Is DTC U0073-11 detected? Perform troubleshooting for each of related Go to step 4.
  • Page 389 HYBRID/TROUBLE SHOOTING 3–385 Inspecting the vehicle control ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0121 (ABS ECU communication blackout) is detected in the vehi- cle control ECU. SHTS03ZZZ0300259 Is DTC U0121 detected? Refer to the "CONTROL CAN COMMUNICA- Replace the HV ECU.
  • Page 390 SYSTEM". items. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U0121- pleted position. 24 is detected: (Temporary 4.
  • Page 391 • [U110A] Vehicle control ECU detected: Go CAN COMMU- (All communi- CAN communication black- Reading the to YES. NICATION cation black- DTC [HINO- LINE outs have • [U0101] AT ECU CAN com- All communi- (HYBRID)" in been gener- munication blackout cation blackout the chapter ated.)

  • Page 392: Dtc: U0155 (Tc25)

    3–388 HYBRID/TROUBLE SHOOTING DTC: U0155 (TC25) EN01H03ZZZ030602003059 DTC: U0155 (TC25) Meter ECU CAN communication blackout INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4) X-21 (CA2+)
  • Page 393 HYBRID/TROUBLE SHOOTING 3–389 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. Pre-inspection work •...
  • Page 394 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU and vehicle control ECU.
  • Page 395 HYBRID/TROUBLE SHOOTING 3–391 Inspecting the HV ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-11 is detected in the HV ECU. SHTS03ZZZ0300262 Is DTC U0073-11 detected? Perform troubleshooting for each of related Go to step 4.
  • Page 396 3–392 HYBRID/TROUBLE SHOOTING Inspecting the vehicle control ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0155 (Meter ECU communication blackout) is detected in the vehicle control ECU. SHTS03ZZZ0300264 Is DTC U0155 detected? Refer to the "CONTROL CAN COMMUNICA- Replace the HV ECU.
  • Page 397 SYSTEM". items. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U0155- pleted. position. 25 is detected: (Temporary 4.
  • Page 398 • [U110A] Vehicle control ECU detected: Go CAN COMMU- (All communi- CAN communication black- Reading the to YES. NICATION cation black- DTC [HINO- LINE outs have • [U0101] AT ECU CAN com- All communi- (HYBRID)" in been gener- munication blackout cation blackout the chapter ated.)

  • Page 399: Dtc: U110A (Tc26)

    HYBRID/TROUBLE SHOOTING 3–395 DTC: U110A (TC26) EN01H03ZZZ030602003060 DTC: U110A (TC26) Vehicle control ECU CAN communication blackout INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4) X-21 (CA2+)
  • Page 400 3–396 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. Pre-inspection work •...
  • Page 401 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU and engine ECU.
  • Page 402 3–398 HYBRID/TROUBLE SHOOTING Inspecting the HV ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-11 is detected in the HV ECU. SHTS03ZZZ0300267 Is DTC U0073-11 detected? Perform troubleshooting for each of related Go to step 4.
  • Page 403 HYBRID/TROUBLE SHOOTING 3–399 Inspecting the engine ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U110A (vehicle control ECU communication blackout) is detected in the engine ECU. SHTS03ZZZ0300269 Is DTC U110A detected? Refer to the "CONTROL CAN COMMUNICA- Replace the HV ECU.
  • Page 404 SYSTEM". items 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U110A- pleted. position. 26 is detected: (Temporary Go to YES.
  • Page 405 Go CAN COMMU- • [U0101] AT ECU CAN com- (All communi- Reading the to YES. NICATION munication blackout cation black- DTC [HINO- LINE • [U1136] clutch ECU CAN outs have All communi- (HYBRID)" in communication blackout been gener- cation blackout the chapter ated.)

  • Page 406: Dtc: U1136 (Tc27)

    3–402 HYBRID/TROUBLE SHOOTING DTC: U1136 (TC27) EN01H03ZZZ030602003061 DTC: U1136 (TC27) Clutch ECU CAN communication blackout INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4) X-21 (CA2+)
  • Page 407 HYBRID/TROUBLE SHOOTING 3–403 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The idling stop function becomes inoperative. • The regeneration function stops, which may reduce the feeling of deceleration during deceleration. Pre-inspection work •...
  • Page 408 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU and vehicle control ECU.
  • Page 409 HYBRID/TROUBLE SHOOTING 3–405 Inspecting the HV ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-11 is detected in the HV ECU. SHTS03ZZZ0300272 Is DTC U0073-11 detected? Perform troubleshooting for each of related Go to step 4.
  • Page 410 3–406 HYBRID/TROUBLE SHOOTING Inspecting the vehicle control ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U1136 (clutch ECU communication blackout) is detected in the vehicle control ECU. SHTS03ZZZ0300274 Is DTC U1136 detected? Refer to the "CONTROL CAN COMMUNICA- Replace the HV ECU.
  • Page 411 SYSTEM". items. 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U1136- pleted. position. 27 is detected: (Temporary 4.
  • Page 412 • [U110A] vehicle control ECU detected: Go CAN COMMU- (All communi- CAN communication black- Reading the to YES. NICATION cation black- DTC [HINO- LINE outs have • [U0101] AT ECU CAN com- All communi- (HYBRID)" in been gener- munication blackout cation blackout the chapter ated.)

  • Page 413: Inverter

    HYBRID/TROUBLE SHOOTING 3–409 INVERTER DIAGNOSIS CODE TABLE EN01H03ZZZ030602004001 Symbol HV warning light lighting timing ☆ Always the light is lighting when confirmed × No light on HV ECU Control for occur- Name of malfunc- Description of mal- HV warn- recogni- rence of malfunc- tion function...
  • Page 414 3–410 HYBRID/TROUBLE SHOOTING HV ECU Control for occur- Name of malfunc- Description of mal- HV warn- recogni- rence of malfunc- tion function ing light tion tion DTC-TC Abnormality in ILK Service plug not ☆ ☆ P0A0D Gate block, SMR off P0A78-21 input locked...
  • Page 415 HYBRID/TROUBLE SHOOTING 3–411 HV ECU Control for occur- Name of malfunc- Description of mal- HV warn- recogni- rence of malfunc- tion function ing light tion tion DTC-TC Abnormality in Main circuit ele- 3-phase ON con- ☆ ☆ P0A1B inverter (ECU sys- ment short circuit P0A78-21 trol, SMR off...
  • Page 416 3–412 HYBRID/TROUBLE SHOOTING HV ECU Control for occur- Name of malfunc- Description of mal- HV warn- recogni- rence of malfunc- tion function ing light tion tion DTC-TC Abnormality in ☆ ☆ P0A2F Motor overheating Normal control P0A78-22 motor temperature Abnormality in Main circuit ele- ☆...
  • Page 417 HYBRID/TROUBLE SHOOTING 3–413 HV ECU Control for occur- Name of malfunc- Description of mal- HV warn- recogni- rence of malfunc- tion function ing light tion tion DTC-TC SMR#1 (negative ☆ ☆ P0AE6 side) Low abnor- Low failure Gate block, SMR off P0A78-21 mality SMR#1 (negative...
  • Page 418 3–414 HYBRID/TROUBLE SHOOTING HV ECU Control for occur- Name of malfunc- Description of mal- HV warn- recogni- rence of malfunc- tion function ing light tion tion DTC-TC W-phase current Out of range High ☆ ☆ P0BF0 sensor High abnor- Gate block, SMR off P0A78-21 failure mality...

  • Page 419: Freeze Frame Data List

    HYBRID/TROUBLE SHOOTING 3–415 FREEZE FRAME DATA LIST EN01H03ZZZ030602004002 Item Description Display range Unit — TC No. Detailed code of DTC No. 00 - $FF (Hex) Represents a torque command value to the Specified value of motor torque -32,768 - 32,767 inverter.
  • Page 420 3–416 HYBRID/TROUBLE SHOOTING Item Description Display range Unit Motor discharge allowable torque MG discharge allowable torque 0 - 65,535 Motor charge allowable torque MG charge allowable torque 0 - 65,535 Motor required revolution Required revolution -32,768 - 32,767 r/min — Torque/revolution control status 0: Torque, 1: Revolution 0, 1...

  • Page 421: Data Monitor Item List

    HYBRID/TROUBLE SHOOTING 3–417 DATA MONITOR ITEM LIST EN01H03ZZZ030602004003 Display Item Description Unit range 00 - $FF — TC No. Detailed code of DTC No. (Hex) Represents the torque command value to the -32,768 - Specified value of motor torque inverter. 32,767 -32,768 - Actual motor torque value...
  • Page 422 3–418 HYBRID/TROUBLE SHOOTING Display Item Description Unit range Represents the unsatisfied difference voltage Difference voltage not satisfied 0 - 255 Times count. -3,276.8 - Motor current effective value (RMS) Motor current RMS 3,276.7 Motor discharge allowable torque MG discharge allowable torque 0 - 65,535 Motor charge allowable torque MG charge allowable torque...
  • Page 423 HYBRID/TROUBLE SHOOTING 3–419 Display Item Description Unit range Shorted phase (upper arm/ lower — 0: Not detected, 1: Upper arm, 2: Lower arm 0 - 2 arm)

  • Page 424: Connection Diagram

    3–420 HYBRID/TROUBLE SHOOTING CONNECTION DIAGRAM EN01H03ZZZ030602004004 A: CONNECTOR No. B: CONNECTOR PIN No. +B(12V) B’ THERMISTOR B’ H’ DIAG ROTATION H’ MACHINE CAN J/C H’ CTRL A’ CAN J/C A’ A’ RESOLVER HV ECU A’ A’ A’ INVERTER INVERTER START RELAY N(-) G’...

  • Page 425: Insulation Resistance Measurement Procedure For Hybrid Motor [Rotation Machine]

    HYBRID/TROUBLE SHOOTING 3–421 INSULATION RESISTANCE MEASUREMENT PROCEDURE FOR HYBRID MOTOR [ROTATION MACHINE] EN01H03ZZZ030602004005 FIGURE 1 FIGURE 2 INSULATION RESISTANCE MEASUREMENT MACHINE TERMINAL * SECURELY SANDWICH THE MEASUREMENT MACHINE TERMINAL BY THE THERMISTER BRACKET BOLT. INSULATION RESISTANCE IDENTIFICATION MEASUREMENT MACHINE LABEL NO.1 TERMINAL IDENTIFICATION LABEL NO.2...
  • Page 426 3–422 HYBRID/TROUBLE SHOOTING MAKE SURE THAT MEASUREMENT VOLTAGE IS DC500V AND INSULATION RESISTANCE IS 5M OR MORE. IN THE CASE THAT IT IS OUT OF STANDARD, LEAVE FOR ONE HOUR IN DRY PLACE AND MEASURE AGAIN. DO NOT USE IF IT IS OUT OF STANDARD AGAIN AS A RESULT OF RE-MEASUREMENT. ! CAUTION •...

  • Page 427: Dtc: P0562 (Tc96)

    HYBRID/TROUBLE SHOOTING 3–423 DTC: P0562 (TC96) EN01H03ZZZ030602004006 DTC: P0562 (TC96) Abnormality in power supply voltage INFORMATION PCI_B_2 20A F_HV_10A Inverter Inverter starter relay GND1 Inverter coolant radiator fan Inverter coolant pump SHTS03ZZZ0300277 Technical description • – <Description of malfunction> • Detected a voltage abnormality in the SMR power supply. DTC set condition DTC detection condition •...
  • Page 428 3–424 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 429 HYBRID/TROUBLE SHOOTING 3–425 INSPECTION PROCEDURE: P0562 (TC96) Inspecting the voltage of 12 V battery Set the starter key to the "LOCK" position. Disconnect the connector of PCU harness (24P). Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the termi- nals of PCU harness (24P) vehicle connector.
  • Page 430 3–426 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for continuity 1 Set the starter key to the "LOCK" position. Disconnect the inverter connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (24P) lower-side connector and inverter connector.
  • Page 431 HYBRID/TROUBLE SHOOTING 3–427 Inspecting the PCU wire harness (lower side) for short circuit 1 Using the electrical tester, measure the resistance between the terminals of PCU harness (24P) lower-side connector and the ground. Vehicle GND Measurement Tester Standard values conditions connections PCU harness (24P) lower-side con-...
  • Page 432 3–428 HYBRID/TROUBLE SHOOTING Inspecting the inverter cooling pump and inverter cooling radiator fan for short circuit Using the electrical tester, measure the resistance between the terminals of inverter cooling pump connector and PCU harness (24P) lower-side connector. Using the electrical tester, measure the resistance between the terminals of inverter cooling radiator fan connector and PCU har- ness (24P) lower-side connector.
  • Page 433 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 434 3–430 HYBRID/TROUBLE SHOOTING CHECKLIST: P0562 (TC96) P0562 (TC96) Abnormality in power supply voltage Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connector of The mea- PCU harness (24P). Inspect the 12 sured value is V battery and...
  • Page 435 HYBRID/TROUBLE SHOOTING 3–431 P0562 (TC96) Abnormality in power supply voltage Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Using the electrical tester, mea- The mea- sure the resistance between sured value is the terminals of inverter con- within the nector and PCU harness (24P) range of stan- lower-side connector.
  • Page 436 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0562- The inspec- (HINO-DX) to the vehicle. 96 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 437: Dtc: P0562 (Tca0)

    HYBRID/TROUBLE SHOOTING 3–433 DTC: P0562 (TCA0) EN01H03ZZZ030602004007 DTC: P0562 (TCA0) Abnormality in power supply voltage INFORMATION PCI_B_2 20A F_HV_10A Inverter Inverter starter relay GND1 Inverter coolant radiator fan Inverter coolant pump SHTS03ZZZ0300285 Technical description • – <Description of malfunction> • Detected an abnormality in control power supply voltage of SMR. DTC set condition DTC detection condition •...
  • Page 438 3–434 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 439 HYBRID/TROUBLE SHOOTING 3–435 INSPECTION PROCEDURE: P0562 (TCA0) Inspecting the voltage of 12 V battery Set the starter key to the "LOCK" position. Disconnect the connector of PCU harness (24P). Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the termi- nals of PCU harness (24P) vehicle connector.
  • Page 440 3–436 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for continuity 1 Set the starter key to the "LOCK" position. Disconnect the inverter connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (24P) lower-side connector and inverter connector.
  • Page 441 HYBRID/TROUBLE SHOOTING 3–437 Inspecting the PCU wire harness (lower side) for short circuit 1 Using the electrical tester, measure the resistance between the terminals of PCU harness (24P) lower-side connector and the ground. Vehicle GND Measurement Tester Standard values conditions connections PCU harness (24P) lower-side con-...
  • Page 442 3–438 HYBRID/TROUBLE SHOOTING Inspecting the inverter cooling pump and inverter cooling radiator fan for short circuit Using the electrical tester, measure the resistance between the terminals of inverter cooling pump connector and PCU harness (24P) lower-side connector. Using the electrical tester, measure the resistance between the terminals of inverter cooling radiator fan connector and PCU har- ness (24P) lower-side connector.
  • Page 443 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 444 3–440 HYBRID/TROUBLE SHOOTING CHECKLIST: P0562 (TCA0) P0562 (TCA0) Abnormality in power supply voltage Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connector of The mea- PCU harness (24P). Inspect the 12 sured value is V battery and...
  • Page 445 HYBRID/TROUBLE SHOOTING 3–441 P0562 (TCA0) Abnormality in power supply voltage Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Using the electrical tester, mea- The mea- sure the resistance between sured value is the terminals of inverter con- within the nector and PCU harness (24P) range of stan- lower-side connector.
  • Page 446 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0562- The inspec- (HINO-DX) to the vehicle. A0 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 447: Dtc: P0604 (Tc18)

    HYBRID/TROUBLE SHOOTING 3–443 DTC: P0604 (TC18) EN01H03ZZZ030602004008 DTC: P0604 (TC18) Abnormality in internal element for control (abnormality in RAM) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the RAM (control microprocessor) in the inverter. DTC set condition DTC detection condition •...
  • Page 448 INSPECTION PROCEDURE: P0604 (TC18) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 449: Dtc: P0604 (Tcd2)

    HYBRID/TROUBLE SHOOTING 3–445 DTC: P0604 (TCD2) EN01H03ZZZ030602004009 DTC: P0604 (TCD2) Abnormality in internal element for control (abnormality in RAM) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the RAM (diagnosis microprocessor) in the inverter. DTC set condition DTC detection condition •...
  • Page 450 INSPECTION PROCEDURE: P0604 (TCD2) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 451: Dtc: P0605 (Tc17)

    HYBRID/TROUBLE SHOOTING 3–447 DTC: P0605 (TC17) EN01H03ZZZ030602004010 DTC: P0605 (TC17) Abnormality in internal element for control (abnormality in ROM) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the ROM (control microprocessor) in the inverter. DTC set condition DTC detection condition •...
  • Page 452 INSPECTION PROCEDURE: P0605 (TC17) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 453: Dtc: P0605 (Tcd1)

    HYBRID/TROUBLE SHOOTING 3–449 DTC: P0605 (TCD1) EN01H03ZZZ030602004011 DTC: P0605 (TCD1) Abnormality in internal element for control (abnormality in ROM) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the ROM (diagnosis microprocessor) in the inverter. DTC set condition DTC detection condition •...
  • Page 454 INSPECTION PROCEDURE: P0605 (TCD1) Restoration check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 455: Dtc: P060B (Tc1A)

    HYBRID/TROUBLE SHOOTING 3–451 DTC: P060B (TC1A) EN01H03ZZZ030602004012 DTC: P060B (TC1A) Abnormality in internal element for control (abnormality in AD converter) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the AD converter in the inverter. DTC set condition DTC detection condition •...
  • Page 456 3–452 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Malfunction of inverter...
  • Page 457 INSPECTION PROCEDURE: P060B (TC1A) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 458: Dtc: P060C (Tc1C)

    3–454 HYBRID/TROUBLE SHOOTING DTC: P060C (TC1C) EN01H03ZZZ030602004013 DTC: P060C (TC1C) Abnormality in internal element for control (abnormality in diagnosis microprocessor) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the diagnosis microprocessor (due to run pulse monitoring) in the inverter. DTC set condition DTC detection condition •...
  • Page 459 INSPECTION PROCEDURE: P060C (TC1C) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 460: Dtc: P062F (Tc41)

    3–456 HYBRID/TROUBLE SHOOTING DTC: P062F (TC41) EN01H03ZZZ030602004014 DTC: P062F (TC41) Abnormality in inverter (abnormality in memory) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the memory in the inverter (memory access abnormality). DTC set condition DTC detection condition •...
  • Page 461 INSPECTION PROCEDURE: P062F (TC41) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 462: Dtc: P0A0D (Tc20)

    3–458 HYBRID/TROUBLE SHOOTING DTC: P0A0D (TC20) EN01H03ZZZ030602004015 DTC: P0A0D (TC20) Abnormality in ILK input INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug SMR3 HV Battery 288 V SHTS03ZZZ0300300 Technical description • – <Description of malfunction>...
  • Page 463 HYBRID/TROUBLE SHOOTING 3–459 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 464 3–460 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A0D (TC20) Inspecting the service plug Check that the service plug is inserted and securely locked. Is any defect found? Insert the service plug and lock it securely. Go to step 2. Inspecting the continuity of service plug Set the starter key to the "LOCK"...
  • Page 465 HYBRID/TROUBLE SHOOTING 3–461 Inspecting the PCU wire harness (lower side) for continuity Disconnect the connectors of inverter and PCU harness (16P). Using the electrical tester, measure the resistance between the terminals of inverter connector and PCU harness (16P) lower-side connector. Measurement Tester Standard values...
  • Page 466 Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history and set the starter key to the "LOCK"...
  • Page 467 HYBRID/TROUBLE SHOOTING 3–463 CHECKLIST: P0A0D (TC20) P0A0D (TC20) Abnormality in ILK input Inspection Procedure Check Step Action Description Judgement (Yes/No) Defect is found: Go to Insert the ser- YES. Inspecting the vice plug and 1. Check that the service plug is Go to step 2.
  • Page 468 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0A0D- (HINO-DX) to the vehicle. 20 is detected: 3. Set the starter key to the "ON" Go to YES. Reproduction position.

  • Page 469: Dtc: P0A1B (Tc16)

    HYBRID/TROUBLE SHOOTING 3–465 DTC: P0A1B (TC16) EN01H03ZZZ030602004016 DTC: P0A1B (TC16) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (abnormality in the main circuit element). DTC set condition DTC detection condition •...
  • Page 470 3–466 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A1B (TC16) Inspecting the three-phase cable 1 Check the three-phase cable connector (inverter-side) for failing connection (looseness, wear, or melting damage). Is any defect found? Retighten the terminals. Go to step 2. Replace the terminals if abnormal wear or melting damage is detected.
  • Page 471 HYBRID/TROUBLE SHOOTING 3–467 Inspecting resistance between HV motor phases Set the starter key to the "LOCK" position. Disconnect the three-phase cable (U, V, and W terminals) from the HV motor. Using the electrical tester, measure the resistance between the HV motor terminals. HINT If the motor temperature is too high, the resistance largely varies.
  • Page 472 3–468 HYBRID/TROUBLE SHOOTING Inspecting the three-phase cable 3 Disconnect the three-phase cable (U, V, and W terminals) from the inverter. Megohmmeter Using the megohm tester (500 V range), measure the insulation resistance between the terminals of three-phase cable. ! CAUTION Terminals must be insulated to avoid contact.
  • Page 473 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 474 3–470 HYBRID/TROUBLE SHOOTING CHECKLIST: P0A1B (TC16) P0A1B (TC16) Abnormality in inverter (ECU system) Inspection Procedure Check Step Action Description Judgement (Yes/No) Retighten the Defect is terminals. found: Go to Replace the 1. Check the three-phase cable Inspecting the YES. terminals if connector (inverter-side) for three-phase Go to step 2.
  • Page 475 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0A1B- (HINO-DX) to the vehicle. 16 is detected: 3. Set the starter key to the "ON" Go to YES. Reproduction The inspec- position.

  • Page 476: Dtc: P0A1B (Tc92)

    3–472 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TC92) EN01H03ZZZ030602004017 DTC: P0A1B (TC92) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (control CAN register stuck (CAN2)). DTC set condition DTC detection condition •...
  • Page 477 INSPECTION PROCEDURE: P0A1B (TC92) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 478: Dtc: P0A1B (Tc97)

    3–474 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TC97) EN01H03ZZZ030602004018 DTC: P0A1B (TC97) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (ALU abnormality, control microprocessor). DTC set condition DTC detection condition •...
  • Page 479 INSPECTION PROCEDURE: P0A1B (TC97) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 480: Dtc: P0A1B (Tc3F)

    3–476 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TC3F) EN01H03ZZZ030602004019 DTC: P0A1B (TC3F) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (DIAG CAN register stuck (CAN1)). DTC set condition DTC detection condition •...
  • Page 481 INSPECTION PROCEDURE: P0A1B (TC3F) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 482: Dtc: P0A1B (Tca1)

    3–478 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA1) EN01H03ZZZ030602004020 DTC: P0A1B (TCA1) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (abnormality in microprocessor power supply voltage). DTC set condition DTC detection condition •...
  • Page 483 INSPECTION PROCEDURE: P0A1B (TCA1) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 484: Dtc: P0A1B (Tca2)

    3–480 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA2) EN01H03ZZZ030602004021 DTC: P0A1B (TCA2) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (resolver REF signal oscillation stop abnormality). DTC set condition DTC detection condition •...
  • Page 485 INSPECTION PROCEDURE: P0A1B (TCA2) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 486: Dtc: P0A1B (Tca3)

    3–482 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA3) EN01H03ZZZ030602004022 DTC: P0A1B (TCA3) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (resolver REF signal cycle abnormality). DTC set condition DTC detection condition •...
  • Page 487 INSPECTION PROCEDURE: P0A1B (TCA3) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 488: Dtc: P0A1B (Tca4)

    3–484 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA4) EN01H03ZZZ030602004023 DTC: P0A1B (TCA4) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (R/D converter resolver angle abnormality). DTC set condition DTC detection condition •...
  • Page 489 INSPECTION PROCEDURE: P0A1B (TCA4) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 490: Dtc: P0A1B (Tca5)

    3–486 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA5) EN01H03ZZZ030602004024 DTC: P0A1B (TCA5) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (R/D converter NM stop abnormality, angle abnormality). DTC set condition DTC detection condition •...
  • Page 491 INSPECTION PROCEDURE: P0A1B (TCA5) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 492: Dtc: P0A1B (Tca6)

    3–488 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA6) EN01H03ZZZ030602004025 DTC: P0A1B (TCA6) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (R/D converter serial communication timeout abnormality). DTC set condition DTC detection condition •...
  • Page 493 INSPECTION PROCEDURE: P0A1B (TCA6) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 494: Dtc: P0A1B (Tca7)

    3–490 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA7) EN01H03ZZZ030602004026 DTC: P0A1B (TCA7) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (R/D converter serial communication deviation abnormality). DTC set condition DTC detection condition •...
  • Page 495 INSPECTION PROCEDURE: P0A1B (TCA7) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 496: Dtc: P0A1B (Tca8)

    3–492 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA8) EN01H03ZZZ030602004027 DTC: P0A1B (TCA8) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (VIN V signal Low abnormality). DTC set condition DTC detection condition •...
  • Page 497 INSPECTION PROCEDURE: P0A1B (TCA8) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 498: Dtc: P0A1B (Tca9)

    3–494 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCA9) EN01H03ZZZ030602004028 DTC: P0A1B (TCA9) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (VIN V signal High abnormality). DTC set condition DTC detection condition •...
  • Page 499 INSPECTION PROCEDURE: P0A1B (TCA9) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 500: Dtc: P0A1B (Tcaa)

    3–496 HYBRID/TROUBLE SHOOTING DTC: P0A1B (TCAA) EN01H03ZZZ030602004029 DTC: P0A1B (TCAA) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (short circuit abnormality in the main circuit element). DTC set condition DTC detection condition •...
  • Page 501 HYBRID/TROUBLE SHOOTING 3–497 INSPECTION PROCEDURE: P0A1B (TCAA) Inspecting the three-phase cable 1 Check the ring tongue terminals of three-phase cable (motor side) for failing connection (looseness, wear, or melting damage). Is any defect found? Retighten the terminals. Go to step 2. Replace the terminals if abnormal wear or melting damage is detected.
  • Page 502 3–498 HYBRID/TROUBLE SHOOTING Inspecting resistance between the HV motor phases Set the starter key to the "LOCK" position. Disconnect the three-phase cable (U, V, and W terminals) from the HV motor. Using the megohm tester (500 V range), measure the insulation resistance between the HV motor terminals and the housing.
  • Page 503 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 504 3–500 HYBRID/TROUBLE SHOOTING CHECKLIST: P0A1B (TCAA) P0A1B (TCAA) Abnormality in inverter (ECU system) Inspection Procedure Check Step Action Description Judgement (Yes/No) Retighten the Defect is terminals. found: Go to 1. Check the ring tongue termi- Replace the Inspecting the YES. nals of three-phase cable terminals if three-phase...
  • Page 505 HYBRID/TROUBLE SHOOTING 3–501 P0A1B (TCAA) Abnormality in inverter (ECU system) Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the three-phase cable (U, V, and W terminals) from the HV motor. 3.
  • Page 506 1. Connect all the connectors that have been disconnected to restore the system. DTC P0A1B- 2. Connect the diagnosis tool AA is (HINO-DX) to the vehicle. detected: Go 3. Set the starter key to the "ON" Reproduction to YES. The inspec- position.

  • Page 507: Dtc: P0A1B (Tcbb)

    HYBRID/TROUBLE SHOOTING 3–503 DTC: P0A1B (TCBB) EN01H03ZZZ030602004030 DTC: P0A1B (TCBB) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (resolver excitation power supply voltage abnormality). DTC set condition DTC detection condition •...
  • Page 508 INSPECTION PROCEDURE: P0A1B (TCBB) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 509: Dtc: P0A1B (Tcbc)

    HYBRID/TROUBLE SHOOTING 3–505 DTC: P0A1B (TCBC) EN01H03ZZZ030602004031 DTC: P0A1B (TCBC) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (current sensor power supply (P side) voltage abnormality). DTC set condition DTC detection condition •...
  • Page 510 INSPECTION PROCEDURE: P0A1B (TCBC) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 511: Dtc: P0A1B (Tcbd)

    HYBRID/TROUBLE SHOOTING 3–507 DTC: P0A1B (TCBD) EN01H03ZZZ030602004032 DTC: P0A1B (TCBD) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (internal standard power supply voltage abnormality). DTC set condition DTC detection condition •...
  • Page 512 INSPECTION PROCEDURE: P0A1B (TCBD) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 513: Dtc: P0A1B (Tcbe)

    HYBRID/TROUBLE SHOOTING 3–509 DTC: P0A1B (TCBE) EN01H03ZZZ030602004033 DTC: P0A1B (TCBE) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (current sensor power supply (N side) voltage abnormality). DTC set condition DTC detection condition •...
  • Page 514 INSPECTION PROCEDURE: P0A1B (TCBE) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 515: Dtc: P0A1B (Tcbf)

    HYBRID/TROUBLE SHOOTING 3–511 DTC: P0A1B (TCBF) EN01H03ZZZ030602004034 DTC: P0A1B (TCBF) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (photo coupler power supply abnormality). DTC set condition DTC detection condition •...
  • Page 516 INSPECTION PROCEDURE: P0A1B (TCBF) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 517: Dtc: P0A1B (Tcd3)

    HYBRID/TROUBLE SHOOTING 3–513 DTC: P0A1B (TCD3) EN01H03ZZZ030602004035 DTC: P0A1B (TCD3) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (ALU abnormality, diagnosis microprocessor). DTC set condition DTC detection condition •...
  • Page 518 INSPECTION PROCEDURE: P0A1B (TCD3) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 519: Dtc: P0A1B (Tcd4)

    HYBRID/TROUBLE SHOOTING 3–515 DTC: P0A1B (TCD4) EN01H03ZZZ030602004036 DTC: P0A1B (TCD4) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (communication abnormality between CPUs, control microprocessor). DTC set condition DTC detection condition •...
  • Page 520 INSPECTION PROCEDURE: P0A1B (TCD4) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 521: Dtc: P0A1B (Tcd5)

    HYBRID/TROUBLE SHOOTING 3–517 DTC: P0A1B (TCD5) EN01H03ZZZ030602004037 DTC: P0A1B (TCD5) Abnormality in inverter (ECU system) INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (communication abnormality between CPUs, diagnosis microprocessor). DTC set condition DTC detection condition •...
  • Page 522 INSPECTION PROCEDURE: P0A1B (TCD5) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).

  • Page 523: Dtc: P0A1D (Tc21)

    HYBRID/TROUBLE SHOOTING 3–519 DTC: P0A1D (TC21) EN01H03ZZZ030602004038 DTC: P0A1D (TC21) HV ECU abnormality INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the HV ECU (abnormality in the HV ECU operation state). DTC set condition DTC detection condition •...
  • Page 524 Reading the DTC (other system) [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] of other system, check if any DTC related to the CAN communication system is detected.
  • Page 525 HYBRID/TROUBLE SHOOTING 3–521 Reproduction check [HINO-DX] Clear the malfunction history. Set the starter key to the "LOCK" position and wait for 1 minute. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if P0A1D-21 is detected.
  • Page 526 "LOCK" position. system is 2. Connect the diagnosis tool detected: Go Reading the Perform trou- (HINO-DX) to the vehicle. to YES. DTC (other bleshooting for 3. Set the starter key to the "ON" Go to step 2. system) each of related position.

  • Page 527: Dtc: P0A2B (Tce9)

    HYBRID/TROUBLE SHOOTING 3–523 DTC: P0A2B (TCE9) EN01H03ZZZ030602004039 DTC: P0A2B (TCE9) Abnormality in characteristics of motor temperature sensor INFORMATION Inverter Motor temperature sensor CN4-26 SLD4 CN4-35 THA1 CN4-34 P5A1 SHTS03ZZZ0300334 Technical description • – <Description of malfunction> • Detected an abnormality in the characteristics (Low abnormality) of the motor temperature detecting sensor. DTC set condition DTC detection condition •...
  • Page 528 3–524 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Malfunction of inverter...
  • Page 529 HYBRID/TROUBLE SHOOTING 3–525 INSPECTION PROCEDURE: P0A2B (TCE9) Inspecting the vehicle wire harness Set the starter key to the "LOCK" position and wait for approxi- mately 3 hours. (To make the motor temperature equivalent to the ambient temperature) Disconnect the PCU harness (12P) connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector.
  • Page 530 3–526 HYBRID/TROUBLE SHOOTING Inspecting the motor temperature sensor Disconnect the connector of motor temperature sensor. Using the electrical tester, measure the resistance between the terminals of motor temperature sensor connector. Measurement Tester Standard values conditions connections Motor tempera- ture sensor con- 16.18 –...
  • Page 531 HYBRID/TROUBLE SHOOTING 3–527 Inspecting the vehicle wire harness for short circuit Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground. Vehicle GND Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector.
  • Page 532 3–528 HYBRID/TROUBLE SHOOTING Inspecting the vehicle wire harness for continuity Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and motor temperature sensor connector. Measurement Tester Standard values conditions connections PCU harness (12P) vehicle-side con- nector –...
  • Page 533 HYBRID/TROUBLE SHOOTING 3–529 Inspecting the PCU wire harness (lower side) for short circuit Disconnect the inverter connector. Using the electrical tester, measure the resistance between the Vehicle GND terminals of PCU harness (12P) lower-side connector and the ground. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector.
  • Page 534 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 535 HYBRID/TROUBLE SHOOTING 3–531 CHECKLIST: P0A2B (TCE9) Abnormality in characteristics of P0A2B (TCE9) Inspection Procedure motor temperature sensor Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position and wait for approximately 3 hours. (To make the motor temperature equivalent to the ambient tem- perature) The mea-...
  • Page 536 3–532 HYBRID/TROUBLE SHOOTING Abnormality in characteristics of P0A2B (TCE9) Inspection Procedure motor temperature sensor Check Step Action Description Judgement (Yes/No) 1. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness The mea- (12P) vehicle-side connector and the ground.
  • Page 537 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0A2B- The inspec- (HINO-DX) to the vehicle. E9 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 538: Dtc: P0A2B (Tced)

    3–534 HYBRID/TROUBLE SHOOTING DTC: P0A2B (TCED) EN01H03ZZZ030602004040 DTC: P0A2B (TCED) Abnormality in characteristics of motor temperature sensor INFORMATION Inverter Motor temperature sensor CN4-26 SLD4 CN4-35 THA1 CN4-34 P5A1 SHTS03ZZZ0300342 Technical description • – <Description of malfunction> • Detected an abnormality in the characteristics of motor temperature detecting sensor (High abnormality). DTC set condition DTC detection condition •...
  • Page 539 HYBRID/TROUBLE SHOOTING 3–535 After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Malfunction of inverter...
  • Page 540 3–536 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A2B (TCED) Inspecting the vehicle wire harness Set the starter key to the "LOCK" position and wait for approxi- mately 3 hours. (To make the motor temperature equivalent to the ambient temperature) Disconnect the PCU harness (12P) connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector.
  • Page 541 HYBRID/TROUBLE SHOOTING 3–537 Inspecting the motor temperature sensor Disconnect the connector of motor temperature sensor. Using the electrical tester, measure the resistance between the terminals of motor temperature sensor connector. Measurement Tester Standard values conditions connections Motor tempera- ture sensor con- 16.18 –...
  • Page 542 3–538 HYBRID/TROUBLE SHOOTING Inspecting the vehicle wire harness for short circuit Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground. Vehicle GND Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector.
  • Page 543 HYBRID/TROUBLE SHOOTING 3–539 Inspecting the vehicle wire harness for continuity Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and motor temperature sensor connector. Measurement Tester Standard values conditions connections PCU harness (12P) vehicle-side con- nector –...
  • Page 544 3–540 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for short circuit Disconnect the inverter connector. Using the electrical tester, measure the resistance between the VEHICLE GND terminals of PCU harness (12P) lower-side connector and the ground. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector.
  • Page 545 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 546 3–542 HYBRID/TROUBLE SHOOTING CHECKLIST: P0A2B (TCED) Abnormality in characteristics of P0A2B (TCED) Inspection Procedure motor temperature sensor Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position and wait for approximately 3 hours. (To make the motor temperature equivalent to the ambient tem- perature) The mea-...
  • Page 547 HYBRID/TROUBLE SHOOTING 3–543 Abnormality in characteristics of P0A2B (TCED) Inspection Procedure motor temperature sensor Check Step Action Description Judgement (Yes/No) 1. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness The mea- (12P) vehicle-side connector and the ground.
  • Page 548 1. Connect all the connectors that have been disconnected to restore the system. DTC P0A2B- 2. Connect the diagnosis tool The inspec- ED is (HINO-DX) to the vehicle. tion is com- detected: Go 3. Set the starter key to the "ON" pleted. Reproduction to YES.

  • Page 549: Dtc: P0A2C (Tcda)

    HYBRID/TROUBLE SHOOTING 3–545 DTC: P0A2C (TCDA) EN01H03ZZZ030602004041 DTC: P0A2C (TCDA) Motor temperature sensor Low abnormality INFORMATION Inverter Motor temperature sensor CN4-26 SLD4 CN4-35 THA1 CN4-34 P5A1 SHTS03ZZZ0300350 Technical description • – <Description of malfunction> • Detected a Low abnormality in the motor temperature sensor (high temperature side of the motor). DTC set condition DTC detection condition •...
  • Page 550 3–546 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A2C (TCDA) Inspecting the vehicle wire harness Set the starter key to the "LOCK" position and wait for approxi- mately 3 hours. (To make the motor temperature equivalent to the ambient temperature) Disconnect the PCU harness (12P) connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector.
  • Page 551 HYBRID/TROUBLE SHOOTING 3–547 Inspecting the motor temperature sensor Disconnect the connector of motor temperature sensor. Using the electrical tester, measure the resistance between the terminals of motor temperature sensor connector. Measurement Tester Standard values conditions connections Motor tempera- ture sensor con- 16.18 –...
  • Page 552 3–548 HYBRID/TROUBLE SHOOTING Inspecting the vehicle wire harness for short circuit Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground. Vehicle GND Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector.
  • Page 553 HYBRID/TROUBLE SHOOTING 3–549 Inspecting the vehicle wire harness for continuity Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and motor temperature sensor connector. Measurement Tester Standard values conditions connections PCU harness (12P) vehicle-side con- nector –...
  • Page 554 3–550 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for short circuit Disconnect the inverter connector. Using the electrical tester, measure the resistance between the Vehicle GND terminals of PCU harness (12P) lower-side connector and the ground. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector.
  • Page 555 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 556 3–552 HYBRID/TROUBLE SHOOTING CHECKLIST: P0A2C (TCDA) P0A2C (TCDA) Motor temperature sensor Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position and wait for approximately 3 hours. (To make the motor temperature equivalent to the ambient tem- perature) The mea-...
  • Page 557 HYBRID/TROUBLE SHOOTING 3–553 P0A2C (TCDA) Motor temperature sensor Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness (12P) vehicle-side connector The mea- sured value is and the ground.
  • Page 558 1. Connect all the connectors that have been disconnected to restore the system. DTC P0A2C- 2. Connect the diagnosis tool The inspec- DA is (HINO-DX) to the vehicle. tion is com- detected: Go 3. Set the starter key to the "ON" pleted. Reproduction to YES.

  • Page 559: Dtc: P0A2D (Tcdb)

    HYBRID/TROUBLE SHOOTING 3–555 DTC: P0A2D (TCDB) EN01H03ZZZ030602004042 DTC: P0A2D (TCDB) Motor temperature sensor High abnormality INFORMATION Inverter Motor temperature sensor CN4-26 SLD4 CN4-35 THA1 CN4-34 P5A1 SHTS03ZZZ0300358 Technical description • – <Description of malfunction> • Detected a High abnormality in the motor temperature sensor (low temperature side of the motor). DTC set condition DTC detection condition •...
  • Page 560 3–556 HYBRID/TROUBLE SHOOTING Estimated failure factors • Disconnection or short circuit of harness • Improper connector connection or fitting • Malfunction of motor temperature sensor • Malfunction of inverter...
  • Page 561 HYBRID/TROUBLE SHOOTING 3–557 INSPECTION PROCEDURE: P0A2D (TCDB) Inspecting the vehicle wire harness Set the starter key to the "LOCK" position and wait for approxi- mately 3 hours. (To make the motor temperature equivalent to the ambient temperature) Disconnect the PCU harness (12P) connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector.
  • Page 562 3–558 HYBRID/TROUBLE SHOOTING Inspecting the motor temperature sensor Disconnect the connector of motor temperature sensor. Using the electrical tester, measure the resistance between the terminals of motor temperature sensor connector. Measurement Tester Standard values conditions connections Motor tempera- ture sensor con- 16.18 –...
  • Page 563 HYBRID/TROUBLE SHOOTING 3–559 Inspecting the vehicle wire harness for short circuit Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground. Vehicle GND Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector.
  • Page 564 3–560 HYBRID/TROUBLE SHOOTING Inspecting the vehicle wire harness for continuity Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and motor temperature sensor connector. Measurement Tester Standard values conditions connections PCU harness (12P) vehicle-side con- nector –...
  • Page 565 HYBRID/TROUBLE SHOOTING 3–561 Inspecting the PCU wire harness (lower side) for short circuit Disconnect the inverter connector. Using the electrical tester, measure the resistance between the Vehicle GND terminals of PCU harness (12P) lower-side connector and the ground. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector.
  • Page 566 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 567 HYBRID/TROUBLE SHOOTING 3–563 CHECKLIST: P0A2D (TCDB) P0A2D (TCDB) Motor temperature sensor High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position and wait for approximately 3 hours. (To make the motor temperature equivalent to the ambient tem- perature) The mea-...
  • Page 568 3–564 HYBRID/TROUBLE SHOOTING P0A2D (TCDB) Motor temperature sensor High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness (12P) vehicle-side connector The mea- sured value is and the ground.
  • Page 569 1. Connect all the connectors that have been disconnected to restore the system. DTC P0A2D- 2. Connect the diagnosis tool The inspec- DB is (HINO-DX) to the vehicle. tion is com- detected: Go 3. Set the starter key to the "ON" pleted. Reproduction to YES.

  • Page 570: Dtc: P0A2F (Tc33)

    3–566 HYBRID/TROUBLE SHOOTING DTC: P0A2F (TC33) EN01H03ZZZ030602004043 DTC: P0A2F (TC33) Abnormality in motor temperature INFORMATION Inverter Motor Motor temperature sensor SHTS03ZZZ0300366 Technical description • – <Description of malfunction> • Detected an abnormality in HV motor temperature (motor overheat). DTC set condition DTC detection condition •...
  • Page 571 HYBRID/TROUBLE SHOOTING 3–567 After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Malfunction of HV motor...
  • Page 572 Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any of the following DTC other than P0A2F-33 is detected: •...
  • Page 573 HYBRID/TROUBLE SHOOTING 3–569 Inspecting resistance between the HV motor phases Set the starter key to the "LOCK" position. Disconnect the three-phase cable (U, V, and W terminals) from the HV motor. Using the electrical tester, measure the resistance between the HV motor terminals.
  • Page 574 3–570 HYBRID/TROUBLE SHOOTING Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 575 1. Set the starter key to the DTC other "LOCK" position. than P0A2F- 2. Connect the diagnosis tool 33 is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Reading the 3. Set the starter key to the "ON" bleshooting for DTC [HINO- Go to step 2.
  • Page 576 33 is detected: 4. Clear the malfunction history. Go to YES. Reproduction The inspec- 5. Perform a test run (accelerate Replace the check [HINO- tion is com- and decelerate running for DTC P0A2F- inverter. pleted. approximately 1 hour). 33 is not detected: Go 6.

  • Page 577: Dtc: P0A3C (Tc34)

    HYBRID/TROUBLE SHOOTING 3–573 DTC: P0A3C (TC34) EN01H03ZZZ030602004044 DTC: P0A3C (TC34) Abnormality in inverter cooling system INFORMATION PCI_B_2 20A F_HV_10A Inverter starter relay Inverter GND1 Inverter coolant HV ECU radiator fan Inverter coolant pump SHTS03ZZZ0300370 Technical description • – <Description of malfunction> •...
  • Page 578 3–574 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • Idling stop does not start. Pre-inspection work • Check the battery voltage to make sure that there is no abnormality. After-inspection work •...
  • Page 579 Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any of the following DTC other than P03AC-34 is detected: •...
  • Page 580 3–576 HYBRID/TROUBLE SHOOTING Inspecting the inverter cooling radiator fan 1 Set the starter key to the "ON" position. Check the operating sound of inverter cooling radiator fan. Can the operating sound be checked? Go to step 4. Replace the inverter cooling radiator fan. After replacement, go to step 4.
  • Page 581 HYBRID/TROUBLE SHOOTING 3–577 Inspecting the PCU wire harness (lower side) for continuity 1 Set the starter key to the "LOCK" position. Remove the inverter start relay. Using the electrical tester, measure the resistance between the terminals of PCU harness (24P) connector and inverter start relay connector (relay block side).
  • Page 582 3–578 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for continuity 2 Disconnect the connectors of inverter cooling radiator fan, inverter cooling pump, inverter, and HV ECU2. Using the electrical tester, measure the resistance between the terminals of inverter cooling radiator fan connector and inverter start relay connector (relay block side).
  • Page 583 HYBRID/TROUBLE SHOOTING 3–579 Inspecting the PCU wire harness (lower side) for continuity 3 Using then electrical tester, measure the resistance between the terminals of inverter cooling pump connector and inverter start relay connector (relay block side). Using the electrical tester, measure the resistance between the 1st terminal of inverter cooling pump connector and the ground.
  • Page 584 3–580 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for continuity 4 Using the electrical tester, measure the resistance between the terminals of inverter start relay connector (relay block side) and inverter connector. Using the electrical tester, measure the resistance between the 2nd terminal of inverter start relay connector and the ground.
  • Page 585 HYBRID/TROUBLE SHOOTING 3–581 Inspecting the PCU wire harness (lower side) for continuity 5 Using the electrical tester, measure the resistance between the terminals of inverter start relay connector (relay block side) and HV ECU2 connector. Measurement Tester Standard values conditions connections Inverter start relay connector (relay...
  • Page 586 3–582 HYBRID/TROUBLE SHOOTING Inspecting the exciting voltage of inverter start relay Connect all the connectors that have been disconnected. Vehicle GND Set the starter key to the "ON" position. Using the electrical tester, measure the voltage between the 27th terminal of HV ECU2 connector and the ground. Measurement Tester Standard values...
  • Page 587 HYBRID/TROUBLE SHOOTING 3–583 Inspecting the inverter cooling radiator fan 2 Set the starter key to the "LOCK" position. Set the starter key to the "ON" position and check the operating sound of inverter cooling radiator fan. Can the operating sound be checked? Go to step 15.
  • Page 588 3–584 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for continuity Set the starter key to the "LOCK" position. Disconnect the connectors of inverter cooling pump and HV ECU2. Using the electrical tester, measure the resistance between the terminals of inverter cooling pump connector and HV ECU2 con- nector.
  • Page 589 HYBRID/TROUBLE SHOOTING 3–585 Inspecting the inverter cooling pump 2 [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position. In [Activation Test] on the diagnosis tool screen, select [HV water pump drive duty value].
  • Page 590 Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool DTC other (HINO-DX) to the vehicle. than P03AC- 34 is detected: 3. Set the starter key to the "ON" Go to YES. Perform trou- position.
  • Page 591 HYBRID/TROUBLE SHOOTING 3–587 P0A3C (TC34) Abnormality in inverter cooling system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Remove the inverter start relay. The mea- 3. Using the electrical tester, mea- sured value is sure the resistance between within the...
  • Page 592 3–588 HYBRID/TROUBLE SHOOTING P0A3C (TC34) Abnormality in inverter cooling system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the connectors of inverter cooling radiator fan, inverter cooling pump, inverter, and HV ECU2. 2. Using the electrical tester, mea- sure the resistance between the terminals of inverter cooling radiator fan connector and...
  • Page 593 HYBRID/TROUBLE SHOOTING 3–589 P0A3C (TC34) Abnormality in inverter cooling system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Using the electrical tester, mea- sure the resistance between the terminals of inverter start relay connector (relay block The mea- side) and inverter connector. sured value is 2.
  • Page 594 3–590 HYBRID/TROUBLE SHOOTING P0A3C (TC34) Abnormality in inverter cooling system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Connect all the connectors that have been disconnected. The mea- sured value is 2. Set the starter key to the "ON" within the position.
  • Page 595 Go to step 18. inverter cool- ing pump 2 to check that the water pump is Defect is not ing pump. [HINO-DX] running (i.e. the number of rev- found: Go to olutions of the fan is changing). <Measurement conditions> Starter key: ON <Measured item>...
  • Page 596 Go to YES. pleted. approximately 1 hour). Reproduction Replace the (Temporary 4. In [Fault Information] on the check [HINO- DTC P0A3C- inverter. actuation of diagnosis tool screen, check if 34 is not protection P0A3C-34 is detected.

  • Page 597: Dtc: P0A3F (Tcb7)

    HYBRID/TROUBLE SHOOTING 3–593 DTC: P0A3F (TCB7) EN01H03ZZZ030602004045 DTC: P0A3F (TCB7) Short-circuit abnormality between resolver phases INFORMATION Inverter Resolver SLD3 SHTS03ZZZ0300385 Technical description • – <Description of malfunction> • Detected the phase-to-phase short circuit in the resolver (position detector). DTC set condition DTC detection condition •...
  • Page 598 3–594 HYBRID/TROUBLE SHOOTING After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Malfunction of resolver (position detector) • Disconnection or short circuit of harness • Improper connector connection or fitting •...
  • Page 599 HYBRID/TROUBLE SHOOTING 3–595 INSPECTION PROCEDURE: P0A3F (TCB7) Inspecting the resolver (sensor) Set the starter key to the "LOCK" position. Disconnect the resolver connector. Using the electrical tester, measure the resistance between the terminals of resolver connector. Measurement Tester Standard values conditions connections Resolver connec-...
  • Page 600 3–596 HYBRID/TROUBLE SHOOTING Inspecting the vehicle wire harness for short circuit Disconnect the PCU harness (12P) connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground. Measurement Tester Standard values conditions connections PCU harness (12P)
  • Page 601 HYBRID/TROUBLE SHOOTING 3–597 Inspecting the PCU wire harness (lower side) for short circuit Disconnect the inverter connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector and the ground. Measurement Tester Standard values conditions connections PCU harness (12P)
  • Page 602 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 603 HYBRID/TROUBLE SHOOTING 3–599 CHECKLIST: P0A3F (TCB7) Short-circuit abnormality between P0A3F (TCB7) Inspection Procedure resolver phases Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the resolver con- nector. The mea- 3. Using the electrical tester, mea- sured value is sure the resistance between within the...
  • Page 604 3–600 HYBRID/TROUBLE SHOOTING Short-circuit abnormality between P0A3F (TCB7) Inspection Procedure resolver phases Check Step Action Description Judgement (Yes/No) 1. Disconnect the PCU harness (12P) connector. 2. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground.
  • Page 605 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0A3F- The inspec- (HINO-DX) to the vehicle. B7 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 606: Dtc: P0A41 (Tcc0)

    3–602 HYBRID/TROUBLE SHOOTING DTC: P0A41 (TCC0) EN01H03ZZZ030602004046 DTC: P0A41 (TCC0) Resolver range Low abnormality INFORMATION Inverter Resolver SLD3 SHTS03ZZZ0300390 Technical description • – <Description of malfunction> • Detected a disconnection or short circuit (Low abnormality) in the resolver (position detector). DTC set condition DTC detection condition •...
  • Page 607 HYBRID/TROUBLE SHOOTING 3–603 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 608 3–604 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A41 (TCC0) Inspecting the resolver (sensor) Set the starter key to the "LOCK" position. Disconnect the resolver connector. Using the electrical tester, measure the resistance between the terminals of resolver connector. Measurement Tester Standard values conditions connections Resolver connec-...
  • Page 609 HYBRID/TROUBLE SHOOTING 3–605 Inspecting the vehicle wire harness for short circuit Disconnect the PCU harness (12P) connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground. Measurement Tester Standard values conditions connections PCU harness (12P)
  • Page 610 3–606 HYBRID/TROUBLE SHOOTING Inspecting the vehicle wire harness for continuity Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and resolver connector. Measurement Tester Standard values conditions connections PCU harness (12P) vehicle-side con- nector –...
  • Page 611 HYBRID/TROUBLE SHOOTING 3–607 Inspecting the PCU wire harness (lower side) for short circuit Disconnect the inverter connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector and the ground. Measurement Tester Standard values conditions connections PCU harness (12P)
  • Page 612 3–608 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for continuity Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector and inverter connector. Measurement Tester Standard values conditions connections PCU harness (12P) lower-side con- nector –...
  • Page 613 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 614 3–610 HYBRID/TROUBLE SHOOTING CHECKLIST: P0A41 (TCC0) P0A41 (TCC0) Resolver range Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the resolver con- nector. The mea- 3. Using the electrical tester, mea- sured value is sure the resistance between within the...
  • Page 615 HYBRID/TROUBLE SHOOTING 3–611 P0A41 (TCC0) Resolver range Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the PCU harness (12P) connector. 2. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground.
  • Page 616 3–612 HYBRID/TROUBLE SHOOTING P0A41 (TCC0) Resolver range Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the inverter con- nector. 2. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness (12P) lower-side connector and the ground.
  • Page 617 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0A41- The inspec- (HINO-DX) to the vehicle. C0 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 618: Dtc: P0A42 (Tcc1)

    3–614 HYBRID/TROUBLE SHOOTING DTC: P0A42 (TCC1) EN01H03ZZZ030602004047 DTC: P0A42 (TCC1) Resolver range High abnormality INFORMATION Inverter Resolver SLD3 SHTS03ZZZ0300397 Technical description • – <Description of malfunction> • Detected a disconnection or short circuit (High abnormality) in the resolver (position detector). DTC set condition DTC detection condition •...
  • Page 619 HYBRID/TROUBLE SHOOTING 3–615 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 620 3–616 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A42 (TCC1) Inspecting the resolver (sensor) Set the starter key to the "LOCK" position. Disconnect the resolver connector. Using the electrical tester, measure the resistance between the terminals of resolver connector. Measurement Tester Standard values conditions connections Resolver connec-...
  • Page 621 HYBRID/TROUBLE SHOOTING 3–617 Inspecting the vehicle wire harness for short circuit Disconnect the PCU harness (12P) connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground. Measurement Tester Standard values conditions connections PCU harness (12P)
  • Page 622 3–618 HYBRID/TROUBLE SHOOTING Inspecting the vehicle wire harness for continuity Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) vehicle-side connector and resolver connector. Measurement Tester Standard values conditions connections PCU harness (12P) vehicle-side con- nector –...
  • Page 623 HYBRID/TROUBLE SHOOTING 3–619 Inspecting the PCU wire harness (lower side) for short circuit Disconnect the inverter connector. Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector and the ground. Measurement Tester Standard values conditions connections PCU harness (12P)
  • Page 624 3–620 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for continuity Using the electrical tester, measure the resistance between the terminals of PCU harness (12P) lower-side connector and inverter connector. Measurement Tester Standard values conditions connections PCU harness (12P) lower-side con- nector –...
  • Page 625 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 626 3–622 HYBRID/TROUBLE SHOOTING CHECKLIST: P0A42 (TCC1) P0A42 (TCC1) Resolver range High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the resolver con- nector. The mea- 3. Using the electrical tester, mea- sured value is sure the resistance between within the...
  • Page 627 HYBRID/TROUBLE SHOOTING 3–623 P0A42 (TCC1) Resolver range High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the PCU harness (12P) connector. 2. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness (12P) vehicle-side connector and the ground.
  • Page 628 3–624 HYBRID/TROUBLE SHOOTING P0A42 (TCC1) Resolver range High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the inverter con- nector. 2. Using the electrical tester, mea- sure the resistance between the terminals of PCU harness (12P) lower-side connector and the ground.
  • Page 629 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0A42- The inspec- (HINO-DX) to the vehicle. C1 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 630: Dtc: P0A51 (Tcd6)

    3–626 HYBRID/TROUBLE SHOOTING DTC: P0A51 (TCD6) EN01H03ZZZ030602004048 DTC: P0A51 (TCD6) Abnormality in inverter (current sensor) INFORMATION Technical description • – <Description of malfunction> • Detected a high resolution signal abnormality in the motor V-phase current sensor. DTC set condition DTC detection condition •...
  • Page 631 INSPECTION PROCEDURE: P0A51 (TCD6) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 632 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0A51- The inspec- 3. Set the starter key to the "ON" D6 is detected: tion is com- position.

  • Page 633: Dtc: P0A51 (Tcd7)

    HYBRID/TROUBLE SHOOTING 3–629 DTC: P0A51 (TCD7) EN01H03ZZZ030602004049 DTC: P0A51 (TCD7) Abnormality in inverter (current sensor) INFORMATION Technical description • – <Description of malfunction> • Detected a high resolution signal abnormality in the motor W-phase current sensor. DTC set condition DTC detection condition •...
  • Page 634 INSPECTION PROCEDURE: P0A51 (TCD7) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 635 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0A51- The inspec- 3. Set the starter key to the "ON" D7 is detected: tion is com- position.

  • Page 636: Dtc: P0A78 (Tc13)

    3–632 HYBRID/TROUBLE SHOOTING DTC: P0A78 (TC13) EN01H03ZZZ030602004050 DTC: P0A78 (TC13) Abnormality in inverter system INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300406 Technical description • – <Description of malfunction>...
  • Page 637 HYBRID/TROUBLE SHOOTING 3–633 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 638 Inspecting the HV battery ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if DTC P0A95 related to the HV battery line is detected.
  • Page 639 HYBRID/TROUBLE SHOOTING 3–635 Inspecting the DC high-voltage cable for continuity 1 Set the starter key to the "LOCK" position. Remove the inverter terminal block cover and the ECU box termi- nal block cover. INV(+) Using the electrical tester, measure the resistance between the INV(-) terminals of inverter and high-voltage J/B (in the ECU box).
  • Page 640 3–636 HYBRID/TROUBLE SHOOTING Inspecting the high-voltage J/B (in the ECU box) Check the high-voltage J/B (in the ECU box) for failing connection (looseness, wear, or melting damage). • BATT(+) terminal BATT(-) • BATT(-) terminal BATT(+) • INV(+) terminal • INV(-) terminal INV(+) INV(-) SHTS03ZZZ0300410...
  • Page 641 HYBRID/TROUBLE SHOOTING 3–637 Inspecting the DC high-voltage cable for continuity 2 Remove the HV battery terminal block cover. BATT OUT(-) BATT(+) BATT(-) Using the electrical tester, measure the resistance between the terminals of high voltage J/B (in the battery pack) and high-voltage J/B (in the ECU box).
  • Page 642 3–638 HYBRID/TROUBLE SHOOTING Inspecting the SMR#1 Remove the SMR#1 from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the SMR#1 terminals. Measurement Tester Standard values conditions connections SMR#1 terminal (switch side) 10 k or more —...
  • Page 643 HYBRID/TROUBLE SHOOTING 3–639 Inspecting the SMR#3 Remove the SMR#3 from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the SMR#3 terminals. Measurement Tester Standard values conditions connections SMR#3 terminal (switch side) 10 k or more —...
  • Page 644 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 645 1. Set the starter key to the "LOCK" position. DTC P0A95 is 2. Connect the diagnosis tool detected: Go Inspecting the (HINO-DX) to the vehicle. Perform trou- to YES. HV battery bleshooting for 3. Set the starter key to the "ON"...
  • Page 646 3–642 HYBRID/TROUBLE SHOOTING P0A78 (TC13) Abnormality in inverter system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Check the high-voltage J/B (in Retighten the Defect is the ECU box) for failing connec- terminals. found: Go to tion (looseness, wear, or melt- Inspecting the Replace the YES.
  • Page 647 HYBRID/TROUBLE SHOOTING 3–643 P0A78 (TC13) Abnormality in inverter system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Remove the SMR#2 from the The mea- high-voltage J/B (in the battery sured value is pack). within the 2. Using the electrical tester, mea- range of stan- sure the resistance between dard value: Go...
  • Page 648 (Yes/No) 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0A78- The inspec- 3. Set the starter key to the "ON" 13 is detected: tion is com- position.

  • Page 649: Dtc: P0A78 (Tc14)

    HYBRID/TROUBLE SHOOTING 3–645 DTC: P0A78 (TC14) EN01H03ZZZ030602004051 DTC: P0A78 (TC14) Abnormality in inverter system INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300417 Technical description • – <Description of malfunction>...
  • Page 650 3–646 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 651 HYBRID/TROUBLE SHOOTING 3–647 INSPECTION PROCEDURE: P0A78 (TC14) Inspecting the DC high-voltage cable for continuity 1 Set the starter key to the "LOCK" position. Remove the inverter terminal block cover and the ECU box termi- nal block cover. INV(+) Using the electrical tester, measure the resistance between the INV(-) terminals of inverter and high-voltage J/B (in the ECU box).
  • Page 652 3–648 HYBRID/TROUBLE SHOOTING Inspecting the high-voltage J/B (in the ECU box) Check the high-voltage J/B terminals (in the ECU box) for failing connection (looseness, wear, or damage). • BATT(+) terminal BATT(-) • BATT(-) terminal BATT(+) • INV(+) terminal • INV(-) terminal INV(+) INV(-) SHTS03ZZZ0300419...
  • Page 653 HYBRID/TROUBLE SHOOTING 3–649 Inspecting the DC high-voltage cable 2 Check the BATT OUT(+) terminal and BATT OUT(-) terminal of the high-voltage J/B (in the battery pack) for failing connection (loose- ness, wear, or damage). BATT OUT(-) BATT OUT(+) SHTS03ZZZ0300421 Is any defect found? Retighten the terminals.
  • Page 654 3–650 HYBRID/TROUBLE SHOOTING Inspecting the PCU wire harness (lower side) for continuity 1 Set the starter key to the "LOCK" position. Disconnect the connectors of inverter and PCU harness (16P). Using the electrical tester, measure the resistance between the terminals of inverter connector and PCU harness (16P) lower-side connector.
  • Page 655 HYBRID/TROUBLE SHOOTING 3–651 Inspecting the PCU wire harness (lower side) for continuity 2 Disconnect the connector of PCU harness (24P). Using the electrical tester, measure the resistance between the terminals of PCU harness (16P) lower-side connector and PCU harness (24P) lower-side connector. Measurement Tester Standard values...
  • Page 656 3–652 HYBRID/TROUBLE SHOOTING Inspecting the wire harness in the HV battery for continuity Disconnect the SMR drive connector from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the terminals of PCU harness (16P) upper-side connector and SMR drive connector.
  • Page 657 HYBRID/TROUBLE SHOOTING 3–653 Inspecting the high-voltage J/B Using the electrical tester, measure the resistance between the SMR drive connector terminals. Measurement Tester Standard values conditions connections SMR drive con- nector 3rd terminal – 2nd terminal: SMR#1: 70 – 190  SMR#1 4th terminal –...
  • Page 658 3–654 HYBRID/TROUBLE SHOOTING Inspecting the SMR#1 Remove the SMR#1 from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the SMR#1 terminals. Measurement Tester Standard values conditions connections SMR#1 70 – 190  — 1st terminal –...
  • Page 659 HYBRID/TROUBLE SHOOTING 3–655 Inspecting the SMR#3 Remove the SMR#3 from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the SMR#3 terminals. Measurement Tester Standard values conditions connections SMR#3 19 – 50  — 1st terminal –...
  • Page 660 3–656 HYBRID/TROUBLE SHOOTING Inspecting the inverter Disconnect the inverter connector. Using the electrical tester, measure the resistance between the terminals of inverter (unit side) connector. Measurement Tester Standard values conditions connections Inverter connec- tor (unit side) 38th terminal – 30th terminal 39th terminal –...
  • Page 661 Inspecting the HV battery ECU [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any DTC related to the HV battery line is detected.
  • Page 662 3–658 HYBRID/TROUBLE SHOOTING CHECKLIST: P0A78 (TC14) P0A78 (TC14) Abnormality in inverter system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Remove the inverter terminal The mea- block cover and the ECU box sured value is terminal block cover.
  • Page 663 HYBRID/TROUBLE SHOOTING 3–659 P0A78 (TC14) Abnormality in inverter system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Remove the HV battery termi- nal block cover. 2. Using the electrical tester, mea- The mea- sure the resistance between sured value is the terminals of high voltage J/ Replace the within the...
  • Page 664 3–660 HYBRID/TROUBLE SHOOTING P0A78 (TC14) Abnormality in inverter system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connectors of inverter and PCU harness The mea- (16P). sured value is 3.
  • Page 665 HYBRID/TROUBLE SHOOTING 3–661 P0A78 (TC14) Abnormality in inverter system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Disconnect the SMR drive con- nector from the high-voltage J/ B (in the battery pack). 2. Using the electrical tester, mea- sure the resistance between The mea- the terminals of PCU harness sured value is...
  • Page 666 3–662 HYBRID/TROUBLE SHOOTING P0A78 (TC14) Abnormality in inverter system Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Remove the SMR#2 from the The mea- high-voltage J/B (in the battery sured value is pack). within the range of stan- 2. Using the electrical tester, mea- dard value: Go Replace the sure the resistance between...
  • Page 667 Go 2. Connect the diagnosis tool Inspecting the Perform trou- (HINO-DX) to the vehicle. to YES. HV battery bleshooting for Go to step 16. 3. Set the starter key to the "ON" ECU [HINO-...

  • Page 668: Dtc: P0A78 (Tc15)

    3–664 HYBRID/TROUBLE SHOOTING DTC: P0A78 (TC15) EN01H03ZZZ030602004052 DTC: P0A78 (TC15) Abnormality in inverter system INFORMATION Inverter Motor SHTS03ZZZ0300433 Technical description • – <Description of malfunction> • Detected an abnormality in the inverter (motor overcurrent). DTC set condition DTC detection condition •...
  • Page 669 HYBRID/TROUBLE SHOOTING 3–665 After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Malfunction of HV motor • Malfunction of three-phase cable • Malfunction of SMR#1 • Malfunction of SMR#2 •...
  • Page 670 3–666 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0A78 (TC15) Inspecting the three-phase cable 1 Check the three-phase cable connector (inverter-side) for failing connection (looseness, wear, or melting damage). Is any defect found? Retighten the terminals. Go to step 2. Replace the terminals if abnormal wear or melting damage is detected.
  • Page 671 HYBRID/TROUBLE SHOOTING 3–667 Inspecting resistance between HV motor phases Set the starter key to the "LOCK" position. Disconnect the three-phase cable (U, V, and W terminals) from the HV motor. Using the electrical tester, measure the resistance between the HV motor terminals. HINT If the motor temperature is too high, the resistance largely varies.
  • Page 672 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 673 HYBRID/TROUBLE SHOOTING 3–669 CHECKLIST: P0A78 (TC15) P0A78 (TC15) Abnormality in inverter system Inspection Procedure Check Step Action Description Judgement (Yes/No) Retighten the Defect is terminals. found: Go to Replace the 1. Check the three-phase cable Inspecting the YES. terminals if connector (inverter-side) for three-phase Go to step 2.
  • Page 674 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0A78- (HINO-DX) to the vehicle. 15 is detected: 3. Set the starter key to the "ON" Go to YES. Reproduction The inspec- position.

  • Page 675: Dtc: P0Aa1 (Tcd8)

    HYBRID/TROUBLE SHOOTING 3–671 DTC: P0AA1 (TCD8) EN01H03ZZZ030602004053 DTC: P0AA1 (TCD8) SMR#2 (positive side) contact sticking INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300437 Technical description • – <Description of malfunction>...
  • Page 676 3–672 HYBRID/TROUBLE SHOOTING Pre-inspection work • Check the battery voltage to make sure that there is no abnormality. After-inspection work • Clear the recorded DTC. • Check that no DTC is detected after test-driving the vehicle. Estimated failure factors • Malfunction of SMR#2 (positive terminal side) •...
  • Page 677 INSPECTION PROCEDURE: P0AA1 (TCD8) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any...
  • Page 678 3–674 HYBRID/TROUBLE SHOOTING Inspecting the SMR#2 Remove the SMR#2 from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the SMR#2 terminals. Measurement Tester Standard values conditions connections SMR#2 terminal (switch side) 10 k or more —...
  • Page 679 HYBRID/TROUBLE SHOOTING 3–675 Restoration check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 680 1. Set the starter key to the DTC other "LOCK" position. than P0AA1- 2. Connect the diagnosis tool D8 is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Reading the bleshooting for 3. Set the starter key to the "ON"...
  • Page 681 Go to YES. pleted. Restoration Replace the (Temporary 3. Clear the malfunction history. check [HINO- DTC P0AA1- inverter. actuation of 4. Perform a test run. (accelerate D8 is not protection and decelerate running for detected: Go function due to approximately 1 hour).

  • Page 682: Dtc: P0Aa4 (Tcd9)

    3–678 HYBRID/TROUBLE SHOOTING DTC: P0AA4 (TCD9) EN01H03ZZZ030602004054 DTC: P0AA4 (TCD9) SMR#1 and 3 (negative side) contact sticking INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300443 Technical description •...
  • Page 683 HYBRID/TROUBLE SHOOTING 3–679 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check the battery voltage to make sure that there is no abnormality. After-inspection work •...
  • Page 684 INSPECTION PROCEDURE: P0AA4 (TCD9) Reading the DTC [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if any...
  • Page 685 HYBRID/TROUBLE SHOOTING 3–681 Inspecting the PN cable for short circuit Install the system main resistor. BATT OUT(-) BATT IN(-) Using the electrical tester, measure the resistance between the terminals of high-voltage J/B (in the battery pack) Measurement Tester Standard values conditions connections High-voltage J/B...
  • Page 686 3–682 HYBRID/TROUBLE SHOOTING Inspecting the SMR#3 Remove the SMR#3 from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the SMR#3 terminals. Measurement Tester Standard values conditions connections SMR#3 terminal (switch side) 10 k or more —...
  • Page 687 HYBRID/TROUBLE SHOOTING 3–683 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 688 1. Set the starter key to the DTC other "LOCK" position. than P0AA4- 2. Connect the diagnosis tool D9 is detected: (HINO-DX) to the vehicle. Go to YES. Perform trou- Reading the bleshooting for 3. Set the starter key to the "ON"...
  • Page 689 HYBRID/TROUBLE SHOOTING 3–685 P0AA4 (TCD9) SMR#1 and 3 (negative side) contact sticking Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Remove the SMR#1 from the The mea- high-voltage J/B (in the battery sured value is pack). within the range of stan- 2.
  • Page 690 Go to YES. pleted. Reproduction Replace the (Temporary 3. Clear the malfunction history. check [HINO- DTC P0AA4- inverter. actuation of 4. Perform a test run. (accelerate D9 is not protection and decelerate running for detected: Go function due to approximately 1 hour).

  • Page 691: Dtc: P0Adb (Tc1F)

    HYBRID/TROUBLE SHOOTING 3–687 DTC: P0ADB (TC1F) EN01H03ZZZ030602004055 DTC: P0ADB (TC1F) SMR#2 (positive side) Low abnormality INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300451 Technical description • – <Description of malfunction>...
  • Page 692 3–688 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 693 HYBRID/TROUBLE SHOOTING 3–689 INSPECTION PROCEDURE: P0ADB (TC1F) Inspecting the PCU wire harness (lower side) for short circuit Set the starter key to the "LOCK" position. Disconnect the connectors of inverter and PCU harness (16P). Vehicle GND Using the electrical tester, measure the resistance between the 39th terminal of inverter connector and the ground.
  • Page 694 3–690 HYBRID/TROUBLE SHOOTING Inspecting the high-voltage J/B (in the battery pack) for short circuit Using the electrical tester, measure the resistance between the 4th terminal of SMR drive connector and the ground. Vehicle GND Measurement Tester Standard values conditions connections SMR drive con- nector 10 k...
  • Page 695 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 696 3–692 HYBRID/TROUBLE SHOOTING CHECKLIST: P0ADB (TC1F) P0ADB (TC1F) SMR#2 (positive side) Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. The mea- 2. Disconnect the connectors of sured value is inverter and PCU harness within the (16P).
  • Page 697 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0ADB- The inspec- (HINO-DX) to the vehicle. 1F is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 698: Dtc: P0Adc (Tc93)

    3–694 HYBRID/TROUBLE SHOOTING DTC: P0ADC (TC93) EN01H03ZZZ030602004056 DTC: P0ADC (TC93) SMR#2 (positive side) High abnormality INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300457 Technical description • – <Description of malfunction>...
  • Page 699 HYBRID/TROUBLE SHOOTING 3–695 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 700 3–696 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0ADC (TC93) Inspecting the PCU wire harness (lower side) for continuity 1 Set the starter key to the "LOCK" position. Disconnect the connectors of inverter and PCU harness (16P). Using the electrical tester, measure the resistance between the terminals of inverter connector and PCU harness (16P) lower-side connector.
  • Page 701 HYBRID/TROUBLE SHOOTING 3–697 Inspecting the wire harness in the HV battery for continuity Remove the PCU top cover. Disconnect the SMR drive connector from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the terminals of PCU harness (16P) upper-side connector and SMR drive connector.
  • Page 702 3–698 HYBRID/TROUBLE SHOOTING Inspecting the SMR drive Using the electrical tester, measure the resistance between the terminals of high-voltage J/B (in the battery pack). Measurement Tester Standard values conditions connections SMR drive con- nector (high-volt- 19 – 50  — age J/B side) 4th terminal –...
  • Page 703 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 704 3–700 HYBRID/TROUBLE SHOOTING CHECKLIST: P0ADC (TC93) P0ADC (TC93) SMR#2 (positive side) High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connectors of The mea- inverter and PCU harness sured value is (16P).
  • Page 705 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0ADC- The inspec- (HINO-DX) to the vehicle. 93 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 706: Dtc: P0Adf (Tc1E)

    3–702 HYBRID/TROUBLE SHOOTING DTC: P0ADF (TC1E) EN01H03ZZZ030602004057 DTC: P0ADF (TC1E) SMR#3 (negative side) Low abnormality INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300463 Technical description • – <Description of malfunction>...
  • Page 707 HYBRID/TROUBLE SHOOTING 3–703 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 708 3–704 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0ADF (TC1E) Inspecting the PCU wire harness (lower side) for short circuit Set the starter key to the "LOCK" position. Disconnect the connectors of inverter and PCU harness (16P). Vehicle GND Using the electrical tester, measure the resistance between the 40th terminal of inverter connector and the ground.
  • Page 709 HYBRID/TROUBLE SHOOTING 3–705 Inspecting the high-voltage J/B (in the battery pack) for short circuit Using the electrical tester, measure the resistance between the 1st terminal of SMR drive connector and the ground. Vehicle GND Measurement Tester Standard values conditions connections SMR drive con- 10 k...
  • Page 710 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 711 HYBRID/TROUBLE SHOOTING 3–707 CHECKLIST: P0ADF (TC1E) P0ADF (TC1E) SMR#3 (negative side) Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. The mea- 2. Disconnect the connectors of sured value is inverter and PCU harness within the (16P).
  • Page 712 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0ADF- The inspec- (HINO-DX) to the vehicle. 1E is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 713: Dtc: P0Ae0 (Tc95)

    HYBRID/TROUBLE SHOOTING 3–709 DTC: P0AE0 (TC95) EN01H03ZZZ030602004058 DTC: P0AE0 (TC95) SMR#3 (negative side) High abnormality INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300469 Technical description • – <Description of malfunction>...
  • Page 714 3–710 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 715 HYBRID/TROUBLE SHOOTING 3–711 INSPECTION PROCEDURE: P0AE0 (TC95) Inspecting the PCU wire harness (lower side) for continuity 1 Set the starter key to the "LOCK" position. Disconnect the connectors of inverter and PCU harness (16P). Using the electrical tester, measure the resistance between the terminals of inverter connector and PCU harness (16P) lower-side connector.
  • Page 716 3–712 HYBRID/TROUBLE SHOOTING Inspecting the wire harness in the HV battery for continuity Remove the PCU top cover. Disconnect the SMR drive connector from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the terminals of PCU harness (16P) upper-side connector and SMR drive connector.
  • Page 717 HYBRID/TROUBLE SHOOTING 3–713 Inspecting the SMR drive Using the electrical tester, measure the resistance between the terminals of high-voltage J/B (in the battery pack). Measurement Tester Standard values conditions connections SMR drive con- nector (high-volt- 19 – 50  — age J/B side) 1st terminal –...
  • Page 718 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 719 HYBRID/TROUBLE SHOOTING 3–715 CHECKLIST: P0AE0 (TC95) P0AE0 (TC95) SMR#3 (negative side) High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connectors of The mea- inverter and PCU harness sured value is (16P).
  • Page 720 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0AE0- The inspec- (HINO-DX) to the vehicle. 95 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 721: Dtc: P0Ae6 (Tc1D)

    HYBRID/TROUBLE SHOOTING 3–717 DTC: P0AE6 (TC1D) EN01H03ZZZ030602004059 DTC: P0AE6 (TC1D) SMR#1 (negative side) Low abnormality INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300475 Technical description • – <Description of malfunction>...
  • Page 722 3–718 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 723 HYBRID/TROUBLE SHOOTING 3–719 INSPECTION PROCEDURE: P0AE6 (TC1D) Inspecting the PCU wire harness (lower side) for short circuit Set the starter key to the "LOCK" position. Disconnect the connectors of inverter and PCU harness (16P). Vehicle GND Using the electrical tester, measure the resistance between the 38th terminal of inverter connector and the ground.
  • Page 724 3–720 HYBRID/TROUBLE SHOOTING Inspecting the high-voltage J/B (in the battery pack) for short circuit Using the electrical tester, measure the resistance between the 3rd terminal of SMR drive connector and the ground. Vehicle GND Measurement Tester Standard values conditions connections SMR drive con- nector 10 k...
  • Page 725 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 726 3–722 HYBRID/TROUBLE SHOOTING CHECKLIST: P0AE6 (TC1D) P0AE6 (TC1D) SMR#1 (negative side) Low abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. The mea- 2. Disconnect the connectors of sured value is inverter and PCU harness within the (16P).
  • Page 727 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0AE6- The inspec- (HINO-DX) to the vehicle. 1D is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 728: Dtc: P0Ae7 (Tc94)

    3–724 HYBRID/TROUBLE SHOOTING DTC: P0AE7 (TC94) EN01H03ZZZ030602004060 DTC: P0AE7 (TC94) SMR#1 (negative side) High abnormality INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300481 Technical description • – <Description of malfunction>...
  • Page 729 HYBRID/TROUBLE SHOOTING 3–725 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 730 3–726 HYBRID/TROUBLE SHOOTING INSPECTION PROCEDURE: P0AE7 (TC94) Inspecting the PCU wire harness (lower side) for continuity 1 Set the starter key to the "LOCK" position. Disconnect the connectors of inverter and PCU harness (16P). Using the electrical tester, measure the resistance between the terminals of inverter connector and PCU harness (16P) lower-side connector.
  • Page 731 HYBRID/TROUBLE SHOOTING 3–727 Inspecting the wire harness in the HV battery for continuity Remove the PCU top cover. Disconnect the SMR drive connector from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the terminals of PCU harness (16P) upper-side connector and SMR drive connector.
  • Page 732 3–728 HYBRID/TROUBLE SHOOTING Inspecting the SMR drive Using the electrical tester, measure the resistance between the terminals of high-voltage J/B (in the battery pack). Measurement Tester Standard values conditions connections SMR drive con- nector (high-volt- 19 – 50  — age J/B side) 3rd terminal –...
  • Page 733 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 734 3–730 HYBRID/TROUBLE SHOOTING CHECKLIST: P0AE7 (TC94) P0AE7 (TC94) SMR#1 (negative side) High abnormality Inspection Procedure Check Step Action Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Disconnect the connectors of The mea- inverter and PCU harness sured value is (16P).
  • Page 735 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool DTC P0AE7- The inspec- (HINO-DX) to the vehicle. 94 is detected: tion is com- 3. Set the starter key to the "ON" Go to YES. pleted.

  • Page 736: Dtc: P0Aee (Tc22)

    3–732 HYBRID/TROUBLE SHOOTING DTC: P0AEE (TC22) EN01H03ZZZ030602004061 DTC: P0AEE (TC22) Abnormality in characteristics of inverter temperature sensor INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the characteristics of main circuit element temperature detecting sensor (Low abnor- mality).
  • Page 737 INSPECTION PROCEDURE: P0AEE (TC22) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 738 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0AEE- The inspec- 3. Set the starter key to the "ON" 22 is detected: tion is com- position.

  • Page 739: Dtc: P0Aee (Tc23)

    HYBRID/TROUBLE SHOOTING 3–735 DTC: P0AEE (TC23) EN01H03ZZZ030602004062 DTC: P0AEE (TC23) Abnormality in characteristics of inverter temperature sensor INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality in the characteristics of main circuit element temperature detecting sensor (High abnor- mality).
  • Page 740 INSPECTION PROCEDURE: P0AEE (TC23) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 741 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0AEE- The inspec- 3. Set the starter key to the "ON" 23 is detected: tion is com- position.

  • Page 742: Dtc: P0Aef (Tc24)

    3–738 HYBRID/TROUBLE SHOOTING DTC: P0AEF (TC24) EN01H03ZZZ030602004063 DTC: P0AEF (TC24) Inverter temperature sensor Low abnormality INFORMATION Inverter Thermistor Rotor A’ A’ A’ A’ Resolver A’ A’ SHTS03ZZZ0300489 Technical description • – <Description of malfunction> • Detected a Low abnormality in the temperature sensor in the inverter (main circuit element temperature sensor). DTC set condition DTC detection condition •...
  • Page 743 HYBRID/TROUBLE SHOOTING 3–739 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 744 INSPECTION PROCEDURE: P0AEF (TC24) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 745 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0AEF- The inspec- 3. Set the starter key to the "ON" 24 is detected: tion is com- position.

  • Page 746: Dtc: P0Af0 (Tc25)

    3–742 HYBRID/TROUBLE SHOOTING DTC: P0AF0 (TC25) EN01H03ZZZ030602004064 DTC: P0AF0 (TC25) Inverter temperature sensor High abnormality INFORMATION Inverter Thermistor Rotor A’ A’ A’ A’ Resolver A’ A’ SHTS03ZZZ0300491 Technical description • – <Description of malfunction> • Detected a High abnormality in the temperature sensor in the inverter (main circuit element temperature sensor). DTC set condition DTC detection condition •...
  • Page 747 HYBRID/TROUBLE SHOOTING 3–743 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 748 INSPECTION PROCEDURE: P0AF0 (TC25) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 749 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0AF0- The inspec- 3. Set the starter key to the "ON" 25 is detected: tion is com- position.

  • Page 750: Dtc: P0Bea (Tcb3)

    3–746 HYBRID/TROUBLE SHOOTING DTC: P0BEA (TCB3) EN01H03ZZZ030602004065 DTC: P0BEA (TCB3) Abnormality in V-phase current sensor characteristics INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (offset abnormality) in the motor V-phase current sensor. DTC set condition DTC detection condition •...
  • Page 751 INSPECTION PROCEDURE: P0BEA (TCB3) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 752 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0BEA- The inspec- 3. Set the starter key to the "ON" B3 is detected: tion is com- position.

  • Page 753: Dtc: P0Bea (Tcb4)

    HYBRID/TROUBLE SHOOTING 3–749 DTC: P0BEA (TCB4) EN01H03ZZZ030602004066 DTC: P0BEA (TCB4) Abnormality in V-phase current sensor characteristics INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (deviation abnormality) in the motor V-phase current sensor. DTC set condition DTC detection condition •...
  • Page 754 INSPECTION PROCEDURE: P0BEA (TCB4) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 755 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0BEA- The inspec- 3. Set the starter key to the "ON" B4 is detected: tion is com- position.

  • Page 756: Dtc: P0Beb (Tc9A)

    3–752 HYBRID/TROUBLE SHOOTING DTC: P0BEB (TC9A) EN01H03ZZZ030602004067 DTC: P0BEB (TC9A) V-phase current sensor High abnormality INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (out-of-range Low abnormality) in the motor V-phase current sensor. DTC set condition DTC detection condition •...
  • Page 757 INSPECTION PROCEDURE: P0BEB (TC9A) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 758 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0BEB- The inspec- 3. Set the starter key to the "ON" 9A is detected: tion is com- position.

  • Page 759: Dtc: P0Bec (Tc9B)

    HYBRID/TROUBLE SHOOTING 3–755 DTC: P0BEC (TC9B) EN01H03ZZZ030602004068 DTC: P0BEC (TC9B) V-phase current sensor High abnormality INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (out-of-range High abnormality) in the motor V-phase current sensor. DTC set condition DTC detection condition •...
  • Page 760 INSPECTION PROCEDURE: P0BEC (TC9B) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 761 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0BEC- The inspec- 3. Set the starter key to the "ON" 9B is detected: tion is com- position.

  • Page 762: Dtc: P0Bee (Tcb5)

    3–758 HYBRID/TROUBLE SHOOTING DTC: P0BEE (TCB5) EN01H03ZZZ030602004069 DTC: P0BEE (TCB5) Abnormality in W-phase current sensor characteristics INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (offset abnormality) in the motor W-phase current sensor. DTC set condition DTC detection condition •...
  • Page 763 INSPECTION PROCEDURE: P0BEE (TCB5) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 764 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0BEE- The inspec- 3. Set the starter key to the "ON" B5 is detected: tion is com- position.

  • Page 765: Dtc: P0Bee (Tcb6)

    HYBRID/TROUBLE SHOOTING 3–761 DTC: P0BEE (TCB6) EN01H03ZZZ030602004070 DTC: P0BEE (TCB6) Abnormality in W-phase current sensor characteristics INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (deviation abnormality) in the motor W-phase current sensor. DTC set condition DTC detection condition •...
  • Page 766 INSPECTION PROCEDURE: P0BEE (TCB6) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 767 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0BEE- The inspec- 3. Set the starter key to the "ON" B6 is detected: tion is com- position.

  • Page 768: Dtc: P0Bef (Tc9C)

    3–764 HYBRID/TROUBLE SHOOTING DTC: P0BEF (TC9C) EN01H03ZZZ030602004071 DTC: P0BEF (TC9C) W-phase current sensor Low abnormality INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (out-of-range Low) in the motor W-phase current sensor. DTC set condition DTC detection condition •...
  • Page 769 INSPECTION PROCEDURE: P0BEF (TC9C) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 770 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0BEF- The inspec- 3. Set the starter key to the "ON" 9C is detected: tion is com- position.

  • Page 771: Dtc: P0Bf0 (Tc9D)

    HYBRID/TROUBLE SHOOTING 3–767 DTC: P0BF0 (TC9D) EN01H03ZZZ030602004072 DTC: P0BF0 (TC9D) W-phase current sensor High abnormality INFORMATION Technical description • – <Description of malfunction> • Detected an abnormality (out-of-range High abnormality) in the motor W-phase current sensor. DTC set condition DTC detection condition •...
  • Page 772 INSPECTION PROCEDURE: P0BF0 (TC9D) Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 773 Description Judgement (Yes/No) 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P0BF0- The inspec- 3. Set the starter key to the "ON" 9D is detected: tion is com- position.

  • Page 774: Dtc: P3126 (Tc12)

    3–770 HYBRID/TROUBLE SHOOTING DTC: P3126 (TC12) EN01H03ZZZ030602004073 DTC: P3126 (TC12) Abnormality in inverter system (only during cranking) INFORMATION High voltage J/B High voltage J/B Inverter SMR1 J/B (+) J/B (-) SMR2 Service plug HV Battery 288 V SMR3 SHTS03ZZZ0300501 Technical description •...
  • Page 775 HYBRID/TROUBLE SHOOTING 3–771 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check the battery voltage to make sure that there is no abnormality. After-inspection work •...
  • Page 776 Inspecting the HV battery ECU [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. In [Fault Information] on the diagnosis tool screen, check if DTC P0A95 related to the HV battery line is detected.
  • Page 777 HYBRID/TROUBLE SHOOTING 3–773 Inspecting the DC high-voltage cable for continuity 1 Set the starter key to the "LOCK" position. Remove the inverter terminal block cover and the ECU box termi- nal block cover. INV(+) Using the electrical tester, measure the resistance between the INV(-) terminals of inverter and high-voltage J/B (in the ECU box).
  • Page 778 3–774 HYBRID/TROUBLE SHOOTING Inspecting the high-voltage J/B (in the ECU box) Check the terminals of the high-voltage J/B (in the ECU box) for failing connection (looseness, wear, or melting damage). • BATT(+) terminal BATT(-) • BATT(-) terminal BATT(+) • INV(+) terminal •...
  • Page 779 HYBRID/TROUBLE SHOOTING 3–775 Inspecting the DC high-voltage cable for continuity 2 Remove the HV battery terminal block cover. BATT OUT(-) BATT(+) BATT(-) Using the electrical tester, measure the resistance between the terminals of high voltage J/B (in the battery pack) and high-voltage J/B (in the ECU box).
  • Page 780 3–776 HYBRID/TROUBLE SHOOTING Inspecting the SMR#1 Remove the SMR#1 from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the SMR#1 terminals. Measurement Tester Standard values conditions connections SMR#1 terminal (switch side) 10 k or more —...
  • Page 781 HYBRID/TROUBLE SHOOTING 3–777 Inspecting the SMR#3 Remove the SMR#3 from the high-voltage J/B (in the battery pack). Using the electrical tester, measure the resistance between the SMR#3 terminals. Measurement Tester Standard values conditions connections SMR#3 terminal (switch side) 10 k or more —...
  • Page 782 Reproduction check [HINO-DX] Connect all the connectors that have been disconnected to restore the system. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Perform a test run. (accelerate and decelerate running for approxi- mately 1 hour).
  • Page 783 1. Set the starter key to the "LOCK" position. DTC P0A95 is 2. Connect the diagnosis tool detected: Go Inspecting the (HINO-DX) to the vehicle. Perform trou- to YES. HV battery bleshooting for 3. Set the starter key to the "ON"...
  • Page 784 3–780 HYBRID/TROUBLE SHOOTING Abnormality in inverter system P3126 (TC12) Inspection Procedure (only during cranking) Check Step Action Description Judgement (Yes/No) 1. Check the terminals of the Retighten the high-voltage J/B (in the ECU Defect is terminals. box) for failing connection found: Go to Inspecting the Replace the...
  • Page 785 HYBRID/TROUBLE SHOOTING 3–781 Abnormality in inverter system P3126 (TC12) Inspection Procedure (only during cranking) Check Step Action Description Judgement (Yes/No) 1. Remove the SMR#2 from the The mea- high-voltage J/B (in the battery sured value is pack). within the range of stan- 2.
  • Page 786 (Yes/No) 1. Connect all the connectors that have been disconnected to restore the system. 2. Connect the diagnosis tool (HINO-DX) to the vehicle. DTC P3126- The inspec- 3. Set the starter key to the "ON" 12 is detected: tion is com- position.
  • Page 787 HYBRID/TROUBLE SHOOTING 3–783 DTC: U0073 (TC91) EN01H03ZZZ030602004074 DTC: U0073 (TC91) Abnormality in CAN communication with inverter (control CAN) INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4)
  • Page 788 3–784 HYBRID/TROUBLE SHOOTING Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 789 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU and inverter.
  • Page 790 3–786 HYBRID/TROUBLE SHOOTING Inspecting the HV ECU [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-11 (abnormality in control CAN communication) is detected in the HV ECU. SHTS03ZZZ0300514 Is DTC U0073-11 detected? Refer to the "CONTROL CAN COMMUNICA- Replace the inverter.

  • Page 791: Dtc: U0073 (Tc91)

    SYSTEM". items 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U0073- pleted. position. 91 is detected: (Temporary Go to YES.

  • Page 792: Dtc: U0074 (Tc3E)

    3–788 HYBRID/TROUBLE SHOOTING DTC: U0074 (TC3E) EN01H03ZZZ030602004075 DTC: U0074 (TC3E) Abnormality in CAN communication with inverter (DIAG CAN) INFORMATION Engine ECU VCS ECU (CANN) (CANP) (CANL) (CANH) J/C CAN1(22P) J/C CAN 2 INST PANEL INST PANEL J/C CAN5 ENGINE No.1 W/H No.1 W/H No.2 W/H J/C CAN1(10P)
  • Page 793 HYBRID/TROUBLE SHOOTING 3–789 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • – Pre-inspection work • Check the battery voltage to make sure that there is no abnormality. After-inspection work •...
  • Page 794 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history. Set the starter key to the "LOCK" position and wait for approxi- mately 1 minute.
  • Page 795 SYSTEM". items 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- Refer to the 3. Set the starter key to the "ON" DTC U0074- pleted. "DIAGNOSIS position.

  • Page 796: Dtc: U0293 (Tc31)

    3–792 HYBRID/TROUBLE SHOOTING DTC: U0293 (TC31) EN01H03ZZZ030602004076 DTC: U0293 (TC31) HV ECU CAN communication blackout INFORMATION Clutch ECU ABS ECU AT ECU To GROUND CIRCUIT (CA2-) (CA2+) HV PCU (CSL2) X-24 (CA1-) (CA1-) X-23 (CA1+) (CA1+) J/C CAN2 J/C CAN2 J/C CAN1 (CSL4) X-21 (CA2+)
  • Page 797 HYBRID/TROUBLE SHOOTING 3–793 Symptoms on the vehicle when the DTC is set <Symptoms on the vehicle due to backup control (fail safe)> • – <Symptoms on the vehicle due to malfunction> • The engine may become unable to start. (Note, however, that vehicles equipped with a starter will be started with the starter.) •...
  • Page 798 Reproduction check [HINO-DX] Set the starter key to the "LOCK" position. Connect the diagnosis tool (HINO-DX) to the vehicle. Set the starter key to the "ON" position. Clear the malfunction history of the HV ECU, inverter, and vehicle control ECU.
  • Page 799 HYBRID/TROUBLE SHOOTING 3–795 Inspecting the HV ECU (CAN register) [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC P0A1D-12 (Control CAN register stuck) is detected in the HV ECU. SHTS03ZZZ0300519 Is DTC P0A1D-12 detected? Replace the HV ECU.
  • Page 800 3–796 HYBRID/TROUBLE SHOOTING Inspecting the HV ECU (communication abnormality) [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0073-11 (Abnormality in control CAN communication) is detected in the HV ECU. SHTS03ZZZ0300521 Is DTC U0073-11 detected? Perform troubleshooting for each of related Go to step 6.
  • Page 801 HYBRID/TROUBLE SHOOTING 3–797 Inspecting the HV ECU (communication blackout) [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0110-14 (Inverter CAN communication blackout) is detected in the HV ECU. SHTS03ZZZ0300523 Is DTC U0110-14 detected? Go to step 8.
  • Page 802 3–798 HYBRID/TROUBLE SHOOTING Inspecting the vehicle control ECU 1 [HINO-DX] In [Fault Information] on the diagnosis tool screen, check if DTC U0155 (Meter CAN communication blackout) is detected in the vehicle control ECU. SHTS03ZZZ0300525 Is DTC U0155 detected? Refer to the "CONTROL CAN COMMUNICA- Replace the HV ECU.

  • Page 803: Dtc: P060B

    SYSTEM". items 1. Set the starter key to the "LOCK" position. 2. Connect the diagnosis tool The inspec- (HINO-DX) to the vehicle. tion is com- 3. Set the starter key to the "ON" DTC U0293- pleted. position. 31 is detected: (Temporary Go to YES.
  • Page 804 Go • [U110A] Vehicle control ECU (All communi- Reading the to YES. CAN communication black- cation black- DTC 1 [HINO- Go to step 10. outs have All communi- • [U0101] AT ECU CAN com- been cation blackout munication blackout occurred.)
  • Page 805 Hino Motors Sales U.S.A., Inc. 41180 Bridge Street, Novi, MI 48375 Telephone: (248) 699-9300 PRINTED IN JAPAN Pub.No. S7-LXJE03A 3/4 '13. 2 '13. 3 S7-LXJE03B 4/7 '13. 6 S7-LXJE03C 4/7 '13. 7...

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