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HINO 195 series
Hino Motors HINO 195 series Manuals
Manuals and User Guides for Hino Motors HINO 195 series. We have
1
Hino Motors HINO 195 series manual available for free PDF download: Workshop Manual
Hino Motors HINO 195 series Workshop Manual (861 pages)
Brand:
Hino Motors
| Category:
Trucks
| Size: 41.92 MB
Table of Contents
Heater and Air Conditioner
3
Table of Contents
5
General Introduction
5
How to Identify Vehicle Type
6
Vehicle Identification Number (VIN) Structure
7
Appearance of Vehicle
8
General Precautions
9
Safety Instructions and Readiness to Work
9
Warning
9
Precautions in Tilting and Lowering the Cab
10
Definition of Safety Terms
11
Towing
12
Clean Air Act
13
Heavy-Duty Engine Rebuilding Practices
13
Maintenance Instructions
13
Identification Information
14
VIN - Vehicle Identification Number
14
Clean Idle Certified Label for US
15
Engine Serial Number
15
Transmission Serial Number
15
Vehicle Noise Emission Control Information
15
Vehicle Emission Control Information
16
Safety Instructions for Work
17
Precautions
17
Removing the Battery Cable
17
Safe Handling of Electrical Systems
17
Handling of Electronic Parts
18
Handling of Wire Harness
18
Handling of Battery Disconnect Switch
19
Handling of Connectors
19
Installation of Battery Disconnect Switch
19
Precaution for Electric Welding
20
Introduction to Workshop Manual
21
General
21
Introduction to Descriptions
22
Introduction to Troubleshooting
23
Definition of Term
25
Troubleshooting with Diagnosis Monitor
26
Connection of Diagnosis Check Wire
26
Troubleshooting Procedure
26
Indication of Diagnosis Monitor Code
27
Apparatus for Trouble Shooting
28
Tag Code and System Name List for Dedicated Harness
28
Connection of HINO DX II
29
Preparation for Connecting HINO DX II
29
Trouble Diagnosis Using the Computer (Hino DX Ⅱ )
29
Step of Trouble Diagnosis
29
Apparatus for Trouble Diagnosis
30
Glossary
31
Definition of Abbreviation
31
Definition of Abbreviation
34
Glossary of SAE and HINO Terms
34
Engine (J05E)
37
Engine ECU (J05E) Troubleshooting
40
Precautions for Diagnosis
40
Illustration of Connector
41
Numbering of Connector Terminals
41
Precautions for Terminal Measurement
41
Illustration of Connector and Measurement Surface
41
Electrical
42
Precautions
43
Harness Wire Connector
43
Using a Circuit Tester
44
Using a Signal Check Harness
44
Signal Check Harness Assembly
45
Radio Installation - Precaution
46
Using a Quick Charger - Precaution
46
Air Conditioner Installation - Precaution
46
Performing Electric Welding - Precautions
46
Computer (ECU) Pin Assignment
47
Removing the Engine ECU Connector
51
Cleaning the Engine ECU Connector
51
Mounting the Engine ECU Connector
53
Engine Inspection
55
Prior Check
55
Malfunction Indicator Light Illumination Pattern
55
Trouble Diagnosis Using the Computer - HINO DX Ⅱ
56
Connection of HINO DX Ⅱ
56
Diagnostic Trouble Code (DTC) Table
57
Group Sharing the Sensor Supply Terminal
79
Group Sharing the Sensor Gnd Terminal
80
Malfunction Codes in Case of Disruption of CAN Communication
81
Engine Equipment/Emission Control Device CAN Line (250 K)
81
CAN Communication Line Malfunction Part Determination Table
82
Engine Control/Diagnosis CAN Line (500 K)
83
Pre-Inspection for Engine CAN Communication Line (250 K)
84
Check the DTC Detected (HINO DX Ⅱ)
84
Check for +B/GND Short-Circuit in CAN H-Line
85
Check for +B/GND Short-Circuit in CAN L-Line
86
Check the Terminating Resistance
87
Check the Resistance
88
Check Harness in CAN Bus Line between J/C DEF SSR and DCU
89
DISCONNECTION INSPECTION for ENGINE CAN_H COMMUNICATION LLINE (250 K) [DIESEL]
89
Check Harness in CAN Bus Line between J/C_Can_Diesel and J/C DEF SSR
90
Check Harness in CAN Bus Line between J/C_ENG_CAN and J/C_Can_Diesel
91
Check Harness in CAN Bus Line between J/C_ENG_CAN2 and J/C_ENG_CAN
92
Check Harness in CAN Bus Line between Engine ECU and J/C_ENG_CAN2
93
Check Harness in CAN Bus Line between Engine ECU and CAN-TMN2
94
Inspect the EGR Controller (HINO DX Ⅱ)
95
Inspect the VNT Controller (HINO DX Ⅱ)
96
Nox Sensor 1 (HINO DX Ⅱ)
96
Inspect the Nox Sensor 2 (HINO DX Ⅱ)
97
Check the DEF Sensor (HINO DX Ⅱ)
97
DISCONNECTION INSPECTION for ENGINE CAN_H COMMUNICATION LLINE (250 K) [HYBRID]
98
Check Harness in CAN Bus Line between J/C_HV1 and J/C DEF SSR
99
Check Harness in CAN Bus Line between J/C_HV2 and J/C_HV1
100
Check Harness in CAN Bus Line between J/C_ENG_CAN and J/C_HV2
101
Check Harness in CAN Bus Line between J/C_ENG_CAN2 / J/C_ENG_CAN
102
Inspect the EGR Controller
105
Inspect the VNT Controller
106
Nox Sensor 1
106
Inspect the Nox Sensor 2
107
Check the DEF Sensor
107
Pre-Inspection for Engine CAN Communication Line (500 K) (Diesel)
108
Check the DTC Detected Engine ECU
108
Pre-Inspection for Engine CAN Communication Line (500 K) (Hybrid)
113
Check the DCU (Terminating Resistance)
116
Check the HV ECU (Terminating Resistance)
117
Disconnection Insp. for Engine CAN_H Comm. L Line (500 K) (Diesel)
119
Check Harness in CAN Bus Line between J/C_CAN5 and DCU
119
Check Harness in CAN Bus Line between J/C_CAN1 (10P) and J/C_CAN5
120
Check Harness in CAN Bus Line between J/C_CAN2 and J/C_CAN1 (10P)
120
Check Harness in CAN Bus Line between J/C_CAN1 (22P) and J/C_CAN2
121
Check Harness in CAN Bus Line between CAN_TMN and J/C_CAN1 (22P)
121
Check Harness in CAN Bus Line between DLC and J/C_CAN1 (22P)
122
Check Harness in CAN Bus Line between Engine ECU and J/C_CAN5
123
Disconnection Inspection for Engine CAN_H Comm. L Line (500K) (Hybrid)
124
Check Harness in CAN Bus Line between J/C_CAN2 and J/C_CAN5
125
Check Harness in CAN Bus Line between J/C_CAN1 (10P) / J/C_CAN1 (22P)
126
Check Harness in CAN Bus Line between HV PCU and J/C_CAN1 (10P)
126
Malfunction Codes for Faulty Actuator Power Relay
129
Eng Basic Inspecton Sheet (Engine Inspectoin Check Sheet)
130
Standard Injection Quantity
133
No DTC
134
Engine Low Power, Missfire, Hesitation, Knocking, Running Rough
134
Cylinder Cut-Off Test
135
Air Filter Visually Check
135
Air Hoses Visually Check
135
Intake Throttle Visually Check
136
Intake Throttle Activation Test
136
Mass Air Flow Sensor Check
136
Exhaust Brake Valve Check
136
DPR Normal Manual Regeneration Is Not Complete
137
Inspectin Procedure for When the DEF Mixed into the Engine Coolant
138
Inspect the DEF in the DEF Tank
138
Inspect for Coolant Leakage from the Coolant Pipe
138
Inspect if Engine Coolant Is Mixed into the DEF Injector
139
Dtc: P0005
140
P0005: Fuel Cut Valve Stuck Closed
140
Inspection Procedure: P0005
141
Inspect the Power Supply for the Fuel Cut Valve
141
Inspect the Fuel Cut Valve Downstream Pipe 1/2
142
Inspect the Fuel Cut Valve Upstream Pipe 1/2
143
DTC: P0006 and P0007
144
P0006: Malfunction of Fuel Cut Valve (Low)
144
P0007: Malfunction of Fuel Cut Valve (High)
145
Inspection Procedure: P0006 and P0007
146
Inspect the Fuel Cut Valve Connector
146
Inspect the Fuel Cut Valve
146
Inspect the Fuel Cut Valve Unit
147
Inspect for Short-Circuit of the Fuel Cut Valve Harness
147
Inspect Disconnection of the Fuel Cut Valve Harness
148
Check the DTC Detected (Engine ECU)
148
Dtc: P0016
149
Crankshaft Position Sensor and Camshaft Position Sensor Rationality
149
Inspection Procedure: P0016
151
Inspect the Camshaft Gear
151
Inspect the Flywheel
151
Inspect Engine Speed Main Sensor, Engine Speed Sub Sensor
151
DTC: P0027: Exhaust Brake Performance
152
Inspection Procedure: P0027
153
Check the DTC Detected 1 (HINO DX Ⅱ)
153
Inspect the Exhaust Brake Valve Piping and Hose
153
Inspect the Exhaust Brake Valve
154
Check the DTC Detected 2 (HINO DX Ⅱ)
154
P003A: Initialization Failure (VNT Actuator Initialize Error)
157
Dtc: P003A
157
Inspection Procedure: P003A
159
Inspect the Operation of the VNT Controller
160
Check the Response Delay of the VNT Controller
161
P0045: DC Motor Terminal Open Circuit or DC Motor Coil Open Circuit
162
Dtc: P0045
162
Inspection Procedure: P0045
164
Check the Connector Connection (HINO DX Ⅱ)
165
Check the Operation of the VNT Controller (HINO DX Ⅱ)
165
P0047: DC Motor Terminal Short Circuit, DC Motor Short Circuit
166
Dtc: P0047
166
Inspection Procedure: P0047
168
P0048: DC Motor Terminal Short Circuit, DC Motor Short Circuit
170
Dtc: P0048
170
Inspection Procedure: P0048
172
Check the Operation of the VNT Controller (HINO DX Ⅱ)
173
P006E: Power Supply Failure (out of Range Low)
174
Dtc: P006E
174
Inspection Procedure: P006E
176
Check the VNT Controller Power Supply Circuit
177
P006F: Power Supply Voltage Failure (out of Range High)
178
Dtc: P006F
178
Inspection Procedure: P006F
180
P007B: Intake Air Temperature Sensor (Intercooler Outlet) Rationality
182
Dtc: P007B
182
Inspection Procedure: P007B
189
Inspect Intercooler Outlet Temperature Sensor Connector
189
Inspect the Intercooler Outlet Temperature Sensor
190
Inspect the Intercooler Outlet Temperature Sensor Unit
190
Inspect the Intercooler Outlet Temperature Sensor Power Supply
191
Short-Circuit in Wire Harness of Intercooler Outlet Temperature Sensor
191
Disconnection in Wire Harness of Intercooler Outlet Temperature Sensor
192
Inspect the Intake Air Temperature Sensor
192
Inspect the Intake Air Temperature Sensor Unit
193
Inspect the Boost Pressure Sensor Hose
193
Inspect the Boost Pressure Sensor Power Supply System
194
Inspect the Intake Manifold Temperature Sensor
194
Inspect the Intake Manifold Temperature Sensor Unit
195
DTC: P007C and P007D
196
P007C: Intake Air Temperature Sensor (Intercooler Outlet) out of Range
196
P007D: Intake Air Temperature Sensor (Intercooler Outlet) out of Range
198
Inspection Procedure: P007C and P007D
200
Inspect the Intercooler Outlet Temperature Sensor Connector
200
P0088: Fuel System Pressure - High
204
Dtc: P0088
204
Inspectin Procedure: P0088
206
Inspect the Start of the Engine
206
Inspect the Supply Pump
206
Function Check of Supply Pump (HINO DX Ⅱ)
207
Inspect the Pre Fuel Filter
207
Inspect the Fuel Pipe
208
Inspect the Fuel Tank Breather
208
Inspect the Fuel Tank Feed Pipe
208
Inspect the Fuel Tank
209
Inspect the Supply Pump Gauze Filter
209
Inspect the Fuel High-Pressure Pipe
209
Inspect the Fuel Filter
209
Inspect the SCV Connector
210
Inspect the Common Rail Pressure Sensor Connector
210
Inspect the Common Rail Pressure Sensor Power Supply
210
Inspect the Engine Speed Main Sensor (Crankshaft Position Sensor)
211
Inspect the Fuel Return Pipe and Hose
211
P0096: Intake Air Temperature Sensor (Intake Manifold) - Rationality
212
Dtc: P0096
212
Inspection Procedure: P0096
216
Inspect the Intake Air Temperature Sensor (Intake Manifold) Connector
216
Inspect the Intake Air Temperature Sensor (Intake Manifold)
217
Inspect the Intake Air Temperature Sensor (Intake Manifold) Unit
217
Inspect the Intake Air Temperature Sensor Power Supply
218
Inspect for Short-Circuit of Intake Air Temper. Sensor Harness
218
Inspect Disconnection of the Intake Air Temperature Sensor Harness
219
Inspect the Intake Air Temperature Sensor (Air Flow Sensor Built-In)
219
Inspect the Intake Air Temperature Sensor (Air Flow Sensor) Unit
220
Inspect the Intake Air Temperature Sensor (Intercooler Outlet)
220
Inspect the Intake Air Temperature Sensor (Intercooler Outlet) Unit
221
DTC: P0097 and P0098
223
P0097: Intake Air Temperature Sensor (Intake Manifold) - out of Range
223
P0098: Intake Air Temperature Sensor out of Range (High)
225
Inspectin Procedure: P0097 and P0098
227
I
227
Short-Circuit of the Intake Air Temperature Sensor Harness
229
Disconnection of the Intake Air Temperature Sensor Harness
229
Inspect the Sensor Power Supply
230
P00AF: Controller Error (VNT Actuator CPU Malfunction)
231
Dtc: P00Af
231
Inspection Procedure: P00AF
233
P0101: Air Flow Sensor - Rationality
235
Dtc: P0101
235
Inspection Procedure: P0101
237
Inspect the Air Cleaner Element
237
Check the Intake System
237
Inspect the Air Flow Sensor
238
Inspect for Short-Circuits in Wire Harness of Air Flow Sensor
238
Inspect for Disconnection in Wire Harness of Air Flow Sensor
239
Inspect the EGR Valve
240
Check the Response Delay of the EGR Valve
241
Inspect the Diesel Throttle Valve
242
Inspect the Intercooler
242
Check the DTC Detected (P0101)
243
P0104: Air Flow Sensor - out of Range
244
Dtc: P0104
244
Inspection Procedure: P0104
246
Inspect the Air Flow Sensor Connector
246
Inspect the Air Flow Senso
247
Inspect for Short-Circuit of the Air Flow Sensor Harness
247
Inspect Disconnection of the Air Flow Sensor Harness
248
Inspect the Air Flow Sensor Power Supply
249
Inspect the Air Flow Sensor Signal
250
Check the DTC Detected (Engine ECU) 2
250
P0106: Boost Pressure Sensor - Rationality
251
Dtc: P0106
251
Inspection Procedure: P0106
253
Inspect the Boost Pressure Sensor Connector
253
Inspect the Boost Pressure Sensor
253
Inspect for Short-Circuits in Wire Harness of Boost Pressure Sensor
254
Inspect for Disconnection in Wire Harness of Boost Pressure Sensor
255
Inspect the Boost Pressure Sensor Power Supply
256
P0108: Boost Pressure Sensor - out of Range (out of Range High)
257
Dtc: P0108
257
Inspection Procedure: P0108
259
Inspect for Short-Circuit of the Boost Pressure Sensor Harness
260
Inspect Disconnection of the Boost Pressure Sensor Harness
261
DTC: P0112 and P0113
263
P0112: Intake Air Temperature Sensor - out of Range (Low)
263
P0113: Intake Air Temperature Sensor - out of Range (High)
265
Inspection Procedure: P0112 and P0113
267
Inspect the Intake Air Temperature Sensor Connector
267
Inspect Short-Circuit in Wire Harness of Intake Air Temperature Sensor
269
Disconnection in Wire Harness of Intake Air Temperature Sensor
270
P0115: Malfunction of Coolant Temperature/Intake Air Temper. Sensor
271
Dtc: P0115
271
Inspection Procedure: P0115
273
Inspect the Engine Coolant Temperature Sensor 1 Connector
273
Inspect the Engine Coolant Temperature Sensor 1
273
Inspect the Engine Coolant Temperature Sensor 1 Unit
274
Inspect the Engine Coolant Temperature Sensor 1 Power Supply
274
Short-Circuit in Wire Harness of Engine Coolant Temperature Sensor 1
275
Disconnection in Wire Harness of Engine Coolant Temperature Sensor 1
275
Inspect the Engine Coolant Temperature Sensor 2 Connector
276
Inspect the Engine Coolant Temperature Sensor 2
276
Inspect the Engine Coolant Temperature Sensor 2 Unit
277
Inspect the Engine Coolant Temperature Sensor 2 Power Supply
277
Short-Circuit in Wire Harness of Engine Coolant Temperature Sensor 2
278
Disconnection in Wire Harness of Engine Coolant Temperature Sensor 2
278
DTC: P0117 and P0118
280
P0117: Engine Coolant Temperature Sensor 1 - out of Range (Low)
280
P0118: Engine Coolant Temperature Sensor 1 - out of Range (High)
282
Inspection Procedure: P0117 and P0118
284
Inspect the Engine Coolant Temperature Sensor Connector
284
Inspect the Engine Coolant Temperature Sensor
284
Inspect the Engine Coolant Temperature Sensor Unit
285
Actuation Power Supply Wire Harness of Engine Coolant Temper. Sensor
285
Inspect for Short-Circuit of Engine Coolant Temperature Sensor Harness
286
Inspect Disconnection of Engine Coolant Temperature Sensor Harness
286
P011A: Engine Coolant Temperature Sensor - Rationality
288
Dtc: P011A
288
Inspection Procedure: P011A
290
Short-Circuit of the Engine Coolant Temperature Sensor 1 Harness
292
Disconnection of the Engine Coolant Temperature Sensor 1 Harness
292
P011C: Intake Air Temperature Sensor - Rationality
297
Dtc: P011C
297
Inspection Procedure: P011C
299
Short-Circuits in Wire Harness of Intake Air Temperature Sensor
301
DTC: P0122 and P0123
303
P0122: Intake Throttle Valve Position Sensor 1 - out of Range (Low)
303
P0123: Intake Throttle Valve Position Sensor 1 - out of Range (High)
305
Inspection Procedure: P0122 and P0123
306
Inspect the Intake Throttle Valve Position Sensor 1 Connector
306
Inspect the Intake Throttle Valve Position Sensor 1
306
Inspect the Intake Throttle Valve Position Sensor 1 Unit
307
Inspect the Intake Throttle Valve Position Sensor 1 Power Supply
308
Inspect the Diesel Throttle Position Sensor 1 Ground Circuit
308
Short-Circuits in Wire Harness of Diesel Throttle Position Sensor 1
309
Disconnection in Wire Harness of Diesel Throttle Position Sensor 1
310
P0128: Thermostat: Coolant Temperature Doesn't Reach Warmed-Up Temp.
312
Dtc: P0128
312
Inspection Procedure: P0128
314
Inspect the Thermostat
315
Inspect the Thermostat Valve-Opening Temperature
316
Inspect the Thermostat Valve-Open Time
316
P0148: Abnormality in Post Injection
318
Dtc: P0148
318
Inspection Procedure: P0148
320
Inspect the Fuel Line
321
Check the DTC Detected 3 (HINO DX Ⅱ)
322
Perform the Cylinder Cut-Off Test (HINO DX Ⅱ)
323
Check the DTC Detected 4 (HINO DX II)
323
Replace the Common Rail Assembly (HINO DX Ⅱ)
324
Check the Injector Clamp
324
Check the Valve Clearance
325
Check the Engine Compression Pressure
326
Check the DTC Detected 5 (HINO DX Ⅱ)
327
Flow-Cut off Test
328
DTC: P016E and P016F
330
P016E: Fuel System Pressure Control - High
330
P016F: Fuel System Pressure Control - Low
332
Inspection Procedure: P016E and P016F
334
DTC: P0182 and P0183
340
P0182: Fuel Temperature Sensor Low
340
P0183: Fuel Temperature Sensor High
342
Inspection Procedure: P0182 and P0183
344
Inspect the Fuel Temperature Sensor Connector
344
Inspect the Fuel Temperature Sensor
344
Inspect the Fuel Temperature Sensor Unit
345
Inspect the Fuel Temperature Sensor Power Supply
345
Inspect for Short-Circuits in Wire Harness of Fuel Temperature Sensor
346
Inspect Disconnection of the Fuel Temperature Sensor Harness
346
P0191: Fuel Rail Pressure Sensor (Main and Sub) - out of Range
348
Dtc: P0191
348
Inspection Procedure: P0191
350
DTC: P0192 and P0193
357
P0192: Fuel Rail Pressure Sensor (Main) - out of Range (Low)
357
P0193: Fuel Rail Pressure Sensor (Main) - out of Range (High)
359
Inspection Procedure: P0192 and P0193
361
Inspect the Common Rail Pressure Sensor Unit
362
Inspect the Common Rail Pressure Sensor Signal Circuit
363
Short-Circuits in Wire Harness of Common Rail Pressure Sensor
364
Inspect Disconnection of the Common Rail Pressure Sensor Harness
365
P01A5: Fuel Rail Pressure Sensor (Sub) - out of Range (Low)
367
Dtc: P01A5
367
Inspection Procedure: P01A5
369
P01A6: Fuel Rail Pressure Sensor (Sub) - out of Range (High)
374
Dtc: P01A6
374
Inspection Procedure: P01A6
376
P0200: Fuel Injector Driver Charge Circuit (Circuit High)
381
Dtc: P0200
381
Inspection Procedure: P0200
383
Check the Engine ECU Internal Circuit (HINO DX Ⅱ)
383
DTC: P0201, P0202, P0203 and P0204 - Fuel Injector - Disconnection
384
Inspection Procedure: P0201, P0202, P0203 and P0204
386
Inspect the Engine ECU Connector, Injector Connector
386
Inspect Disconnection of the Engine ECU Harness
386
Check for Disconnection in Wire Harness of Injector Central Connector
387
Inspect Disconnection of the Injector Harness
388
Inspect the Injector Unit
388
P0217: Engine Coolant over Temperature Condition
389
Dtc: P0217
389
Inspection Procedure: P0217
391
Inspect the Engine
391
Inspect the Cooling Fan
391
Inspect the Fan Clutch
391
Inspect the Coolant Temperature Sensor Connector
392
P0219: Engine Overspeed Condition
394
Dtc: P0219
394
Inspection Procedure: P0219
396
Inspect the Engine Oil Level
396
Inspect the Engine Speed Main Sensor Connector
396
Check the Engine Speed Main Sensor
397
Inspect the Engine Speed Main Sensor Power Supply
397
Check for Disconnection in Wire Harness of Engine Speed Main Sensor
398
Check for Short-Circuit in Wire Harness of Engine Speed Main Sensor
399
Check the Engine Speed Main Sensor Signal
400
DTC: P0222 and P0223
402
P0222: Intake Throttle Valve Position Sensor 2 - out of Range (Low)
402
P0223: Intake Throttle Valve Position Sensor 2 - out of Range (High)
404
Inspection Procedure: P0222 and P0223
406
Inspect the Intake Throttle Valve Position Sensor 2 Connector
406
Inspect the Intake Throttle Valve Position Sensor 2
406
Inspect the Intake Throttle Valve Position Sensor 2 Unit
407
Inspect the Intake Throttle Valve Position Sensor 2 Power Supply
408
Inspect the Intake Throttle Valve Position Sensor 2 Signal Circuit
408
Short-Circuits in Wire Harness of Intake Throttle Valve Pos. Sensor 2
409
Inspect for Disconnections in Wire Harness of Intake Throttle Valve
410
P0234: Overboost
412
Dtc: P0234
412
Inspection Procedure: P0234
414
Inspect the Response Delay of the VNT Controller
416
Inspect the Response Delay of the EGR Valve
417
P0237: Boost Pressure Sensor - out of Range (out of Range Low)
418
Dtc: P0237
418
Inspection Procedure: P0237
420
DTC: P0263, P0266, P0269 and P0272 - Injection Quantity and Timing
424
Inspection Procedure: P0263, P0266, P0269 and P0272
427
Check the DTC Detected 4 (Engine ECU)
430
Replace the Common Rail Assembly
430
Check the DTC Detected 5 (Engine ECU)
434
P026C: All Injector (#1 - #4) Injection Quantity and Timing
435
P026D: All Injector (#1 - #4) Injection Quantity and Timing
435
DTC: P026C and P026D
435
Inspection Procedure: P026C and P026D
437
Perform the Cylinder Cut-Off Test (HINO DX Ⅱ )
440
P0299: Underboost
448
Dtc: P0299
448
Inspection Procedure: P0299
450
P0300: All Injector (#1 - #4) Misfire
454
Dtc: P0300
454
Inspection Procedure: P0300
456
Inspect the Fuel Pipes
456
Perform the Cylinder Cut-Off Test
457
Check the Compression Ratio
459
Check the DTC Detected (Engine ECU) 3
459
DTC: P0301, P0302, P0303 and P0304 - Misfire
462
Inspection Procedure: P0301, P0302, P0303 and P0304
464
Inspect the Fuel Injection Pipe between Common Rail and Injector
465
P0335: Engine Speed Main Sensor - Disconnection
471
Dtc: P0335
471
Inspection Procedure: P0335
473
Inspect the Engine Speed Main Sensor Connector
473
Inspect the Engine Speed Main Sensor
473
Inspect the Engine Speed Main Sensor (Crankshaft Position Sensor) Unit
474
Inspect the Engine Speed Main Sensor Power Supply
475
Inspect for Short-Circuit of the Engine Speed Main Sensor Harness
476
Inspect Disconnection of the Engine Speed Main Sensor Harness
477
P0336: Engine Speed Main Sensor - Rationality
478
Dtc: P0336
478
Inspection Procedure: P0336
479
Inspect the Engine Speed Main Sensor Power Supply
480
Inspect Disconnection of the Engine Speed Main Sensor Harness
481
Check the Engine Speed Main Sensor (Crankshaft Position Sensor) Signal
483
P0340: Engine Speed Sub Sensor - Disconnection
485
Dtc: P0340
485
Inspection Procedure: P0340
486
Inspect the Engine Speed Sub Sensor Connector
486
Inspect the Engine Speed Sub Sensor (Camshaft Position Sensor)
486
Inspect the Sensor Power Supply 1
487
Inspect the Sensor Power Supply 2
488
P0341: Engine Speed Sub Sensor - Rationality
489
Dtc: P0341
489
Inspection Procedure: P0341
491
Inspect the Engine Speed Sub Sensor Connector
491
Inspect for Short-Circuit of the Engine Speed Sub Sensor Harness
492
Inspect Disconnection of the Engine Speed Sub Sensor Harness
493
Inspect the Engine Speed Sub Sensor Power Supply
494
Inspect the Engine Speed Sub Sensor (Camshaft Position Sensor) Signal
495
P0381: Glow Lamp (Wait-To-Start Lamp) - Circuit
497
Dtc: P0381
497
Inspection Procedure: P0381
499
Inspect the Combination Meter Connector
499
Check the Combination Meter Operation
499
Check the Glow Light Circuit
500
Check for Short-Circuit in Wire Harness of Glow Light
501
Check for Disconnection in Glow Light Wire Harness
502
P0401: EGR Low Flow
503
Dtc: P0401
503
Inspection Procedure: P0401
505
Check the Boost Pressure Sensor Output Signal
506
Inspect the EGR Cooler
509
Inspect the SCV
510
Inspect the Injector
511
SCV Free Acceleration Test
513
Types of HINO DX Ⅱ Data to be Measured
514
If the Following Symptoms Occur, FAIL. if Not, OK
514
Final Value of Pump Current Target Test
518
P0402: EGR High Flow
519
Dtc: P0402
519
Inspection Procedure: P0402
522
Check the Air Intake System
524
P0404: Valve Position Control Failure - DC Motor out of Range
530
Dtc: P0404
530
Inspection Procedure: P0404
532
Inspect the EGR Valve Power Supply
533
DTC: P0405 and P0406
535
P0405: EGR Valve Controller Position Sensor Signal too Low
535
P0406: Valve Position Sensor Magnet Lost
537
Inspection Procedure: P0405 and P0406
539
Inspect the EGR Valve Connector
539
P041B: EGR Gas Temperature Sensor - Rationality
541
Dtc: P041B
541
P041B: EGR Gas Temperature Sensor Rationality
543
Inspection Procedure: P041B
547
Inspect the EGR Cooler Outlet Temperature Sensor Connector
547
Inspect the EGR Cooler Outlet Temperature Sensor
548
Inspect the EGR Cooler Outlet Temperature Sensor Unit
548
Inspect the EGR Cooler Outlet Temperature Sensor Power Supply
549
Short-Circuit of the EGR Cooler Outlet Temperature Sensor Harness
549
Disconnection of the EGR Cooler Outlet Temperature Sensor Harness
550
Inspect the Intake Air Temperature Sensor Unit
552
DTC: P041C and P041D
554
P041C: EGR Gas Temperature Sensor - out of Range (out of Range Low)
554
P041D: EGR Gas Temperature Sensor - out of Range (out of Range High)
556
Inspection Procedure: P041C and P041D
558
P0420: Tentative Determination of ATC Deterioration
562
Dtc: P0420
562
Inspection Procedure: P0420
563
P0421: Determination of ATC Deterioration
564
Dtc: P0421
564
Inspection Procedure: P0421
565
Inspect the Exhaust Gas Temperature Sensor (DPF Inlet) Connector
565
Inspect the Exhaust Gas Temperature Sensor (DPF Inlet)
566
P0422: DOC Deterioration
567
Dtc: P0422
567
Inspection Procedure: P0422
568
Inspect Fuel
568
Inspect the Exhaust Gas Temperature Sensor Connector
568
Inspect the Exhaust Gas Temperature Sensor
569
DTC: P0489 and P0490
570
P0489: EGR Valve Controller Motor (Open Circuit)
570
P0490: EGR Valve Controller Motor (Short Circuit)
572
Inspection Procedure: P0489 and P0490
574
Check the DTC Detected 2 (Engine ECU)
575
P049D: Position Failure (EGR Actuator Wiping Fault)
576
Dtc: P049D
576
Inspection Procedure: P049D
578
Check the Response Delay of the EGR Controller
580
DTC: P04D5 and P04D6
581
P04D5: Exhaust Brake - Circuit (Circuit Low)
581
P04D6: Exhaust Brake - Circuit (Circuit High)
583
Inspection Procedure: P04D5 and P04D6
585
Inspect the Exhaust Brake Magnetic Valve Connector
585
Inspect the Exhaust Brake Magnetic Valve
585
Inspect the Exhaust Brake Magnetic Valve Unit
586
Inspect for Power – Circuit of the Exhaust Brake Magnetic Valve
586
Short-Circuit of the Exhaust Brake Magnetic Valve Harness
587
Inspect Disconnection of the Exhaust Brake Magnetic Valve Harness
587
P04DA: EGR Feedback Failure
589
Dtc: P04Da
589
Inspection Procedure: P04DA
591
P0500: Vehicle Speed Sensor - Low
599
DTC: P0500 and P0501
599
P0501: Vehicle Speed Sensor - High
601
Inspection Procedure: P0500 and P0501
602
Inspect the Combination Meter
602
Check the DTC Detected (Vehicle Control ECU)
602
Short-Circuits in Wire Harness of Vehicle Speed Signal Circuit
603
Disconnection in Wire Harness of Vehicle Speed Signal Circuit
604
P0504: Brake Switch Correlation
606
Dtc: P0504
606
Inspection Procedure: P0504
607
Inspect the Brake Switch Connector
607
Inspect the Brake Switch
607
Inspect the Brake Switch Unit
608
Check the Brake Switch Power Supply
608
Check the Brake Switch Signal
609
P0506: Idle Speed Control System
611
Dtc: P0506
611
Inspection Procedure: P0506
612
Check the Injector Fuel Injection Quantity (HINO DX Ⅱ)
613
Inspect the Air Compressor
614
Inspect the Power Steering Pump
614
P0507: Idle Speed Control System
615
Dtc: P0507
615
Inspection Procedure: P0507
616
P0521: Malfunction of Oil Pressure Switch (High)
619
Dtc: P0521
619
Inspection Procedure: P0521
620
Check the Engine Oil Level
620
Check for Engine Oil Leaks
620
Inspect the Oil Pressure Switch Connector
621
Inspect the Oil Pressure Switch Unit
621
Inspect for Short-Circuit of the Oil Pressure Switch Harness
622
P0524: Engine Oil Pressure too Low
623
Dtc: P0524
623
Inspection Procedure: P0524
624
Inspect Disconnection of the Oil Pressure Switch Harness
627
P0545: Exhaust Gas Temperature Sensor (DOC1 Inlet) - out of Range
628
DTC: P0545 and P0546
628
P0546: Exhaust Gas Temperature Sensor (DOC1 Inlet) - out of Range
630
Inspection Procedure: P0545 and P0546
632
Inspect the Exhaust Gas Temperature Sensor (DOC1 Inlet) Connector
632
Inspect the Exhaust Gas Temperature Sensor (DOC1 Inlet)
632
Inspect the Exhaust Gas Temperature Sensor (DOC1 Inlet) Unit
633
Check Short-Circuit in Wire Harness of Exhaust Gas Temperature Sensor
634
Check Disconnection in Wire Harness of Exhaust Gas Temperature Sensor
635
P054E: Idling Injection Rate Abnormality (Low)
636
Dtc: P054E
636
Inspection Procedure: P054E
637
P054F: Idling Injection Rate Abnormality (High)
640
Dtc: P054F
640
Inspection Procedure: P054F
641
P0562: Battery Voltage - out of Range (out of Range Low)
644
DTC: P0562 and P0563
644
P0563: Battery Voltage - out of Range (out of Range High)
645
Inspection Procedure: P0562 and P0563
646
Inspect the Fuse or Fusible Link
646
Inspect the Connection of the Battery Cable
646
Inspect the Alternator
646
Inspect the Engine ECU Power Supply
647
P05F1: Crankcase Ventilation System
649
Dtc: P05F1
649
Inspection Procedure: P05F1
651
Check the Response Delay of the EGR Valve (HINO DX Ⅱ)
654
Inspect the Intake Throttle Valve
655
P0605: Flash ROM Error
657
Dtc: P0605
657
Inspection Procedure: P0605
658
Inspect the Engine ECU Circuit (HINO DX Ⅱ)
658
P0606: Control Module Processor
659
Dtc: P0606
659
Inspection Procedure: P0606
660
P0607: Control Module Performance
661
Dtc: P0607
661
Inspection Procedure: P0607
662
P0610: VIN Data Error
663
Dtc: P0610
663
Inspection Procedure: P0610
664
Check the DTC Detected 1 (Engine ECU)
664
Inspect the Vehicle Information (HINO DX Ⅱ)
664
Reprogram the Vehicle Control ECU (HINO DX Ⅱ)
665
Reprogram the Engine ECU (HINO DX Ⅱ)
665
P0611: Fuel Injector Driver Charge Circuit - Circuit (Circuit Low)
666
Dtc: P0611
666
Inspection Procedure: P0611
667
P0617: Starter Key - Rationality
668
Dtc: P0617
668
Inspection Procedure: P0617
669
Inspect the Starter Key Connector
669
Inspect the Starter Key "Start" Signal
669
Short-Circuit of Wire Harness of Starter Key "Start" Signal
670
Inspect Disconnection of Wire Harness of Starter Key "Start" Signal
671
P0628: Suction Control Valve for Fuel Supply Pump - Circuit
672
DTC: P0628 and P0629
672
P0629: Suction Control Valve for Fuel Supply Pump - Circuit
674
Inspection Procedure: P0628 and P0629
676
Inspect the Suction Control Valve (SCV) Connector
676
Inspect the Suction Control Valve (SCV) Unit
676
Inspect for Short-Circuit in Wire Harness of Suction Control Valve
677
Inspect for Disconnection in Wire Harness of Suction Control Valve
678
P062F: Controller Store Data Error (VNT Actuator EEPROM Error)
680
Dtc: P062F
680
Inspection Procedure: P062F
682
Check Operation of VNT Controller (HINO DX Ⅱ)
683
P0630: VIN Not Programmed or Mismatch
684
Dtc: P0630
684
Inspection Procedure: P0630
686
Check the Vehicle Information (HINO DX Ⅱ)
686
Check the Vehicle Control ECU (HINO DX Ⅱ)
687
Check the DTC Detected (Engine ECU) (HINO DX Ⅱ)
687
P0642: ECU Sensor Power Supply 1 Failure (out of Range Low)
688
Dtc: P0642
688
Inspection Procedure: P0642
690
Check the Wire Harness of the Sensor Power Supply
693
P0643: ECU Sensor Power Supply 1 Failure (out of Range High)
694
Dtc: P0643
694
Inspection Procedure: P0643
696
Check the Power Supply of Common Rail Pressure Sensor 1
696
Check the Power Supply of Accelerator Sensor 2
697
Check the Power Supply of Boost Pressure Sensor
698
Check the Power Supply of Intake Throttle Valve Position Sensor
699
Check the Power Supply of Engine Speed Sub Sensor
700
Check the Power Supply of All Sensors
701
P064C: Glow Controller - Battery for Glow Plug Open
702
Dtc: P064C
702
Inspection Procedure: P064C
704
Inspect the Fuse (GCU (M)), Fusible Link (GLOW)
704
Inspect the Ground Circuit of the Glow Control Unit
704
Inspect the Glow Control Unit Power Supply Circuit
705
Inspect the GCU Harness
705
Inspect the Ground Circuit Voltage
706
P0652: ECU Sensor Power Supply 2 Failure (out of Range Low)
707
Dtc: P0652
707
Inspection Procedure: P0652
709
Inspect the Wire Harness of the Sensor Power Supply
712
P0653: ECU Sensor Power Supply 2 Failure (out of Range High)
713
Dtc: P0653
713
Inspection Procedure: P0653
715
Inspect the Power Supply of Common Rail Pressure Sensor 2
715
Inspect the Power Supply of Accelerator Sensor 1
716
Inspect the Power Supply of DPR Differential Pressure Sensor
716
Inspect the Power Supply of the PTO Accelerator Sensor
717
Power Supply of Aftertreatment Fuel Injection Line Pressure Sensor
718
Inspect the Power Supply of All Sensors
719
P0671: Glow Plug (Circuit Low) (#1Cyl), Glow Plug (Circuit High)
720
DTC: P0671 and P0672
720
P0672: Glow Plug (Circuit Low) (#2Cyl), Glow Plug (Circuit High)
722
Inspection Procedure: P0671 and P0672
724
Inspect the Fusible Link (GLOW)
724
Inspect the Power Supply Wire Harness of the Glow Control Unit (GCU)
724
Inspect the Wire Harness of the Glow Plug
725
P0673: Glow Plug (Circuit Low) (#3Cyl), Glow Plug (Circuit High)
726
DTC: P0673 and P0674
726
P0674: Glow Plug (Circuit Low) (#4Cyl), Glow Plug (Circuit High)
728
Inspection Procedure: P0673 and P0674
730
P0683: Glow Controller - Battery for Glow Controller Open
732
Dtc: P0683
732
Inspection Procedure: P0683
734
Inspect the Fuse and Fusible Link
734
Inspect the GCU Circuit
734
Inspect the GCU Power Supply Circuit
735
Inspect the Harness of the GCU
736
Check the Ground Circuit Voltage
737
P0686: ECM/PCM Power Relay Control Circuit High
738
Dtc: P0686
738
Inspection Procedure: P0686
740
Inspect the Main (EDU) Relay
740
Inspect the Main Relay Unit
740
Inspect the Main Relay Power Supply Circuit
741
Inspect the Main Relay Power Supply
742
P06D3: Air Flow Sensor Power Supply Failure Short to GND
743
DTC: P06D3 and P06D4
743
P06D4: Air Flow Sensor Power Supply Failure (High)
745
Inspection Procedure: P06D3 and P06D4
747
Inspect for Short-Circuit in Wire Harness or Air Flow Sensor
748
Inspect for Disconnection in Wire Harness or Air Flow Sensor
749
Inspect the Air Flow Sensor Signal Unit
750
P073D: Transmission Information - Rationality
752
Dtc: P073D
752
Inspection Procedure: P073D
754
Inspect the Neutral Switch (HINO DX Ⅱ)
754
Check the Neutral Switch Signal
755
P081A: Starter Disable Circuit Low
756
Dtc: P081A
756
Inspection Procedure: P081A
758
Inspect the Starter Cut Relay Connector
758
Short-Circuit in Wire Harness of Starter Cut Relay Signal Circuit
759
Disconnection in Wire Harness of Starter Cut Relay Signal Circuit
760
Inspect for Disconnection in Wire Harness of Starter Cut Relay
760
P081B: Starter Disable Circuit High
762
Dtc: P081B
762
Inspection Procedure: P081B
764
Inspect the Starter Block Relay Connector
764
Inspect for Disconnection in Wire Harness of Starter Block Relay
764
P0A7B: HV BATTERY System Failure
766
Dtc: P0A7B
766
Inspection Procedure: P0A7B
767
P0AC4: HV System Failure
768
Dtc: P0Ac4
768
Inspection Procedure: P0AC4
769
P0CA1: HV MOTOR System Failure
770
Dtc: P0Ca1
770
Inspection Procedure: P0CA1
771
P1133: PTO Accelerator Sensor (Hi)
772
Dtc: P1133
772
Inspection Procedure: P1133
773
Inspect the PTO Accelerator Sensor Connector
773
Inspect the PTO Accelerator Sensor
773
Inspect the PTO Accelerator Sensor Unit
774
Inspect for Short-Circuit of the PTO Accelerator Sensor Harness
775
Inspect Disconnection of the PTO Accelerator Sensor Harness
776
P119F: Fuel Rail Pressure Sensor - Rationality
778
Dtc: P119F
778
Inspection Procedure: P119F
780
Inspect the Signal of the Common Rail Pressure Sensor
782
P1426: Differential Pressure Sensor - Rationality
784
Dtc: P1426
784
Inspection Procedure: P1426
786
Check the Differential Pressure Hose and Pipe
786
Inspect the Differential Pressure Sensor Connector
786
Inspect the Differential Pressure Sensor
786
Inspect the Differential Pressure Sensor Unit
787
Inspect for Short-Circuit of Differential Pressure Sensor Harness
788
Inspect Disconnection of the Differential Pressure Sensor Harness
789
P1427: Differential Pressure Sensor - out of Range (out of Range Low)
791
Dtc: P1427
791
Inspection Procedure: P1427
793
Inspect the Power Supply of the Sensor
795
Inspect Disconnection of Differential Pressure Sensor Harness
796
P1428: Differential Pressure Sensor - out of Range (out of Range High)
798
Dtc: P1428
798
Inspection Procedure: P1428
800
P1458: Valve Position Control Failure - DC Motor out of Range
806
Dtc: P1458
806
Inspection Procedure: P1458
808
P1459: Controller High Temperature
811
Dtc: P1459
811
Inspection Procedure: P1459
813
Check the EGR Valve Power Supply
814
P14B0: Controller Store Data Error
816
Dtc: P14B0
816
Inspection Procedure: P14B0
818
P14B2: EGR Controller Power Supply Open Circuit
820
Dtc: P14B2
820
Inspection Procedure: P14B2
822
P14B3: Battery Voltage (High) (EGR Actuator Power Supply too High)
824
DTC: P14B3 and P14B4
824
P14B4: Battery Voltage (Low) (EGR Actuator Power Supply too Low)
826
Inspection Procedure: P14B3 and P14B4
828
P14B7: EGR Valve Controller Temperature Sensor 1 (Signal too Low)
830
DTC: P14B7 and P14B8
830
P14B8: EGR Valve Controller Temperature Sensor 1 (Signal too High)
832
Inspection Procedure: P14B7 and P14B8
834
P14BC: EGR Valve Controller Temperature Sensor 2 (Signal too Low)
836
DTC: P14BC and P14BD
836
P14BD: EGR Valve Controller Temperature Sensor 2 (Signal too High)
838
Inspection Procedure: P14BC and P14BD
840
P14BF: EGR Valve Controller Temperature Sensor 1, 2 - Rationality
842
Dtc: P14Bf
842
Inspection Procedure: P14BF
844
P1515: Charge Air Undercooling
847
Dtc: P1515
847
Inspection Procedure: P1515
849
Inspect the Radiator Curtain
849
Inspect the Radiator Fan
850
Inspect the Intercooler Tube
851
Inspect the Radiator
851
P1530: Engine Stop Switch Malfunction
852
Dtc: P1530
852
Inspection Procedure: P1530
853
Inspect the Engine Stop Switch
853
Inspect the Engine Stop Switch Connector
853
Inspect the Engine Stop Switch Unit
853
Power Supply Short-Circuit in Wire Harness of Engine Stop Switch
854
Inspect for Disconnection in the Wire Harness of Engine Stop Switch
855
P1601: Fuel Injector Adjustment Data Error
856
Dtc: P1601
856
Inspection Procedure: P1601
858
Check the Injector Replaced Record
858
Check the QR CODE 1 (HINO DX Ⅱ)
858
Check the QR CODE 2 (HINO DX Ⅱ)
859
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