Hino 195h Series Workshop Manual Download Page 400

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HYBRID/TROUBLE SHOOTING

3–396

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

•

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

•

Temporary communication blackout due to noise

•

Disconnection or short circuit of harness

•

Improper connector connection or fitting

•

Malfunction of vehicle control ECU

•

Malfunction of HV ECU

•

Malfunction of control CAN connection ECU

Summary of Contents for 195h Series

Page 1: ... 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 Manual Name Pub No Chassis Workshop Manual S1 LXJE03A S1 LXJE03A ...

Page 2: ...e this chart to the appropriate chapter numbers for servicing your particular vehicle CHAPTER MANUAL No S7 LXJE03C 4 7 U S A S7 LXJE04C 4 7 CANADA MODELS HINO 155 155h 195 195h Production Code XFC710 XFC720 XFC740 XJC700 XJC710 XJC720 XJC740 HYBRID 3 001 ...

Page 3: ...SUSPENSION BODY CONSTRUCTION INDEX TROUBLE SHOOTING GROUP 1 2 SUSPENSION WORKSHOP MANUAL All rights reserved This manual may not be reproduced or copied in whole in part with out the written consent of Hino Motors Ltd BODY INSIDE ACCESSORY BODY OUTSIDE ACCESSORY AIR BAG AND SEAT BELT HEATER AND AIR CONDITIONER GENERAL INTRODUCTION ...

Page 4: ...CONTROL SYSTEM INDEX TROUBLE SHOOTING GROUP 2 2 ELECTRICAL ...

Page 5: ...C6B 3 217 DTC P0BCA TC68 3 221 DTC P0C73 TC80 3 227 DTC P3000 TC42 3 234 DTC P3001 TC41 3 243 DTC P3001 TC43 3 246 DTC P3001 TC44 3 249 DTC P3001 TC45 3 252 DTC P3001 TC46 3 255 DTC P3001 TC47 3 259 DTC P3001 TC4A 3 263 DTC P3001 TC4B 3 267 DTC P3001 TC4C 3 270 DTC P3009 TC49 3 273 DTC P3128 TC7D 3 289 DTC P3129 TC7C 3 301 DTC P314C TC82 3 306 DTC P314D TC81 3 311 DTC P324B TC62 3 323 DTC P324C TC...

Page 6: ...22 3 732 DTC P0AEE TC23 3 735 DTC P0AEF TC24 3 738 DTC P0AF0 TC25 3 742 DTC P0BEA TCB3 3 746 DTC P0BEA TCB4 3 749 DTC P0BEB TC9A 3 752 DTC P0BEC TC9B 3 755 DTC P0BEE TCB5 3 758 DTC P0BEE TCB6 3 761 DTC P0BEF TC9C 3 764 DTC P0BF0 TC9D 3 767 DTC P3126 TC12 3 770 DTC U0073 TC91 3 783 DTC U0074 TC3E 3 788 DTC U0293 TC31 3 792 BATTERY ECU 3 801 DIAGNOSIS CODE TABLE 3 801 LIST OF FREEZE FRAME DATA 3 804...

Page 7: ...P3014 3 1054 DTC P3015 3 1059 DTC P3016 3 1064 DTC P3017 3 1069 DTC P3018 3 1074 DTC P3019 3 1079 DTC P301B 3 1084 DTC P3020 3 1087 DTC P3021 3 1092 DTC P3022 3 1097 DTC P3023 3 1102 DTC P3024 3 1107 DTC P3025 3 1112 DTC P3026 3 1117 DTC P3027 3 1122 DTC P3028 3 1127 DTC P3029 3 1132 DTC P302F 3 1137 DTC P3065 3 1142 DTC P308A 3 1147 DTC U0074 3 1152 DTC U0293 3 1156 ...

Page 8: ...WARNING LIGHT ENGINE ECU VEHICLE CONTROL ECU CLUTCH ECU MIL HV ECU OR COMMUNICATION FUNCTION PERFORM ALARMING ONLY WHEN THE FUNCTION FAILS INVERTER MALFUNCTION INFORMATION MIL ON REQUEST MALFUNCTION INFORMATION MIL ON REQUEST MALFUNCTION INFORMATION MIL ON REQUEST MIL ON REQUEST HV ECU READ CODE AND DIAGNOSE READ CODE AND DIAGNOSE READ CODE AND DIAGNOSE SERVICE TOOL HYBRID CONTROL SYSTEM CAN SIGNA...

Page 9: ...urn on or turn off MIL 2 When a malfunction relevant to emission occurs in the HV system or vehicle control ECU the MIL light ON request is sent from the HV ECU to the engine ECU using CAN 3 HV battery ECU inverter and vehicle control ECU send the MIL light ON request to the engine ECU using CAN via HV ECU LIGHT ON OR LIGHT OFF HV WARNING LIGHT HV ECU MALFUNCTION INFORMATION HV BATTERY ECU INVERTE...

Page 10: ...function is recovered control is switched from failsafe control to normal control however the Confirmed diagnosis code is not deleted Code name Definition of diagnosis code HV warning light MIL Effect on vehicle Pending diagnosis code Diagnosis code that is being detected malfunc tion is not confirmed Light OFF Light OFF Normal control Confirmed diagnosis code Diagnosis code in which the malfuncti...

Page 11: ...ction in 1DCY 1 For the malfunction in which the Confirmed malfunction is confirmed in DCY the Pending malfunction is not confirmed COMPLETION OF DCY 1 COMPLETION OF DCY 2 DETECTION OF MALFUNCTION CONFIRMATION DETECTION OF MALFUNCTION CONFIRMATION LIGHT ON LIGHT ON DCY VEHICLE CONDITION PENDING MALFUNCTION CONFIRMED MALFUNCTION HV WARNING LIGHT MIL SHTS03ZZZ0300005 CONFIRMATION LIGHT ON LIGHT ON C...

Page 12: ...condition is not satisfied in 1DCY Instant deletion Confirmed diagnosis code None Instant deletion Permanent diagnosis code This code is deleted when condition to be judged normal is satisfied in 3DCY 1 This code is deleted after performing the predetermined operation when condition to be judged normal is sat isfied and malfunction detection con dition is not satisfied in 1DCY after deleting the d...

Page 13: ...ETION OF DCY 5 DETECTION OF MALFUNCTION DETECTION OF MALFUNCTION DCY VEHICLE CONDITION PENDING MALFUNCTION CONFIRMED MALFUNCTION PERMANENT MALFUNCTION HV WARNING LIGHT MIL NORMAL JUDGMENT 1 NORMAL JUDGMENT 2 NORMAL JUDGMENT 3 NORMAL JUDGMENT DCY 1 NORMAL JUDGMENT DCY 2 NORMAL JUDGMENT DCY 3 SHTS03ZZZ0300008 CONFIRMATION DELETION DELETION DELETION DELETION OF THE MALFUNCTION CODE USING THE SERVICE ...

Page 14: ...ff when the diagnosis code is deleted at b When the HV warning light turns off it is possible to check that there is no malfunction in the HV system Condition to be judged normal for the malfunction occurred in the above steps d to g must be satisfied Condition to be judged normal varies depending on malfunction 2 Procedure for deleting the Permanent diagnosis code in 3DCY a Turn the starter key O...

Page 15: ...ary noise due to partial fitting of the connector if parts are returned to normal without repairing or replacing parts using the diagnostic chart The service tool or trouble shooting tool described in the trouble shooting chart indicates the genuine Hino ser vice tool If the starter key is turned ON in the state that connectors etc are disconnected while performing the trouble shooting chart the m...

Page 16: ...d high voltage circuit is acti vated when the starter key is turned to ON CAUTION Since any failure may occur when the starter key is turned to ON with the service plug removed never turn the starter key to ON unless otherwise instructed in this document 2 All wire harness connectors for the high voltage circuit are orange colored Further HIGH VOLTAGE caution label is attached to high voltage comp...

Page 17: ...condition of high voltage terminals and connector conditions again before connecting the service plug 9 Do not reserve the hybrid battery 10 Do not disassemble the hybrid battery CAUTION High voltage is applied to the hybrid battery even when the ser vice plug is disconnected Further high alkaline electrolyte is used 11 Make sure to use the insulated tools Recommended tools FACON s Facom quality i...

Page 18: ...HYBRID TROUBLE SHOOTING 3 14 SHTS03ZZZ0300012 ...

Page 19: ...4 8 11 12 13 14 15 16 17 18 19 2 3 4 5 6 7 8 9 20 24 23 25 26 27 28 29 21 22 30 1 10 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 30 31 12131415 1617181920 2122232425 26272829 3233343536 37383940 7 8 9 10 1112 3 4 13 14 15 16 17 18 19 20 21 22 23 24 1 2 5 6 1819 20 21 22 23 24 25 26 7 8 9 1011121314151617 1 2 3 4 5 6 BATTERY ECU CAN A B F G J C DIAG CAN INVERTER COOLING WATER PUMP BATTERY ECU TEMPERATURE MONIT...

Page 20: ...1 2 3 4 GRAY BLACK WHITE RELAY BLOCK SIDE BLACK BLACK BLACK BLACK WHITE WHITE BLACK BLACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 RELAY BLOCK SIDE COMPONENT SIDE COMPONENT SIDE 3 5 L N 2 1 3 5 2 1 1 2 INVERTER START RELAY L N HV BATTERY START RELAY O J C CTRL CAN P PCU HARNESS 16 PIN R HV BATTERY COOLING FAN S SMR DRIVE SERVICE PLUG SWITCH T X PCU HARNESS 24 P...

Page 21: ... BATT OUT F BATT IN D BATT OUT I J H G 10 12 13 14 15 16 17 18 19 20 2 3 4 5 6 7 8 9 21 24 11 23 25 26 27 28 29 22 30 1 1 21 2 22 3 23 4 24 5 25 6 26 7 27 8 28 9 29 30 10 31 11 32 12 33 13 34 14 35 15 36 16 37 17 38 18 39 19 40 20 METER 1 d 1 A RESOLVER B ROTATION MACHINE TEMPERATURE SENSOR C D E F G H HIGH VOLTAGE J B IN BATTERY PACK INVERTER HIGH VOLTAGE I J SERVICE PLUG a STARTER SWITCH b AT EC...

Page 22: ... 15 36 16 37 17 38 18 39 19 40 20 5 1 3 2 4 6 7 8 9 1314 24 151617181920 212223 25262728293031323334 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 h BATT m BATT p INV 3 1 2 5 q INV k DDC I DDC 101112 e f ABS ECU CLUTCH ECU k l m n p q HIGH VOLTAGE J B IN ECU BOX r IG1 1 RELAY t NEUTRAL SWITCH h DLC3 1 10 5 4 3 2 8 9 6 7 SHTS03ZZZ0300016 ...

Page 23: ...VICE PLUG 288V HV BATTERY CURRENT SENSOR GND L 1 L L x PCI_B_2 20A PCI_B_20A x L 3 n p J B l 2 5 WATER PUMP RADIATOR FAN HV BATTERY START RELAY F F E F F E E 4 1 3 3 2 R R P P R 3 A 1 A 2 A 13 A 18 A 19 A 12 9 P 13 P 14 4 1 2 1 11 R P 2 12 P 15 P 6 P 7 P 2 3 4 5 1 P 16 N 1 N x N N 3 1 2 3 2 5 1 2 3 4 5 6 7 8 9 12 11 10 14 13 15 16 18 19 20 21 22 23 24 25 m q J B k P P P P HV BATTERY COOLING FAN KE...

Page 24: ... 24 D 12 D 14 D 13 D 15 D 27 D 3 Y 8 Y 4 Y ROTATION MACHINE THERMISTER ROTATION MACHINE 16 X W1 V1 U1 CN4 40 CON3 CN4 39 CON2 CN3 38 CON1 CN4 16 ILK1 CN4 5 ILKO INVERTER PCU INTERNAL CIRCUIT HV ECU CAN J C CONTROL CAN J C DIAG c c ABS ECU 20 H 29 Y 1 R2 Y 2 S1 Y 5 S2 Y 6 RESOLVER S3 Y 10 S4 F F GND B ON Y 11 SLD3 Y 9 19 J 21 J 22 J G h h h h h DLC3 15 5 6 3 4 7 8 1 2 f f X x x x X CLUTCH ECU 13 23...

Page 25: ... week month Running condition Road surface state When starting During acceleration During steady running During deceleration During braking During stoppage During parking During turning During ABS operation Others Vehicle speed km h Shift position display Lighting of warning light Brake operation Frequency of occurrence A C status 1 2 3 4 5 at operation 6 R Engine status Flat horizonal road Upward...

Page 26: ...ty in power supply voltage 71 Control power supply voltage reduction HV system stop Since the hybrid system stops the following symp tom occur The engine may not start running However the engine starts up by the starter for starter equipped vehicles Idling stop is not working Lowering the speed during deceleration may decrease to deactivate the regenera tion function 1 P060B Abnormality in A D con...

Page 27: ... HV water pump drive signal Low abnormal ity 7F Disconnection or GND short circuit of the HV water pump drive signal cir cuit Behavior of vehicle does not vary 1 P0A07 HV water pump drive signal High abnormal ity 7E HV water pump drive signal cir cuit power sup ply positive side shorted Behavior of vehicle does not vary 1 P0A0F Engine system abnormality 31 Engine misfire The engine does not start ...

Page 28: ...eed during deceleration may decrease to deactivate the regenera tion function 1 P0A7E Abnormality in high tempera ture of HV bat tery 48 Abnormally high tempera ture of the HV battery Idling stop is not working Lowering the speed during deceleration may decrease to deactivate the regenera tion function 1 P0A82 Abnormality in function of HV battery cooling fan 67 Abnormality in the HV battery cooli...

Page 29: ...ality in HV battery cooling fan revolving num ber signal High 68 HV battery cooling fan speed signal circuit power supply positive side shorted Behavior of vehicle does not vary 1 P0C73 Abnormality in HV water pump function 80 Abnormality in the HV water pump function Behavior of vehicle does not vary 2 P3000 Abnormality in status of HV battery ECU IG signal 42 Abnormality in the HV battery ECU IG...

Page 30: ...ine starts up by the starter for starter equipped vehicles Idling stop is not working Lowering the speed during deceleration may decrease to deactivate the regenera tion function 1 P3001 Abnormality in HV battery line 46 Request for stopping dis charge of the HV battery The engine may not start running However the engine starts up by the starter for starter equipped vehicles Idling stop is not wor...

Page 31: ...for stopping charge The engine may not start running However the engine starts up by the starter for starter equipped vehicles Idling stop is not working Lowering the speed during deceleration may decrease to deactivate the regenera tion function 1 P3009 Abnormality in leakage 49 Electrical leak age Behavior of vehicle does not vary 1 P3128 Abnormality in HV radiator fan revolution num ber Low 7D ...

Page 32: ...ay Low 64 GND short cir cuit of the HV battery ECU start relay exci tation circuit Idling stop is not working Lowering the speed during deceleration may decrease to deactivate the regenera tion function 1 P33B2 Abnormality in HV battery ECU start relay High 63 The HV battery ECU start relay excitation cir cuit discon nected or power supply positive side shorted Idling stop is not working Lowering ...

Page 33: ...V battery ECU CAN communi cation blackout Idling stop is not working Lowering the speed during deceleration may decrease to deactivate the regenera tion function 1 U0121 ABS ECU CAN communica tion blackout 24 ABS ECU CAN communica tion blackout Idling stop is not working 1 U0155 Meter ECU CAN communica tion blackout 25 Meter ECU CAN communica tion blackout Idling stop is not working 1 U110A Vehicl...

Page 34: ... request mode Represents the operation request to the engine 0 No request 1 Rotational request 2 Rota tional restriction 3 Torque limiting Torque instruction 4 0 4 Required engine torque limiting value Ratio of limiting request torque to the engine to standard engine torque 128 127 Specified value of motor torque Represents a torque command value to the inverter 32 768 32 767 Nm Effective motor to...

Page 35: ...st brake switch CAN reception Represents the retarder lever signal input status ON 1 OFF 0 0 1 HV control mode information Represents the operating condition of the HV system 0 OFF 1 Engine startup 2 At acceleration by motor 3 Deceleration by motor retarder 4 Deceleration by motor or foot brake 5 Battery charging 6 Engine stop 7 Forced battery charging 8 At manufacturing inspection 9 At EV 10 At g...

Page 36: ...ooling FAN drive request Duty HV battery cooling FAN drive request Duty 0 100 HV battery cooling FAN drive request revolution HV battery cooling FAN drive request revolution 0 10 000 r min HV battery cooling FAN revolu tion HV battery cooling FAN revolution HINT Even if the HV battery cooling FAN drive request revolution is 0 r min 0 100 r min appears 0 10 000 r min HV battery cooling FAN revolu t...

Page 37: ... HV battery current Represents the HV battery DC current 500 500 A Power supply voltage Represents the HV ECU power supply voltage 0 40 V HV battery capacity SOC Represents the HV battery capacity SOC 0 100 Maximum temperature of the HV battery Represents the maximum temperature of the HV battery 128 127 C Minimum temperature of the HV battery Represents the minimum temperature the HV battery 128 ...

Page 38: ...ange 5 AT Others 6 0 255 Clutch state CAN reception Clutch state Engaged 0 partial clutch 1 disengaged 2 unknown 3 0 3 Shift transmission condition CAN reception Shift transmission condition OFF 0 UP 1 DOWN 2 Changing gear 3 HINT The indication of UP means Charging gear 0 3 Vehicle driving mode Vehicle driving mode Normal 0 ECO 1 PWR 2 0 2 System required torque System required torque 32 768 32 76...

Page 39: ...ump drive request revo lution HV water pump drive request revolution 0 10 000 r min HV water pump revolution HV water pump revolution HINT Even if the HV water pump drive request revolu tion is 0 r min approximately 0 480 r min appears 0 10 000 r min HV system coolant temperature sensor voltage HV system coolant temperature sensor voltage 0 5 V Item Description Display range Unit ...

Page 40: ...ance of the terminal is required on the common inspection chart do not determine the terminal as NG and proceed to measurement of the next terminal 1 CHART FOR INSPECTION OF THE SIGNAL LINE AT THE PCU LOWER SIDE WIRE HARNESS FOR SHORT CIR CUIT 1 Set the starter key to the LOCK position and remove the PCU harness 24 pin connector and the PCU harness 16 pin connector 2 Measure resistance between the...

Page 41: ...ctors 1st to 16th except 10th Standard value 10 k or more NO YES 1 Set the starter key to the LOCK position 2 Disconnect the following connectors Inverter start relay HV battery start relay Inverter cooling radiator fan connector Inverter cooling water pump connector Coolant temperature sensor connector Inverter connector 2 Inspection of the signal line to the PCU harness 12 pin connector at the P...

Page 42: ...connectors 1st to 5th except 4th 5 Measure resistance between the connector terminal specified in the trouble shooting chart and the inverter cooling radiator fan con nector PCU lower harness side Target connectors 1st to 3rd 6 Measure resistance between the connector terminal specified in the trouble shooting chart and the inverter cooling water pump connector PCU lower harness side Target connec...

Page 43: ...U lower harness side Target connectors 1st and 2nd 8 Measure resistance between the connector terminal specified in the trouble shooting chart and the inverter connector PCU lower harness side Target connectors 8th and 9th Standard value 10 k or more NO YES TARGET CONNECTORS SHTS03ZZZ0300028 TARGET CONNECTORS SHTS03ZZZ0300029 Common inspection NG Common inspection OK ...

Page 44: ...onnector Battery ECU CAN connector 3 Measure resistance between the connector terminal specified in the trouble shooting chart and the PCU harness 16 pin connector PCU upper harness side Target connectors 1st to 16th except 10th Standard value 10 k or more NO YES 1 Inspection of the signal line to the PCU harness 16 pin connector at the PCU upper side wire harness for short circuit TARGET CONNECTO...

Page 45: ...ning is 5 or more The accelerator sensor shows no abnormality 2 Judgement criteria The signal input of vehicle speed sensor remains 0 Hz for 10 seconds or more 3 Reset condition The signal input of vehicle speed sensor remains 3 mph or more for 10 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC ...

Page 46: ...Check that no DTC is detected after test driving the vehicle 8 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 47: ... the ABS ECU vehicle side connector and the terminal of combination meter 40P vehicle side connector NO YES 1 Inspecting the ABS ECU HINO DX SHTS03ZZZ0300032 Is any DTC detected from the ABS Perform troubleshooting for each DTC of ABS ECU Go to step 2 2 Inspecting the continuity of vehicle wire harness between ABS ECU and the combination meter SHTS03ZZZ0300033 Measurement conditions Tester connect...

Page 48: ...vehicle wire harness between the combination meter and the PCU harness vehicle side connector SHTS03ZZZ0300034 Measurement conditions Tester connections Standard values Starter key LOCK Combination meter 40P vehi cle side connec tor PCU harness 24P vehicle side connector 23rd terminal 18th terminal Less than 1 Is the measured value within the range of standard value Go to step 4 Repair or replace ...

Page 49: ...PCU wire harness lower side SHTS03ZZZ0300035 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 24P lower side con nector HV ECU3 connector 18th terminal 24th terminal Less than 1 Is the measured value within the range of standard value Go to step 5 Replace the PCU wire harness lower side 5 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND...

Page 50: ...or inspect the signal line of PCU wire harness lower side for short circuit See Inspecting the PCU harness signal line for short cir cuit NO YES 6 Inspecting the engine ECU HINO DX SHTS03ZZZ0300037 Is any DTC detected from the engine ECU Inspect the combination meter Go to step 7 7 Inspecting the PCU wire harness signal line for short circuit Measurement conditions Tester connections Standard valu...

Page 51: ... malfunction history 5 Perform a test run For 1 minutes at the vehicle speed of 10 km h or more 6 In Fault Information on the diagnosis tool screen check if P0500 51 is detected NO YES 8 Reproduction check HINO DX SHTS03ZZZ0300038 Is DTC P0500 51 detected Replace the HV ECU The inspection is completed If no repair or parts replacement is performed there may be an improper contact due to connector ...

Page 52: ...s Starter key LOCK Tester connections ABS ECU vehicle side connector Combination meter 40P vehi cle side connector 22nd terminal 22nd terminal Standard values Less than 1 The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Repair or replace the vehicle wire harness between the ABS ECU and the comb...

Page 53: ...the electrical tester mea sure the resistance between the lower side connector 18th terminal of PCU harness 24P and the ground Measurement conditions Starter key LOCK Tester connections PCU harness 24P lower side connector 18th terminal 24th terminal 18th terminal GND Standard values 10 k or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within...

Page 54: ...ness lower side Go to step 8 8 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 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 For 1 min utes at the vehicle speed of 10 km h or more 6 In Fault Information on the diagnosis tool screen check if P...

Page 55: ...ore for 10 seconds or more 3 Reset condition The signal input of vehicle speed sensor remains less than 112 mph for 10 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 functio...

Page 56: ...G 3 52 8 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: ...rminal of PCU harness 24P 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 NO YES 1 Inspecting the ABS ECU HINO DX SHTS03ZZZ0300040 Is any DTC detected from the ABS Perform troubleshooting for each DTC of ABS ECU Go to step 2 2 Inspecting the signal line of PCU wire harness lower side for sho...

Page 58: ...on the diagnosis tool screen check if P0501 5B is detected NO YES 3 Inspecting the engine ECU HINO DX SHTS03ZZZ0300041 Measurement conditions Measured item Standard values Starter key ON Drive at the vehicle speed of 20 km h Vehicle speed The monitored vehicle speed is approximately the same as the driv ing speed Is the measured value within the range of standard value Go to step 4 Inspect the veh...

Page 59: ... signal line of PCU wire harness lower side for short circuit See Inspect ing the PCU harness signal line for short circuit Measurement conditions Starter key LOCK Tester connections PCU harness 24P lower side connector 18th terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness lower side Go to step 3 3 Inspectin...

Page 60: ...s at the vehicle speed of 10 km h or more 6 In Fault Information on the diagnosis tool screen check if P0501 5B is detected DTC P0501 5B is detected Go to YES DTC P0501 5B is not detected Go to NO Replace the HV ECU The inspec tion is com pleted If no repair or parts replacement is performed there may be an improper contact due to connector dis connection P0501 TC5B Abnormality in characteristics ...

Page 61: ...r system control regulation when the DTC is set MIL OFF HV warning light ON 5 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 hybrid system stops causing the following phenomena The engine may become unable to start Note however that vehicles equipped with a starter will be started with the starter I...

Page 62: ...HYBRID TROUBLE SHOOTING 3 58 8 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: ...ctor 3 Using the electrical tester measure the voltage between the vehi cle side connector terminals of PCU harness 24P NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300044 Is DTC P060B B2 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the vehicle wire harness SHTS03ZZZ0300045 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 24...

Page 64: ...short cir cuit NO YES 3 Inspecting the PCU wire harness lower side SHTS03ZZZ0300046 Measurement conditions Tester connections Standard values Starter key LOCK HV ECU3 connec tor 1st terminal 5th terminal 10 16 V Is the measured value within the range of standard value Go to step 4 Replace the PCU wire harness lower side 4 Inspecting the signal line of PCU wire harness lower side for short circuit ...

Page 65: ...nitor on the diagnosis tool screen and monitor Power supply voltage of HV ECU NO YES 5 Inspecting the signal line of PCU wire harness upper side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P upper side con nector 16th terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness upper side Go to step 6 6 Inspe...

Page 66: ...to the ON position and wait for 1 minute 3 In Fault Information on the diagnosis tool screen check if DTC P0562 71 is detected NO YES 7 Reproduction check HINO DX SHTS03ZZZ0300048 Is DTC P0562 71 detected Re inspect the 12 V battery and power supply circuit The inspection is completed ...

Page 67: ... the vehicle side connector termi nals of PCU harness 24P Measurement conditions Starter key LOCK Tester connections PCU harness 24P vehicle side connector 2nd terminal 16th terminal Standard values 10 16 V The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Inspect the power supply circuit HV 10 ...

Page 68: ...e signal line of PCU wire harness upper side for short circuit See Inspecting the PCU harness signal line for short circuit Measurement conditions Starter key ON Tester connections PCU harness 16P upper side connector 16th terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness upper side Go to step 6 6 Inspecting ...

Page 69: ... Fault Information on the diagnosis tool screen check if DTC P0562 71 is detected DTC P0562 71 is detected Go to YES DTC P0562 71 is not detected Go to NO Re inspect the 12 V battery and power supply circuit The inspec tion is com pleted P0562 TC71 Abnormality in power supply voltage Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 70: ...es successively 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 71: ...o the ON position 4 Clear the malfunction history 5 Start the engine and keep it idling for 1 minute 6 In Fault Information on the diagnosis tool screen check if P060B B2 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300049 Is DTC P060B B2 detected Replace the HV ECU The inspection is completed The abnormal ity may have been caused by a temporary factor such as noise ...

Page 72: ...ct the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Start the engine and keep it idling for 1 minute 6 In Fault Information on the diagnosis tool screen check if P060B B2 is detected DTC P060B B2 is detected Go to YES DTC P060B B2 is not detected Go to NO Replace the HV ECU The inspec tion is com pleted The abnormality may have be...

Page 73: ...00 r min or more The motor revolution sensor shows no abnormality 2 Judgement criteria The starter signal remains ON for 20 seconds or more 3 Reset condition The starter signal remains OFF for 0 1 second or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control...

Page 74: ... work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper contact or fitting of connector Malfunction of starter key Malfunction of HV ECU ...

Page 75: ...ound NO YES 1 Inspecting the neutral switch 1 SHTS03ZZZ0300051 Measurement conditions Tester connections Standard values Starter key ON Shift lever N position Neutral switch connector 6th terminal 10th terminal Less than 3 Is the measured value within the range of standard value Go to step 2 Replace the neutral switch 2 Inspecting the neutral switch 2 VEHICLE GND SHTS03ZZZ0300052 Measurement condi...

Page 76: ... vehicle wire harness for short circuit 1 starter key signal circuit VEHICLE GND SHTS03ZZZ0300053 Measurement conditions Tester connections Standard values Starter key ON Starter key vehi cle side connector 6th terminal GND Less than 1 V Is the measured value within the range of standard value Go to step 4 Repair or replace the wire harness Starter key signal circuit 4 Inspecting the key cylinder ...

Page 77: ...ness for short circuit 2 starter key signal circuit VEHICLE GND SHTS03ZZZ0300055 Measurement conditions Tester connections Standard values Starter key ON PCU harness 24P vehicle side con nector 12th terminal GND Less than 1 V Is the measured value within the range of standard value Go to step 6 Repair or replace the wire harness Starter key signal circuit 6 Inspecting the PCU wire harness lower si...

Page 78: ...he engine speed remain at 25 km h or more and 1500 r min or more respectively for 30 seconds or more 6 In Fault Information on the diagnosis tool screen check if P0617 59 is detected NO YES 7 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 24P lower side con nector 12th terminal Each ...

Page 79: ... switch connector 6th terminal 10th terminal Standard values Less than 3 The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 2 Replace the neutral switch 2 Inspecting the neutral switch 2 1 Using the electrical tester mea sure the resistance between each terminal of neutral switch connector and the ...

Page 80: ...rminal of key cylinder connector and the ground Measurement conditions Starter key ON Tester connections Key cylinder connector 6th terminal GND Standard values Less than 1 V The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 5 Replace the key cylinder 5 Inspecting the vehicle wire harness for shor...

Page 81: ...it See Inspect ing the PCU harness signal line for short circuit Measurement conditions Starter key LOCK Tester connections PCU harness 24P lower side connector 12th terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness lower side Go to step 8 8 Reproduction check HINO DX 1 Connect all the connectors that have be...

Page 82: ...PROM 3 Reset condition Successful access to EEPROM 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 Recording of malfunction code DTC may become unavailable 6 Pre inspection work Check the battery voltage to...

Page 83: ...YES 1 Clear the malfunction history 2 Set the starter key to the ON position and wait for 1 minute 3 In Fault Information on the diagnosis tool screen check if P062F B3 is detected NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300058 Is DTC P0562 71 detected Perform troubleshooting for each of related DTC Go to step 2 2 Reproduction check HINO DX SHTS03ZZZ0300059 Is DTC P062F B3 detected Replace the ...

Page 84: ...DTC P0562 71 other than P062F B3 is detected DTC P0562 71 is detected Go to YES DTC P0562 71 is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the ON position and wait for 1 minute 3 In Fault Information on the diagnosis tool screen check if P062F B3 is detected DTC P062F B3 i...

Page 85: ...ication 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 Notification of clutch slip abnormality Notification of clutch revolution alignment abnormality Notification that the HV damper friction material is worn ABS ECU CAN H2 CAN L2 HV PCU HV ECU I...

Page 86: ...fication of clutch slip abnormality Notification of clutch revolution alignment abnormality Notification that the HV damper friction material is worn 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON 5 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 idl...

Page 87: ...DX to the vehicle 3 Set the starter key to the ON position 4 In Fault Information on the diagnosis tool screen check if any DTC other than P0810 9C is detected NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300061 Is any DTC other than P0810 9C detected Perform troubleshooting for each of related DTC Perform troubleshooting of the clutch ECU ...

Page 88: ...t the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 In Fault Information on the diagnosis tool screen check if any DTC other than P0810 9C is detected DTC other than P0810 9C is detected Go to YES DTC other than P0810 9C is not detected Go to NO Perform trou bleshooting for each of related DTC Perform trou bleshootin...

Page 89: ...ation that the clutch ECU starter key signal is stuck 3 Reset condition When the notification that there is none of the following abnormality is received from the clutch ECU Notification that the electric oil pump power supply relay for the clutch is stuck to ON Notification that the clutch ECU power supply is stuck Notification that the clutch ECU starter key signal is stuck ABS ECU CAN H2 CAN L2...

Page 90: ...cle due to backup control fail safe Symptoms on the vehicle due to malfunction The idling stop function may become inoperative 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that any DTC will not be detected after test driving the vehicle 8 Estimated failure factors Malfunctioning of clutch system ...

Page 91: ...DX to the vehicle 3 Set the starter key to the ON position 4 In Fault Information on the diagnosis tool screen check if any DTC other than P0810 9D is detected NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300063 Is any DTC other than P0810 9D detected Perform troubleshooting for each of related DTC Perform troubleshooting of the clutch ECU ...

Page 92: ...t the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 In Fault Information on the diagnosis tool screen check if any DTC other than P0810 9D is detected DTC other than P0810 9D is detected Go to YES DTC other than P0810 9D is not detected Go to NO Perform trou bleshooting for each of related DTC Perform trou bleshootin...

Page 93: ...um of motor current for 20 seconds is 200 000 A2 or more The motor current sensor shows no abnormality The output of inverter start relay is ON 2 Judgement criteria The difference in the inverter coolant temperature Max Min for 20 seconds is less than 0 5 C 32 9 F 3 Reset condition The difference in the inverter coolant temperature Max Min for 20 seconds is 0 5 C 32 9 F or more 4 Indication warnin...

Page 94: ...the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Malfunction of inverter cooling circuit Malfunction of inverter coolant temperature sensor Malfunction of HV ECU ...

Page 95: ... height from the coolant level to the filling port NO YES 1 Inspecting the coolant line route Is any defect found Repair or replace the defective part After repair replacement perform the inspec tion again Go to step 2 2 Inspecting the coolant level Is the coolant level about 10 mm from the filling port Go to step 3 Add coolant See Adding coolant After adding coolant perform the inspection again ...

Page 96: ...emperature sensor 3 Using the electrical tester measure the resistance between the terminals of coolant temperature sensor connector NO YES 3 Reading the DTC HINO DX SHTS03ZZZ0300065 Is any DTC other than P0A01 7B detected Perform troubleshooting for each of related DTC Go to step 4 4 Inspecting the coolant temperature sensor SHTS03ZZZ0300066 Measurement conditions Tester connections Standard valu...

Page 97: ...or short circuit See Inspecting the PCU harness signal line for short cir cuit NO YES 5 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK Coolant tempera ture sensor con nector 2nd terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness lower side Go to step 6 ...

Page 98: ...iagnosis tool screen measure HV sys tem coolant temperature NO YES 6 Reproduction check HINO DX SHTS03ZZZ0300067 Measurement conditions Measured item Standard values Starter key ON HV system coolant temperature Equivalent to ambient tempera ture Is the measured value within the range of standard value Replace the HV ECU The inspection is completed If no repair or parts replacement is per formed th...

Page 99: ... ant level to the filling port Coolant level is about 10 mm from the filling port Go to YES Coolant level is not about 10 mm from the filling port Go to NO Go to step 3 Add coolant See Adding coolant After adding coolant per form the inspection again 3 Reading the DTC HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the...

Page 100: ... of stan dard value Go to NO Go to step 5 Replace the coolant tem perature sen sor 5 Inspecting the signal line of PCU wire har ness lower side for short circuit 1 Set the starter key to the LOCK position 2 For the 2nd terminal of coolant temperature sensor connector inspect the signal line of PCU wire harness lower side for short circuit See Inspecting the PCU harness signal line for short circui...

Page 101: ... Starter key ON Measured item HV system coolant temperature Standard values Equivalent to ambient tempera ture The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Replace the HV ECU The inspec tion is com pleted If no repair or parts replace ment is per formed there may be an improper con tact due to connector...

Page 102: ...ns less than 0 2 V for 10 seconds or more 3 Reset condition The voltage of inverter coolant temperature sensor remains at 0 5 V or more for 10 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 103: ...D TROUBLE SHOOTING 3 99 8 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: ...perature sensor connector and the HV ECU1 connec tor terminal NO YES 1 Inspecting the continuity of PCU wire harness lower side SHTS03ZZZ0300069 Measurement conditions Tester connections Standard values Starter key LOCK Coolant tempera ture sensor con nector HV ECU1 connector 1st terminal 30th terminal 2nd terminal 29th terminal Less than 1 Is the measured value within the range of standard value ...

Page 105: ...ditions Tester connections Standard values Starter key LOCK Coolant tempera ture sensor con nector 1st terminal GND 2nd terminal GND 10 k or more Is the measured value within the range of standard value Go to step 3 Replace the PCU wire harness lower side 3 Inspecting the PCU wire harness lower side for short circuit 2 SHTS03ZZZ0300071 Measurement conditions Tester connections Standard values Star...

Page 106: ...Measurement conditions Tester connections Standard values Starter key LOCK Coolant tempera ture sensor connector sen sor side 1st terminal 2nd terminal 0 C 32 F 5 3 k 6 2 k 20 C 68 F 2 3 k 2 6 k 30 C 86 F 1 5k 1 8 k Is the measured value within the range of standard value Go to step 5 Replace the coolant temperature sensor 5 Inspecting the signal line of PCU wire harness lower side for short circu...

Page 107: ...iagnosis tool screen measure HV sys tem coolant temperature NO YES 6 Reproduction check HINO DX SHTS03ZZZ0300073 Measurement conditions Measured item Standard values Starter key ON HV system coolant temperature Equivalent to ambient tempera ture Is the measured value within the range of standard value Replace the HV ECU The inspection is completed If no repair or parts replacement is per formed th...

Page 108: ...e 2 Inspecting the PCU wire har ness lower side for short circuit 1 1 Using the electrical tester mea sure the resistance between each terminal of coolant tem perature sensor connector and the ground Measurement conditions Starter key LOCK Tester connections Coolant temperature sensor con nector 1st terminal GND 2nd terminal GND Standard values 10 k or more The mea sured value is within the range ...

Page 109: ...ey LOCK Tester connections Coolant temperature sensor con nector 2nd terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness lower side Go to step 6 6 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set t...

Page 110: ...e speed remains at 600 r min or more for 60 seconds or more The vehicle speed remains at 12 4 mph or more for 30 seconds or more 2 Judgement criteria The voltage of inverter coolant temperature sensor remains above 4 8 V for 10 seconds or more 3 Reset condition The voltage of inverter coolant temperature sensor remains at 4 5 V or less for 10 seconds or more 4 Indication warning or system control ...

Page 111: ...the recorded DTC Check that no DTC is detected after test driving the vehicle 8 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 112: ...perature sensor connector and the HV ECU1 connec tor terminal NO YES 1 Inspecting the continuity of PCU wire harness lower side SHTS03ZZZ0300075 Measurement conditions Tester connections Standard values Starter key LOCK Coolant tempera ture sensor con nector HV ECU1 connector 1st terminal 30th terminal 2nd terminal 29th terminal Less than 1 Is the measured value within the range of standard value ...

Page 113: ...easurement conditions Tester connections Standard values Starter key LOCK Coolant tempera ture sensor con nector sensor side 1st terminal 2nd terminal 0 C 32 F 5 3 k 6 2 k 20 C 68 F 2 3 k 2 6 k 30 C 86 F 1 5 k 1 8 k Is the measured value within the range of standard value Go to step 3 Replace the coolant temperature sensor 3 Inspecting the signal line of PCU wire harness lower side for short circu...

Page 114: ...gnosis tool screen measure HV sys tem coolant temperature NO YES 4 Reproduction check HINO DX SHTS03ZZZ0300077 Measurement conditions Tester connections Standard values Starter key ON HV system coolant temperature Equivalent to ambient tempera ture Is the measured value within the range of standard value Replace the HV ECU The inspection is completed If no repair or parts replacement is per formed...

Page 115: ...olant tem perature sen sor 1 Using the electrical tester mea sure the resistance of coolant temperature sensor Measurement conditions Starter key LOCK Tester connections Coolant temperature sensor con nector sensor side 1st terminal 2nd terminal Standard values 0 C 32 F 5 3 k 6 2 k 20 C 68 F 2 3 k 2 6 k 30 C 86 F 1 5 k 1 8 k The mea sured value is within the range of stan dard value Go to YES The ...

Page 116: ... conditions Starter key ON Tester connections HV system coolant temperature Standard values Equivalent to ambient tempera ture The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Replace the HV ECU The inspec tion is com pleted If no repair or parts replace ment is per formed there may be an improper con tact ...

Page 117: ...s met continuously for 0 5 second or more Input signal for monitoring HV water pump drive signal is 0 Hz Input signal for monitoring HV water pump drive signal is less than 0 2 V 3 Reset condition Input signal for monitoring HV water pump drive signal remains at 1 Hz or more for 5 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Sym...

Page 118: ...n work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector contact or fitting Malfunction of HV water pump Malfunction of HV ECU ...

Page 119: ...reen select HV water pump drive duty value 2 Run the inverter cooling pump at a duty value of 90 to check that the cooling fan is rotating NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300079 Is DTC P324B 62 or P324C 61 detected Perform troubleshooting for each of related DTC Go to step 2 2 Checking the activation of inverter cooling pump HINO DX SHTS03ZZZ0300080 Measurement conditions Measured item ...

Page 120: ... 24P vehicle side connector and the ground NO YES 3 Inspecting the voltage of vehicle wire harness VEHICLE GND SHTS03ZZZ0300081 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 24P vehicle side con nector 3rd terminal GND 9 V or more Is the measured value within the range of standard value Go to step 4 Inspect the power supply circuit PCU B2 20A fuse and wire ...

Page 121: ...the 1st and 2nd terminals of inverter start relay and measure the resistance between the 3rd and 5th terminals With voltage applied NO YES 4 Inspecting the inverter start relay 3 5 1 2 SHTS03ZZZ0300082 Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay 3rd terminal 5th terminal Without voltage 10 k or more With voltage less than 1 Is the measured value ...

Page 122: ...sing the electrical tester measure the voltage between the con nector terminals of inverter cooling pump NO YES 5 Inspecting the voltage of PCU wire harness lower side SHTS03ZZZ0300083 Measurement conditions Tester connections Standard values Starter key ON Inverter cooling pump connector 1st terminal 4th terminal 9 V or more Is the measured value within the range of standard value Go to step 6 Re...

Page 123: ...de SHTS03ZZZ0300084 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling pump connector HV ECU2 connec tor 3rd terminal 17th terminal Less than 1 Is the measured value within the range of standard value Go to step 7 Replace the PCU wire harness lower side 7 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND SHTS03ZZZ0300085 Measurement c...

Page 124: ...story 5 Set the starter key to the ON position and wait for 1 minute 6 In Fault Information on the diagnosis tool screen check if P0A06 7F is detected NO YES 8 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling pump connector 3rd terminal Each signal line 10 k or more Is any defect ...

Page 125: ... the inverter cooling pump at a duty value of 90 to check that the cooling fan is rotating Measurement conditions Starter key ON Measured item HV water pump drive duty value Standard values The cooling fan is running rotat ing Cooling fan is running Go to YES Cooling fan is not run ning Go to NO Go to step 6 Go to step 3 3 Inspecting the voltage of vehicle wire harness 1 Set the starter key to the...

Page 126: ...within the range of stan dard value Go to NO Go to step 5 Replace the inverter start relay 5 Inspecting the voltage of PCU wire har ness lower side 1 Set the starter key to the LOCK position 2 Connect the PCU harness 24P connector and the inverter start relay 3 Disconnect the inverter cooling pump connector 4 Set the starter key to the ON position 5 Using the electrical tester mea sure the voltage...

Page 127: ...ND Measurement conditions Starter key LOCK Tester connections Inverter cooling pump connector 3rd terminal GND Standard values 10 k or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 8 Replace the PCU wire har ness lower side 8 Inspecting the signal line of PCU wire har ness lower side for ...

Page 128: ...on 4 Clear the malfunction history 5 Set the starter key to the ON position and wait for 1 minute 6 In Fault Information on the diagnosis tool screen check if P0A06 7F is detected DTC P0A06 7F is detected Go to YES DTC P0A06 7F is not detected Go to NO Replace the HV ECU The inspec tion is com pleted P0A06 TC7F HV water pump drive signal Low abnormality Inspection Procedure Step Action Description...

Page 129: ...is set to the ON position The control power supply voltage is 10 V or more The requested drive duty of HV water pump is above 0 The output of inverter start relay is ON 2 Judgement criteria When one of the following conditions is met Condition 1 Input signal for monitoring HV water pump drive signal remains above 4 6 V for 0 1 second or more Condition 2 The following conditions are met continuousl...

Page 130: ...tion when the DTC is set MIL ON HV warning light ON 5 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 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Est...

Page 131: ... ON position 4 Clear the malfunction history 5 Set the starter key to the LOCK position and wait for 1 minute 6 Set the starter key to the ON position and wait for 1 minute 7 In Fault Information on the diagnosis tool screen check if P0A07 7E is detected NO YES 1 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values St...

Page 132: ...s Inverter cooling pump connector 3rd terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness lower side Replace the inverter cool ing pump After replace ment go to step 2 2 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Connect the diagnosis tool HINO DX...

Page 133: ... The engine coolant temperature or HV battery minimum temperature remains below 10 C 14 F for 8 seconds or more 3 Reset condition V control mode information is not When starting the engine The engine speed remains at 650 r min or more for 1 second or more 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light OFF 5 Symptoms on the vehicle when the DTC is set...

Page 134: ... tool screen check if any engine system DTC is detected NO YES 1 Check the fuel meter in the combination meter to make sure that the fuel level is Lo level or above NO YES 1 Inspecting the engine ECU HINO DX SHTS03ZZZ0300089 Is any DTC detected from the engine ECU Perform troubleshooting for each DTC of engine ECU Go to step 2 2 Inspecting the fuel level Is the fuel level at Lo level or above Go t...

Page 135: ...e to read the HV battery temperature 2 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 NO YES 3 Reproduction check HINO DX SHTS03ZZZ0300090 Did the engine start The inspection is completed Inspect the engine ECU ...

Page 136: ...u bleshooting for each DTC of engine ECU Go to step 2 2 Inspecting the fuel level 1 Check the fuel meter in the combination meter to make sure that the fuel level is Lo level or above Fuel level is Lo level or above Go to YES Fuel level is not Lo level or above Go to NO Go to step 3 Fill the fuel and go to step 3 3 Reproduction check HINO DX 1 In the Data Monitor on the diagnosis tool screen selec...

Page 137: ...nd writing of the control CAN controller ID message register are normally executed 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp ON 5 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...

Page 138: ...ar the malfunction history 5 Set the starter key to the LOCK position and wait for 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0A1D 12 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300091 Is DTC P0A1D 12 detected Replace the HV ECU The inspection is completed Temporary actuation of protection function due to external n...

Page 139: ...HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Set the starter key to the LOCK position and wait for 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0A1D 12 is detected DTC P0A1D 12 is detected Go to YES DTC P0A1D 12 is not detected Go to NO Replace the HV ECU The inspec tion is com p...

Page 140: ...iting of the DIAG CAN controller ID message register are normally executed 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ...

Page 141: ...rter key to the LOCK position and wait for 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0A1D 17 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300092 Is DTC P0A1D 17 detected Replace the HV ECU Take the same steps when communication with the diagnosis tool is not available The inspection is completed Temporary actuation ...

Page 142: ... key to the ON position 4 Clear the malfunction history 5 Set the starter key to the LOCK position and wait for 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0A1D 17 is detected DTC P0A1D 17 is detected Go to YES DTC P0A1D 17 is not detected Go to NO Replace the HV ECU Take the same steps when commu nication with the diagnosis tool ...

Page 143: ...mmunication 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON 5 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 Note however that vehicles equipped with a starter will be started with the starter Idling stop may ...

Page 144: ...nction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Perform a test run for approximately 1 hour Replace the inverter if starting fails 4 In Fault Information on the diagnosis tool screen check if P0A78 21 is detected NO YES 1 Inspecting the inverter HINO DX SHTS03ZZZ0300093 Is any DTC related to the inverter line detected Perform troubleshooting for each of related DT...

Page 145: ... inverter line is detected DTC related to the inverter line is detected Go to YES DTC related to the inverter line is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Perform a test run for approxi mately 1 hour Replace the inverter if s...

Page 146: ...munication 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become u...

Page 147: ...nction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Perform a test run for approximately 1 hour Replace the inverter if starting fails 4 In Fault Information on the diagnosis tool screen check if P0A78 22 is detected NO YES 1 Inspecting the inverter HINO DX SHTS03ZZZ0300095 Is any DTC related to the inverter line detected Perform troubleshooting for each of related DT...

Page 148: ... inverter line is detected DTC related to the inverter line is detected Go to YES DTC related to the inverter line is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Perform a test run for approxi mately 1 hour Replace the inverter if s...

Page 149: ...s to be within the standard range 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 du...

Page 150: ...e ON position 4 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 P0A84 66 P0A65 65 P0BCA 68 P0A82 67 NO YES 1 Inspecting the blower duct Is any defect found Replace the blower duct After replacement go to step 2 Go to step 2 2 Reading the DTC HINO DX SHTS03ZZZ0300097 Is any DTC other than P0A7E 48 detec...

Page 151: ...e of 90 to check that the cooling fan is rotating NO YES 3 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300098 Is any DTC related to the HV battery temperature sensor detected Perform troubleshooting for each of related DTC Go to step 4 4 Inspecting the operation of HV battery cooling fan HINO DX SHTS03ZZZ0300099 Measurement conditions Measured item Standard values Starter key ON HV battery coo...

Page 152: ... 48 is detected NO YES 5 Inspecting the HV battery temperature sensor HINO DX SHTS03ZZZ0300100 Measurement conditions Measured item Standard values Starter key ON After cooling idling state Maximum temper ature of HV battery Less than 80 C 176 F Is the measured value within the range of standard value Go to step 6 Replace the HV battery ECU After replacement go to step 6 6 Reproduction check HINO ...

Page 153: ...r than P0A7E 48 is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 3 3 Inspecting the HV battery ECU HINO DX 1 Select Fault Information on the diagnosis tool screen check if any DTC related to the HV battery temperature sensor is detected in the HV battery ECU DTC related to the HV battery temperature sensor is detected Go to YES DTC related to the HV battery temp...

Page 154: ...ured value is not within the range of stan dard value Go to NO Go to step 6 Replace the HV battery ECU After replace ment go to step 6 6 Reproduction check HINO DX 1 Restore the system 2 Clear the malfunction history 3 Perform a test run for approxi mately 1 hour 4 In Fault Information on the diagnosis tool screen check if P0A7E 48 is detected DTC P0A7E 48 is detected Go to YES DTC P0A7E 48 is not...

Page 155: ...ly for 10 seconds or more The number of revolution of the HV battery cooling fan is higher than the upper limit The number of revolution of the HV battery cooling fan is lower than the lower limit For the upper and lower limits see below Lower limit HV battery cooling fan drive duty of 20 252 0 r min HV battery cooling fan drive duty of 30 595 0 r min HV battery cooling fan drive duty of 40 892 0 ...

Page 156: ... min HV battery cooling fan drive duty of 50 1150 0 r min HV battery cooling fan drive duty of 60 1391 0 r min HV battery cooling fan drive duty of 70 1609 0 r min HV battery cooling fan drive duty of 80 1802 0 r min HV battery cooling fan drive duty of 90 1976 0 r min 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 c...

Page 157: ...HYBRID TROUBLE SHOOTING 3 153 8 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: ...to the ON position 4 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 P0A84 66 P0A65 65 P0BCA 68 NO YES 1 Inspecting the blower duct Is any defect found Replace the blower duct After replacement go to step 2 Go to step 2 2 Reading the DTC HINO DX SHTS03ZZZ0300103 Is any DTC other than P0A82 67 detected ...

Page 159: ...at each duty value NO YES 3 Inspecting the operation of HV battery cooling fan HINO DX SHTS03ZZZ0300104 Measurement conditions Measured item Standard values Starter key ON HV battery cool ing fan duty value The cooling fan is running rotating Is the cooling fan running Go to step 4 Replace the HV battery cooling fan 4 Checking the number of revolutions of HV battery cooling fan HINO DX SHTS03ZZZ03...

Page 160: ...harness lower side SHTS03ZZZ0300106 Measurement conditions Tester connections Standard values Starter key LOCK HV ECU1 connec tor PCU harness 16P lower side connector 24th terminal 12th terminal Less than 1 Is the measured value within the range of standard value Go to step 6 Replace the PCU wire harness lower side 6 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND SHTS03ZZ...

Page 161: ... the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P lower side con nector 12th terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness lower side Go to step 8 8 Inspecting the continuity of PCU wire harness upper side SHTS03ZZZ0300108 Measurement conditions Teste...

Page 162: ...signal line for short cir cuit NO YES 9 Inspecting the signal line of PCU wire harness upper side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P upper side con nector 12th terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness upper side Replace the HV battery cooling fan After replacement go to step 10 ...

Page 163: ... min ute 6 Run the HV battery cooling fan at the duty value of 90 for 1 min ute 7 Set the starter key to the LOCK position and wait for 1 minute 8 Set the starter key to the ON position 9 Run the HV battery cooling fan at the duty value of 20 for 1 min ute 10 Run the HV battery cooling fan at the duty value of 90 for 1 min ute 11 In Fault Information on the diagnosis tool screen check if P0A82 67 ...

Page 164: ...iagnosis tool screen check if any of the following DTC related to malfunction of HV battery cooling fan is detected P0A84 66 P0A65 65 P0BCA 68 DTC other than P0A82 67 is detected Go to YES DTC other than P0A82 67 is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 3 3 Inspecting the operation of HV battery cooling fan HINO DX 1 From Activation Test on the diagnosis...

Page 165: ...r mea sure the resistance between the HV ECU1 connector and the lower side connector termi nal of PCU harness 16P Measurement conditions Starter key LOCK Tester connections HV ECU1 connector PCU har ness 16P lower side connector 24th terminal 12th terminal Standard values Less than 1 The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of...

Page 166: ...ey LOCK Tester connections PCU harness 16P upper side connector HV battery cooling fan connector 12th terminal 2nd terminal Standard values Less than 1 The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 9 Replace the PCU wire har ness upper side 9 Inspecting the signal line of PCU wire har ness upp...

Page 167: ...uty value of 90 for 1 minute 7 Set the starter key to the LOCK position and wait for 1 minute 8 Set the starter key to the ON position 9 Run the HV battery cooling fan at the duty value of 20 for 1 minute 10 Run the HV battery cooling fan at the duty value of 90 for 1 minute 11 In Fault Information on the diagnosis tool screen check if P0A82 67 is detected DTC P0A82 67 is detected Go to YES DTC P0...

Page 168: ... battery ECU start relay is ON 2 Judgement criteria The following conditions are met continuously for 0 5 second or more Input signal for monitoring HV battery cooling fan drive signal is 0 Hz Input signal for monitoring HV battery cooling fan drive signal is less than 0 2V 3 Reset condition Input signal for monitoring HV battery cooling fan drive signal remains at 1 Hz or more for 5 seconds or mo...

Page 169: ...ion 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 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 170: ...starter key to the ON position 4 Using the electrical tester measure the voltage between the 1st terminal of PCU harness 24P vehicle side connector and the ground NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300111 Is any DTC other than P0A84 66 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the voltage of vehicle wire harness VEHICLE GND SHTS03ZZZ0300112 Measurem...

Page 171: ...e 1st and 2nd terminals of HV battery start relay and measure the resistance between the 3rd and 5th terminals With voltage applied NO YES 3 Inspecting the HV battery start relay 3 5 1 2 SHTS03ZZZ0300113 Measurement conditions Tester connections Standard values Starter key LOCK HV battery start relay 3rd terminal 5th terminal Without voltage 10 k or more With voltage less than 1 Is the measured va...

Page 172: ...asure the voltage between the lower side connector terminals of PCU harness 16P NO YES 4 Inspecting the voltage of PCU wire harness lower side SHTS03ZZZ0300114 Measurement conditions Tester connections Standard values Starter key ON PCU harness 16P lower side con nector 9th terminal 15th terminal 9 V or more Is the measured value within the range of standard value Go to step 5 Replace the PCU wire...

Page 173: ...lower side SHTS03ZZZ0300115 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P lower side con nector HV ECU2 connector 11th terminal 18th terminal Less than 1 Is the measured value within the range of standard value Go to step 6 Replace the PCU wire harness lower side 6 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND SHTS03ZZZ0300116...

Page 174: ...e con nector terminals of HV battery cooling fan NO YES 7 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P lower side con nector 11th terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness lower side Go to step 8 8 Inspecting the voltage of PCU wire...

Page 175: ...the ON position 5 Clear the malfunction history 6 Set the starter key to the LOCK position and wait for 1 minute 7 Set the starter key to the ON position 8 In Fault Information on the diagnosis tool screen check if P0A84 66 is detected NO YES 9 Inspecting the signal line of PCU wire harness upper side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU ...

Page 176: ...her than P0A84 66 is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 2 2 Inspecting the voltage of vehicle wire harness 1 Set the starter key to the LOCK position 2 Disconnect the PCU harness 24P connector 3 Set the starter key to the ON position 4 Using the electrical tester mea sure the voltage between the 1st terminal of PCU harness 24P vehicle side connector a...

Page 177: ...ed value is not within the range of stan dard value Go to NO Go to step 4 Replace the HV battery start relay 4 Inspecting the voltage of PCU wire har ness lower side 1 Connect the PCU harness 24P connector and the HV battery start relay 2 Disconnect the PCU harness 16P connector 3 Set the starter key to the ON position 4 Using the electrical tester mea sure the voltage between the lower side conne...

Page 178: ... PCU harness 16P and the ground Measurement conditions Starter key LOCK Tester connections PCU harness 16P lower side connector 11th terminal GND Standard values 10 k or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 7 Replace the PCU wire har ness lower side 7 Inspecting the signal line o...

Page 179: ...o to step 9 Replace the PCU wire har ness upper side 9 Inspecting the signal line of PCU wire har ness upper side for short circuit 1 Set the starter key to the LOCK position 2 Disconnect the PCU harness 16P connector 3 For the 11th terminal of PCU upper side wire harness con nector inspect the signal line of PCU wire harness upper side for short circuit See Inspect ing the PCU harness signal line...

Page 180: ...lear the malfunction history 6 Set the starter key to the LOCK position and wait for 1 minute 7 Set the starter key to the ON position 8 In Fault Information on the diagnosis tool screen check if P0A84 66 is detected DTC P0A84 66 is detected Go to YES DTC P0A84 66 is not detected Go to NO Replace the HV ECU The inspec tion is com pleted P0A84 TC66 Abnormality in HV battery cooling fan drive signal...

Page 181: ...Condition B The starter key is set to the ON position The control power supply voltage is 10 V or more 2 Judgement criteria When one of the following conditions is met Condition A Input signal for monitoring HV battery cooling fan drive signal remains higher than 3 6 V for 0 1 second or more Condition B The following conditions are met continuously for 0 5 second or more Input signal for monitorin...

Page 182: ...DTC is set MIL ON HV warning light ON 5 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 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure...

Page 183: ...ct the signal line of PCU wire harness lower side for short circuit See Inspecting the PCU harness signal line for short cir cuit NO YES 1 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P lower side con nector 11th terminal Each signal line 10 k or more Is any defect found Replace ...

Page 184: ...tion history 6 Set the starter key to the LOCK position and wait for 1 minute 7 Set the starter key to the ON position 8 In Fault Information on the diagnosis tool screen check if P0A85 65 is detected NO YES 2 Inspecting the signal line of PCU wire harness upper side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P upper side con nector 1...

Page 185: ...key LOCK Tester connections PCU harness 16P lower side connector 11th terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness lower side Go to step 2 2 Inspecting the signal line of PCU wire har ness upper side for short circuit 1 For the 11th terminal of PCU harness 16P upper side con nector inspect the signal lin...

Page 186: ...ear the malfunction history 6 Set the starter key to the LOCK position and wait for 1 minute 7 Set the starter key to the ON position 8 In Fault Information on the diagnosis tool screen check if P0A85 65 is detected DTC P0A85 65 is detected Go to YES DTC P0A85 65 is not detected Go to NO Replace the HV ECU The inspec tion is com pleted P0A85 TC65 Abnormality in HV battery cooling fan drive signal ...

Page 187: ...e motor torque is higher than 100 Nm No SMR OFF is requested No GATE is requested SMR 1 is OFF SMR 2 is ON SMR 3 is ON 2 Judgement criteria The following condition occurs twice during 1 DCY The difference between the requested torque and the effective torque remains larger than 100 Nm for 3 sec onds 3 Reset condition The difference between the requested torque and the effective torque remains at 1...

Page 188: ...tarted with the starter Idling stop is not available The regeneration function stops which may reduce the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short c...

Page 189: ...k if any DTC related to the inverter line is detected NO YES 1 Set the starter key to the LOCK position 2 Disconnect the service plug and wait for 7 minutes or more NO YES 1 Inspecting the inverter HINO DX SHTS03ZZZ0300122 Is any DTC related to the inverter line detected Perform troubleshooting for each of related DTC Go to step 2 2 Preparation for inspection Is the inspection preparation complete...

Page 190: ...specting the continuity of three phase cable 1 W V U SHTS03ZZZ0300123 Measurement conditions Tester connections Standard values Starter key LOCK Three phase cable U terminal U terminal V terminal V terminal W terminal W terminal Less than 1 Is the measured value within the range of standard value Go to step 4 When the central terminal block is pro vided Go to step 7 When no central terminal block ...

Page 191: ...n resistance of three phase cable 1 W V U SHTS03ZZZ0300124 Measurement conditions Tester connections Standard values Starter key LOCK Three phase cable U terminal V terminal V terminal W terminal W terminal U terminal 10 M or more Is the measured value within the range of standard value Go to step 5 When the central terminal block is pro vided Go to step 8 When no central terminal block is pro vid...

Page 192: ...orm a test run Repeat the following cycle 10 times or more Stop the vehicle Acceleration to 40 km h Deceleration Stop the vehicle 6 In Fault Information on the diagnosis tool screen check if P0A90 2A is detected NO YES 5 Inspecting the resistance between the HV motor phases SHTS03ZZZ0300125 Measurement conditions Tester connections Standard values Starter key LOCK 8 hours after the vehicle has sto...

Page 193: ...otor side NO YES 7 Inspecting the continuity of three phase cable 2 W V U SHTS03ZZZ0300127 Measurement conditions Tester connections Standard values Starter key LOCK Three phase cable on the HV motor side U terminal U terminal V terminal V terminal W terminal W terminal Less than 1 Is the measured value within the range of standard value Replace the three phase cable on the inverter side Replace t...

Page 194: ...ted to avoid contact NO YES 8 Inspecting the insulation resistance of three phase cable 2 W V U SHTS03ZZZ0300128 Measurement conditions Tester connections Standard values Starter key LOCK Three phase cable on the HV motor side U terminal V terminal V terminal W terminal W terminal U terminal 10 M or more Is the measured value within the range of standard value Replace the three phase cable on the ...

Page 195: ...t the service plug and wait for 7 minutes or more Inspection preparation is completed Go to YES Inspection preparation is not com pleted Go to NO Go to step 3 Perform the inspection preparation again 3 Inspecting the continuity of three phase cable 1 1 Disconnect the three phase cable U V and W terminals from the inverter and HV motor 2 Using the electrical tester mea sure the resistance between t...

Page 196: ... ter minal block is provided Replace the three phase cable 5 Inspecting the resistance between the HV motor phases 1 Using the electrical tester mea sure the resistance between the HV motor terminals HINT If the motor temperature is too high the resistance will change largely Therefore measure the resistance at least 8 hours after the vehicle has stopped Measurement conditions Starter key LOCK 8 h...

Page 197: ... pleted 7 Inspecting the continuity of three phase cable 2 1 Disconnect the three phase cable U V and W terminals from the relay terminal block 2 Using the electrical tester mea sure the resistance between the terminals of both ends of the three phase cable on the HV motor side Measurement conditions Starter key LOCK Tester connections Three phase cable on the HV motor side U terminal U terminal V...

Page 198: ...ns Starter key LOCK 8 hours after the vehicle has stopped Tester connections Three phase cable on the HV motor side U terminal V terminal V terminal W terminal W terminal U terminal Standard values 10 M or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Replace the three phase cable on the inverter si...

Page 199: ...HV battery current sensor shows no abnormality The HV battery voltage detection circuit has no abnormality GATE is ON The output of inverter start relay is ON No SMR OFF is requested No GATE is requested SMR 1 is OFF SMR 2 is ON SMR 3 is ON 2 Judgement criteria The state in which one of the following conditions is met continuously for 3 seconds or more occurs twice in 1 DCY Charging power generate...

Page 200: ... HV warning light ON 5 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 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunct...

Page 201: ... inverter line is detected NO YES 1 In Fault Information on the diagnosis tool screen check if any DTC related to the HV battery line is detected NO YES 1 Inspecting the inverter HINO DX SHTS03ZZZ0300130 Is any DTC related to the inverter line detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300131 Is any DTC related to the HV ...

Page 202: ...r measure the insulation resistance between each terminal of high voltage J B in the battery pack and the ground NO YES 3 Preparation for inspection Is the inspection preparation completed Go to step 4 Perform the inspection preparation again 4 Inspecting the HV battery BATT IN 4 BATT IN 3 SHTS03ZZZ0300132 Measurement conditions Tester connections Standard values Starter key LOCK High voltage J B ...

Page 203: ...rminal of frame wire and the ground NO YES 5 Inspecting the service plug 1 2 1 SHTS03ZZZ0300133 Measurement conditions Tester connections Standard values Starter key LOCK Frame wire 1st terminal GND 2nd terminal GND 10 M or more Is the measured value within the range of standard value Go to step 6 Replacing the frame wire with a service plug socket 6 Inspecting the service plug 2 2 1 SHTS03ZZZ0300...

Page 204: ...ation resistance of high voltage J B in the battery pack BATT OUT 6 BATT IN 4 BATT OUT 5 BATT IN 3 SHTS03ZZZ0300135 Measurement conditions Tester connections Standard values Starter key LOCK High voltage J B in the battery pack 3rd terminal 4th terminal 5th terminal 6th terminal 3rd terminal 6th terminal 4th terminal 5th terminal 3rd terminal GND 4th terminal GND 5th terminal GND 6th terminal GND ...

Page 205: ...etween the terminals of frame wire and the ground NO YES 8 Inspecting the insulation resistance of frame wire to the high voltage J B 9 10 SHTS03ZZZ0300136 Measurement conditions Tester connections Standard values Starter key LOCK Frame wire 9th terminal 10th terminal 9th terminal GND 10th terminal GND 10 M or more Is the measured value within the range of standard value Go to step 9 Replace the f...

Page 206: ...e J B in the ECU box and the ground NO YES 9 Inspecting the insulation resistance of high voltage J B in the ECU box 9 BATT 10 BATT SHTS03ZZZ0300137 Measurement conditions Tester connections Standard values Starter key LOCK High voltage J B in the ECU box 9th terminal 10th terminal 9th terminal GND 10th terminal GND 10 M or more Is the measured value within the range of standard value Go to step 1...

Page 207: ...S 10 Inspecting the insulation resistance of frame wire between the high voltage J B in the ECU box and the inverter 15 16 SHTS03ZZZ0300138 Measurement conditions Tester connections Standard values Starter key LOCK Frame wire 15th terminal 16th terminal 15th terminal GND 16th terminal GND 10 M or more Is the measured value within the range of standard value Replace the HV battery pack After replac...

Page 208: ... or more Stop the vehicle Acceleration to 40 km h Deceleration Stop the vehicle 6 After the vehicle has stopped set the starter key to the LOCK position and wait for 1 minute 7 Perform a test run Repeat the following cycle 10 times or more Stop the vehicle Acceleration to 40 km h Deceleration Stop the vehicle 8 In Fault Information on the diagnosis tool screen check if P0A92 29 is detected NO YES ...

Page 209: ...y line is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 3 3 Preparation for inspection 1 Set the starter key to the LOCK position 2 Disconnect the service plug and wait for 7 minutes or more 3 Disconnect the 16 P and 22 P connectors of HV battery ECU Inspection preparation is completed Go to YES Inspection preparation is not com pleted Go to NO Go to step 4 Perf...

Page 210: ...d value Go to NO Go to step 6 Replacing the frame wire with a service plug socket 6 Inspecting the service plug 2 1 Connect the 1st and 2nd termi nals to the HV battery and then install the frame wire 2 Using the electrical tester mea sure the insulation resistance between each terminal of frame wire and the ground Measurement conditions Starter key LOCK Tester connections Frame wire 1st terminal ...

Page 211: ...tan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 8 Replace the high voltage J B in the bat tery pack 8 Inspecting the insulation resistance of frame wire to the high volt age J B 1 Disconnect the 9th and 10th terminals from the high voltage J B in the ECU box and then remove the frame wire 2 Using the electrical tester mea sure the insulat...

Page 212: ... step 10 Replace the high voltage J B in the ECU box 10 Inspecting the insulation resistance of frame wire between the high voltage J B in the ECU box and the inverter 1 Disconnect the 15th and 16th terminals from the inverter and then remove the frame wire 2 Using the electrical tester mea sure the insulation resistance between the terminals of frame wire and the ground Measurement conditions Sta...

Page 213: ...km h Deceleration Stop the vehi cle 6 After the vehicle has stopped set the starter key to the LOCK position and wait for 1 minute 7 Perform a test run Repeat the following cycle 10 times or more Stop the vehicle Acceleration to 40 km h Deceleration Stop the vehi cle 8 In Fault Information on the diagnosis tool screen check if P0A92 29 is detected DTC P0A92 29 is detected Go to YES DTC P0A92 29 is...

Page 214: ...olant temperature remains at 70 C 158 F or less for 15 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ...

Page 215: ...s 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 Malfunction of HV ECU ...

Page 216: ...e height from the coolant level to the filling port NO YES 1 Inspecting the coolant system route Is any defect found Repair or replace the defective part After repair replacement perform the inspec tion again Go to step 2 2 Inspecting the coolant level Is the coolant level about 10 mm from the filling port Go to step 3 Add coolant See Adding coolant After adding coolant perform the inspection agai...

Page 217: ...temperature sensor 3 Using the electrical tester measure the resistance between the terminals of coolant temperature sensor connector NO YES 3 Reading the DTC HINO DX SHTS03ZZZ0300141 Is any DTC other than P0A93 7A detected Perform troubleshooting for each of related DTC Go to step 4 4 Inspecting the coolant temperature sensor SHTS03ZZZ0300142 Measurement conditions Tester connections Standard val...

Page 218: ...ition 4 Clear the malfunction history 5 Perform a test run for approximately 30 minutes 6 In Fault Information on the diagnosis tool screen check if P0A93 7A is detected NO YES 5 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK Coolant tempera ture sensor con nector 2nd terminal Each signal line 1...

Page 219: ... the filling port Coolant level is about 10 mm from the filling port Go to YES Coolant level is not about 10 mm from the filling port Go to NO Go to step 3 Add coolant See Adding coolant After adding coolant per form the inspection again 3 Reading the DTC HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position ...

Page 220: ... sensor connector inspect the signal line of PCU wire harness lower side for short circuit See Inspecting the PCU harness signal line for short circuit Measurement conditions Starter key LOCK Tester connections Coolant temperature sensor con nector 2nd terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness lower s...

Page 221: ...mains at 12 4 mph or more for 30 seconds or more The square sum of HV battery current for 1800 seconds is 200 000 A2 or more 2 Judgement criteria The HV battery temperature remains less than 30 C 22 F for 10 seconds or more 3 Reset condition The HV battery temperature remains at 30 C 22 F or more for 10 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV...

Page 222: ... inverter line is detected NO YES 1 In Fault Information on the diagnosis tool screen check if any DTC related to the HV battery line is detected NO YES 1 Inspecting the inverter HINO DX SHTS03ZZZ0300144 Is any DTC related to the inverter line detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300145 Is any DTC related to the HV ...

Page 223: ...INO DX SHTS03ZZZ0300146 Measurement conditions Tester connections Standard values Starter key ON HV battery mini mum temperature HV battery mini mum temperature 30 C 22 F or more Is the measured value within the range of standard value The inspection is completed An abnormally low temperature of HV bat tery may occur due to the outside tempera ture Replace the battery ECU ...

Page 224: ... DX 1 In Fault Information on the diagnosis tool screen check if any DTC related to the HV bat tery line is detected DTC related to the HV battery line is detected Go to YES DTC related to the HV battery line is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 3 3 Inspecting the HV battery temperature HINO DX 1 Select Data Monitor on the diagnosis tool screen and m...

Page 225: ...e is 10 V or more 2 Judgement criteria The HV battery cooling fan revolving number voltage remains more than 4 8 V for 1 second or more 3 Reset condition The HV battery cooling fan revolving number voltage remains at 4 8 V or less for 1 second or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Sympt...

Page 226: ...ere is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 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 227: ...r 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 NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300148 Is DTC P060B B2 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester conn...

Page 228: ...er key to the LOCK position and wait for 1 minute 5 Set the starter key to the ON position 6 In Fault Information on the diagnosis tool screen check if P0BCA 68 is detected NO YES 3 Inspecting the signal line of PCU wire harness upper side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P upper side con nector 12th terminal Each signal lin...

Page 229: ...wire harness lower side for short circuit See Inspect ing the PCU harness signal line for short circuit Measurement conditions Starter key LOCK Tester connections PCU harness 16P lower side connector 12th terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness lower side Go to step 3 3 Inspecting the signal line of...

Page 230: ...the LOCK position and wait for 1 minute 5 Set the starter key to the ON position 6 In Fault Information on the diagnosis tool screen check if P0BCA 68 is detected DTC P0BCA 68 is detected Go to YES DTC P0BCA 68 is not detected Go to NO Replace the HV ECU The inspec tion is com pleted P0BCA TC68 Abnormality in HV battery cooling fan revolving number signal High Inspection Procedure Step Action Desc...

Page 231: ...trol supply voltage is 10 V or more The drive duty of HV water pump is 61 or less The drive duty of HV water pump is 40 or more The output of inverter start relay is ON The vehicle speed remains at 12 4 mph for 30 seconds or more The engine intake air temperature sensor shows no abnormality The engine intake air temperature is 10 C 14 F or more The HV system coolant temperature is 20 C 4 F or more...

Page 232: ...mit The number of revolutions of the HV water pump is higher than or equal to the lower limit For upper and lower limits see below Lower limit When HV water pump drive duty is 40 1273 0 r min When HV water pump drive duty is 50 1806 0 r min When HV water pump drive duty is 61 2319 7 r min Upper limit When HV water pump drive duty is 40 2473 2 r min When HV water pump drive duty is 50 3206 0 r min ...

Page 233: ...DTC is detected P314C 82 P314D 81 P324B 62 P324C 61 P0A06 7F P0A07 7E NO YES 1 Check the coolant system route radiator inverter and hose for any damage or water leakage NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300151 Is any DTC other than P0C73 80 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the coolant system route Is any defect found Repair or replace the ...

Page 234: ...t circuit See Inspecting the PCU harness signal line for short circuit NO YES 3 Inspecting the coolant level 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 4 Inspecting the signal line of PCU wire harness lower side for short circuit 1 Measurement conditions Tester connections Standard values Star...

Page 235: ...the LOCK position and wait for 1 minute 6 Perform a test run For 1 minutes at the vehicle speed of 30 km h or more 7 Set the starter key to the ON position 8 In Fault Information on the diagnosis tool screen check if P0C73 80 is detected NO YES 5 Inspecting the signal line of PCU wire harness lower side for short circuit 2 Measurement conditions Tester connections Standard values Starter key LOCK ...

Page 236: ...ective part After repair replacement perform the inspection again Go to step 3 3 Inspecting the coolant level Remove the radiator cap and check the height from the coolant level to the filling port Coolant level is about 10 mm from the filling port Go to YES Coolant level is not about 10 mm from the filling port Go to NO Go to step 4 Add coolant See Adding coolant After adding coolant per form the...

Page 237: ...ol ing pump After replace ment go to step 6 6 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Set the starter key to the ON position 3 Clear the malfunction history 4 Perform a test run For 1 min utes at the vehicle speed of 30 km h or more 5 Set the starter key to the LOCK position and wait for 1 minute 6 Perform a test run For 1 min ute...

Page 238: ...The control power supply voltage is 10 V or more The output of HV battery ECU start relay is ON 2 Judgement criteria The output of HV battery ECU start relay and the IG2 status of CAN data remain unmatched for 2 seconds or more 3 Reset condition The output of HV battery ECU start relay and the IG2 status of CAN data are matched 4 Indication warning or system control regulation when the DTC is set ...

Page 239: ...function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that any DTC will not be detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting Malfuncti...

Page 240: ...et the starter key to the ON position 4 Using the electrical tester measure the voltage between the vehi cle side connector terminals of PCU harness 24P NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300154 Is DTC P33B1 64 or P33B2 63 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the power supply of vehicle wire harness SHTS03ZZZ0300155 Measurement conditions Teste...

Page 241: ...e 1st and 2nd terminals of HV battery start relay and measure the resistance between the 3rd and 5th terminals With voltage applied NO YES 3 Inspecting the HV battery start relay 3 5 1 2 SHTS03ZZZ0300156 Measurement conditions Tester connections Standard values Starter key LOCK HV battery start relay 3rd terminal 5th terminal Without voltage 10 k or more With voltage less than 1 Is the measured va...

Page 242: ...r measure the voltage between the lower side connector terminals of PCU harness 16P NO YES 4 Inspecting the PCU wire harness lower side SHTS03ZZZ0300157 Measurement conditions Tester connections Standard values Starter key ON PCU harness 16P lower side con nector 14th terminal 16th terminal 9 V or more Is the measured value within the range of standard value Go to step 5 Replace the PCU wire harne...

Page 243: ... measure the voltage between the bat tery ECU 26P connector terminals NO YES 5 Inspecting the PCU wire harness upper side SHTS03ZZZ0300158 Measurement conditions Tester connections Standard values Starter key ON Battery ECU 26P connector 2nd terminal 12th terminal 13th terminal 12th terminal 9 V or more Is the measured value within the range of standard value Replace the HV battery ECU Replace the...

Page 244: ... 64 or P33B2 63 is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 2 2 Inspecting the power supply of vehicle wire harness 1 Set the starter key to the LOCK position 2 Disconnect the PCU harness 24P connector 3 Set the starter key to the ON position 4 Using the electrical tester mea sure the voltage between the vehicle side connector termi nals of PCU harness 24P ...

Page 245: ...e mea sured value is not within the range of stan dard value Go to NO Go to step 4 Replace the HV battery start relay 4 Inspecting the PCU wire har ness lower side 1 Connect the HV battery start relay and PCU harness 24P connectors 2 Disconnect the PCU harness 16P connector 3 Set the starter key to the ON position 4 Using the electrical tester mea sure the voltage between the lower side connector ...

Page 246: ...nector terminals Measurement conditions Starter key ON Tester connections Battery ECU 26P connector 2nd terminal 12th terminal 13th terminal 12th terminal Standard values 9 V or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Replace the HV battery ECU Replace the PCU wire har ness upper side P3000 TC...

Page 247: ...trol regulation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become unavailable The regeneration function stops wh...

Page 248: ...N position and wait for 1 minute 4 In Fault Information on the diagnosis tool screen check if any of the following DTC is detected P3001 41 P3001 43 P3001 44 P3001 45 P3001 4B P3001 4C NO YES 1 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300159 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC If communication between the diagnosis tool and the ...

Page 249: ...detected Go to NO Perform trou bleshooting for each of related DTC If communica tion between the diagnosis tool and the HV battery ECU is not available replace the HV battery ECU Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Set the starter key to the ON position and wait for 1 minute 4 In Fault Informat...

Page 250: ...esult HV battery ECU CAN received data BTER2 1 abnormality in current detection line 3 Reset condition HV battery ECU CAN received data BTER0 0 HV battery ECU CAN received data BTER1 0 HV battery ECU CAN received data BTER2 0 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to...

Page 251: ...N position and wait for 1 minute 4 In Fault Information on the diagnosis tool screen check if any of the following DTC is detected P3001 41 P3001 43 P3001 44 P3001 45 P3001 4B P3001 4C NO YES 1 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300161 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC If communication between the diagnosis tool and the ...

Page 252: ...detected Go to NO Perform trou bleshooting for each of related DTC If communica tion between the diagnosis tool and the HV battery ECU is not available replace the HV battery ECU Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Set the starter key to the ON position and wait for 1 minute 4 In Fault Informat...

Page 253: ...lation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become unavailable The regeneration function stops which may r...

Page 254: ...N position and wait for 1 minute 4 In Fault Information on the diagnosis tool screen check if any of the following DTC is detected P3001 41 P3001 43 P3001 44 P3001 45 P3001 4B P3001 4C NO YES 1 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300163 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC If communication between the diagnosis tool and the ...

Page 255: ...detected Go to NO Perform trou bleshooting for each of related DTC If communica tion between the diagnosis tool and the HV battery ECU is not available replace the HV battery ECU Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Set the starter key to the ON position and wait for 1 minute 4 In Fault Informat...

Page 256: ...em control regulation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become unavailable The regeneration function st...

Page 257: ...N position and wait for 1 minute 4 In Fault Information on the diagnosis tool screen check if any of the following DTC is detected P3001 41 P3001 43 P3001 44 P3001 45 P3001 4B P3001 4C NO YES 1 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300165 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC If communication between the diagnosis tool and the ...

Page 258: ...detected Go to NO Perform trou bleshooting for each of related DTC If communica tion between the diagnosis tool and the HV battery ECU is not available replace the HV battery ECU Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Set the starter key to the ON position and wait for 1 minute 4 In Fault Informat...

Page 259: ... control regulation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become unavailable The regeneration function stop...

Page 260: ...ng is detected P3001 46 P3001 47 P3001 4A NO YES 1 In Fault Information on the diagnosis tool screen check if any DTC related to the inverter line is detected NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300167 Is any DTC other than P3001 46 P3001 47 or P3001 4A detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the inverter HINO DX SHTS03ZZZ0300168 Is any DTC related...

Page 261: ...up stop the vehicle Acceleration to 40 km h Deceleration Stop the vehicle 3 In Fault Information on the diagnosis tool screen check if DTC P3001 46 is detected NO YES 3 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300169 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC Go to step 4 4 Reproduction check HINO DX SHTS03ZZZ0300170 Is DTC P3001 46 de...

Page 262: ...elated to the inverter line is detected DTC related to the inverter line is detected Go to YES DTC related to the inverter line is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 3 3 Inspecting the HV battery ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if any DTC related to the HV bat tery line is detected DTC related to the HV battery li...

Page 263: ...ol regulation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become unavailable The regeneration function stops whic...

Page 264: ...ng is detected P3001 46 P3001 47 P3001 4A NO YES 1 In Fault Information on the diagnosis tool screen check if any DTC related to the inverter line is detected NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300171 Is any DTC other than P3001 46 P3001 47 or P3001 4A detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the inverter HINO DX SHTS03ZZZ0300172 Is any DTC related...

Page 265: ...up stop the vehicle Acceleration to 40 km h Deceleration Stop the vehicle 3 In Fault Information on the diagnosis tool screen check if DTC P3001 47 is detected NO YES 3 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300173 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC Go to step 4 4 Reproduction check HINO DX SHTS03ZZZ0300174 Is DTC P3001 47 de...

Page 266: ...elated to the inverter line is detected DTC related to the inverter line is detected Go to YES DTC related to the inverter line is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 3 3 Inspecting the HV battery ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if any DTC related to the HV bat tery line is detected DTC related to the HV battery li...

Page 267: ...l regulation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become unavailable The regeneration function stops which...

Page 268: ...ng is detected P3001 46 P3001 47 P3001 4A NO YES 1 In Fault Information on the diagnosis tool screen check if any DTC related to the inverter line is detected NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300175 Is any DTC other than P3001 46 P3001 47 or P3001 4A detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the inverter HINO DX SHTS03ZZZ0300176 Is any DTC related...

Page 269: ...up stop the vehicle Acceleration to 40 km h Deceleration Stop the vehicle 3 In Fault Information on the diagnosis tool screen check if DTC P3001 4A is detected NO YES 3 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300177 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC Go to step 4 4 Reproduction check HINO DX SHTS03ZZZ0300178 Is DTC P3001 4A de...

Page 270: ...elated to the inverter line is detected DTC related to the inverter line is detected Go to YES DTC related to the inverter line is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 3 3 Inspecting the HV battery ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if any DTC related to the HV bat tery line is detected DTC related to the HV battery li...

Page 271: ... control regulation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become unavailable The regeneration function stop...

Page 272: ...N position and wait for 1 minute 4 In Fault Information on the diagnosis tool screen check if any of the following DTC is detected P3001 41 P3001 43 P3001 44 P3001 45 P3001 4B P3001 4C NO YES 1 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300179 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC If communication between the diagnosis tool and the ...

Page 273: ...detected Go to NO Perform trou bleshooting for each of related DTC If communica tion between the diagnosis tool and the HV battery ECU is not available replace the HV battery ECU Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Set the starter key to the ON position and wait for 1 minute 4 In Fault Informat...

Page 274: ...ing or system control regulation when the DTC is set MIL OFF HV warning light ON 5 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 Idling stop may become unavailable The regeneration ...

Page 275: ...N position and wait for 1 minute 4 In Fault Information on the diagnosis tool screen check if any of the following DTC is detected P3001 41 P3001 43 P3001 44 P3001 45 P3001 4B P3001 4C NO YES 1 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300181 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC If communication between the diagnosis tool and the ...

Page 276: ...detected Go to NO Perform trou bleshooting for each of related DTC If communica tion between the diagnosis tool and the HV battery ECU is not available replace the HV battery ECU Go to step 2 2 Reproduction check HINO DX 1 Clear the malfunction history 2 Set the starter key to the LOCK position and wait for 1 minute 3 Set the starter key to the ON position and wait for 1 minute 4 In Fault Informat...

Page 277: ...condition After return to normal 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light OFF 5 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 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 17 U P N W V 18 19 15 16 13 14 24...

Page 278: ...Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of high voltage circuit Malfunction of HV battery ...

Page 279: ...ectrical tester measure the insulation resistance between the terminals of high voltage J B in the battery pack and the ground NO YES 1 Preparation for inspection Is the inspection preparation completed Go to step 2 Perform the inspection preparation again 2 Inspection of HV battery BATT IN 4 BATT IN 3 SHTS03ZZZ0300184 Measurement conditions Tester connections Standard values Starter key LOCK High...

Page 280: ...d the ground NO YES 3 Inspecting the service plug 1 2 1 SHTS03ZZZ0300185 Measurement conditions Tester connections Standard values Starter key LOCK Frame wire 1st terminal GND 2nd terminal GND 10 M or more Is the measured value within the range of standard value Go to step 4 Replacing the frame wire with the service plug socket 4 Inspecting the service plug 2 2 1 SHTS03ZZZ0300186 Measurement condi...

Page 281: ...ry pack and the ground NO YES 5 Inspecting the insulation resistance of high voltage J B in the battery pack BATT OUT 6 BATT IN 4 BATT OUT 5 BATT IN 3 SHTS03ZZZ0300187 Measurement conditions Tester connections Standard values Starter key LOCK High voltage J B in the battery pack 3rd terminal GND 4th terminal GND 5th terminal GND 6th terminal GND 10 M or more Is the measured value within the range ...

Page 282: ...und NO YES 6 Inspecting the insulation resistance of frame wire to the high voltage J B 9 10 SHTS03ZZZ0300188 Measurement conditions Tester connections Standard values Starter key LOCK Frame wire 9th terminal GND 10th terminal GND 10 M or more Is the measured value within the range of standard value Go to step 7 Replace the frame wire 7 Inspecting the insulation resistance of high voltage J B in t...

Page 283: ...als of frame wire and the ground NO YES 8 Inspecting the insulation resistance of frame wire between the high voltage J B in the ECU box and the inverter 15 16 SHTS03ZZZ0300190 Measurement conditions Tester connections Standard values Starter key LOCK Frame wire 15th terminal GND 16th terminal GND 10 M or more Is the measured value within the range of standard value Go to step 9 Replace the frame ...

Page 284: ...of inverter and the ground NO YES 9 Inspecting the insulation resistance of inverter 19 17 18 15 16 MEGGER VEHICLE GND SHTS03ZZZ0300191 Measurement conditions Tester connections Standard values Starter key LOCK Inverter 15th terminal GND 16th terminal GND 17th terminal GND 18th terminal GND 19th terminal GND 3 M or more Is the measured value within the range of standard value Go to step 10 Replace...

Page 285: ... Inspecting the insulation resistance of frame wire between the inverter and the relay terminal block U V W 20 21 22 SHTS03ZZZ0300192 Measurement conditions Tester connections Standard values Starter key LOCK Frame wire 20th terminal GND 21st terminal GND 22nd terminal GND 10 M or more Is the measured value within the range of standard value Go to step 11 For vehicles with no relay terminal block ...

Page 286: ... block Measurement conditions Tester connections Standard values Starter key LOCK Relay terminal block 20th terminal GND 21st terminal GND 22nd terminal GND 10 M or more Is the measured value within the range of standard value Go to step 12 Replace the relay terminal block 12 Inspecting the insulation resistance of frame wire between the inverter and the HV motor U V W 23 24 25 SHTS03ZZZ0300193 Me...

Page 287: ...lfunction history 6 Perform a test run For 30 minutes or more 7 In Fault Information on the diagnosis tool screen check if P3009 49 is detected NO YES 13 Inspecting the insulation resistance of HV motor 25 24 23 SHTS03ZZZ0300194 Measurement conditions Tester connections Standard values Starter key LOCK HV motor 23rd terminal GND 24th terminal GND 25th terminal GND 5 M or more Is the measured value...

Page 288: ...ttery pack and the ground Measurement conditions Starter key LOCK Tester connections High voltage J B in battery pack BATT IN 3 terminal GND BATT IN 4 terminal GND Standard values 10 M or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 5 Go to step 3 3 Inspecting the service plug 1 1 Discon...

Page 289: ...conditions Starter key LOCK Tester connections High voltage J B in the battery pack 3rd terminal GND 4th terminal GND 5th terminal GND 6th terminal GND Standard values 10 M or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 6 Replace the high voltage J B in the bat tery pack 6 Inspecting th...

Page 290: ... tester mea sure the insulation resistance between the terminals of frame wire and the ground Measurement conditions Starter key LOCK Tester connections Frame wire 15th terminal GND 16th terminal GND Standard values 10 M or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 9 Replace the frame...

Page 291: ...ls and the ground Measurement conditions Starter key LOCK Tester connections Relay terminal block 20th terminal GND 21st terminal GND 22nd terminal GND Standard values 10 M or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 12 Replace the relay terminal block 12 Inspecting the insulation re...

Page 292: ...O Go to step 14 Replace the HV motor 14 Reproduction check HINO DX 1 Connect all the cables and con nectors that have been discon nected to restore the system 2 Set the starter key to the LOCK position 3 Connect the diagnosis tool HINO DX to the vehicle 4 Set the starter key to the ON position 5 Clear the malfunction history 6 Perform a test run For 30 min utes or more 7 In Fault Information on th...

Page 293: ...e number of revolutions of the HV radiator fan remains less than 2500 r min for 10 seconds or more 3 Reset condition The number of revolutions of the HV radiator fan remains 2500 r min or more for 10 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup con...

Page 294: ...ork Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of HV radiator fan Malfunction of HV ECU ...

Page 295: ...24B 62 P324C 61 NO YES 1 Check that the HV radiator and the inverter cooling radiator fan have no damage or clogging NO YES 1 Set the starter key to the ON position 2 Check that the inverter cooling radiator fan is running NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300197 Is DTC P324B 62 or P324C 61 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the HV radiator ...

Page 296: ...erminal of PCU harness 24P vehicle side connector and the ground NO YES 4 Inspecting the voltage of vehicle wire harness VEHICLE GND SHTS03ZZZ0300198 Measurement conditions Tester connections Standard values Starter key ON PCU harness 24P vehicle side con nector 3rd terminal GND 9 V or more Is the measured value within the range of standard value Go to step 5 Inspect the power supply circuit PCI B...

Page 297: ...the 1st and 2nd terminals of inverter start relay and measure the resistance between the 3rd and 5th terminals With voltage applied NO YES 5 Inspecting the inverter start relay 3 5 1 2 SHTS03ZZZ0300199 Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay 3rd terminal 5th terminal Without voltage 10 k or more With voltage less than 1 Is the measured value ...

Page 298: ...r measure the voltage between the con nector terminals of inverter cooling radiator fan NO YES 6 Inspecting the voltage of PCU wire harness lower side SHTS03ZZZ0300200 Measurement conditions Tester connections Standard values Starter key ON Inverter cooling radiator fan con nector 1st terminal 2nd terminal 9 V or more Is the measured value within the range of standard value Go to step 7 Replace th...

Page 299: ...ower side SHTS03ZZZ0300201 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling radiator fan con nector to HV ECU1 connector 3rd terminal 25th terminal Less than 1 Is the measured value within the range of standard value Go to step 8 Replace the PCU wire harness lower side 8 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND SHTS03ZZZ030...

Page 300: ...and wait for 1 minute 7 Set the starter key to the LOCK position and wait for 1 minute 8 Set the starter key to the ON position and wait for 1 minute 9 In Fault Information on the diagnosis tool screen check if P3128 7D is detected NO YES 9 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK Inverter...

Page 301: ... is found Go to YES Defect is not found Go to NO Repair clean or replace the defective part Go to step 3 3 Checking the inverter cool ing radiator fan 1 Set the starter key to the ON position 2 Check that the inverter cooling radiator fan is running Inverter cool ing radiator fan is running Go to YES Inverter cool ing radiator fan is not running Go to NO Go to step 7 Go to step 4 4 Inspecting the ...

Page 302: ...ot within the range of stan dard value Go to NO Go to step 6 Replace the inverter start relay 6 Inspecting the voltage of PCU wire har ness lower side 1 Connect the PCU harness 24P connector and the inverter start relay 2 Disconnect the connector of inverter cooling radiator fan 3 Set the starter key to the ON position 4 Using the electrical tester mea sure the voltage between the connector termin...

Page 303: ...connector and the ground Measurement conditions Starter key LOCK Tester connections Inverter cooling radiator fan con nector 3rd terminal GND Standard values 10 k or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 9 Replace the PCU wire har ness lower side 9 Inspecting the signal line of PC...

Page 304: ...arter key to the ON position and wait for 1 minute 7 Set the starter key to the LOCK position and wait for 1 minute 8 Set the starter key to the ON position and wait for 1 minute 9 In Fault Information on the diagnosis tool screen check if P3128 7D is detected DTC P3128 7D is detected Go to YES DTC P3128 7D is not detected Go to NO Replace the HV ECU The inspec tion is com pleted P3128 TC7D Abnorm...

Page 305: ...teria The number of revolutions of the HV radiator fan remains less than 4500 r min for 10 seconds or more 3 Reset condition The number of revolutions of the HV radiator fan remains 4500 r min or more for 10 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup con...

Page 306: ...ork Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of HV radiator fan Malfunction of HV ECU ...

Page 307: ...or short circuit See Inspecting the PCU harness signal line for short cir cuit NO YES 1 Inspecting the inverter cooling radiator fan Is any defect found Replace the inverter cooling radiator fan Go to step 2 2 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling radiator fan con necto...

Page 308: ...position 5 Clear the malfunction history 6 Set the starter key to the ON position and wait for 1 minute 7 Set the starter key to the LOCK position and wait for 1 minute 8 Set the starter key to the ON position and wait for 1 minute 9 In Fault Information on the diagnosis tool screen check if P3129 7C is detected NO YES 3 Reproduction check HINO DX SHTS03ZZZ0300205 Is DTC P3129 7C detected Replace ...

Page 309: ...ircuit Measurement conditions Starter key LOCK Tester connections Inverter cooling radiator fan con nector 3rd terminal Each signal line Standard values 10 k or more Defect is found Go to YES Defect is not found Go to NO Replace the PCU wire har ness lower side Replace the inverter cool ing radiator fan After replace ment go to step 3 3 Reproduction check HINO DX 1 Connect all the connectors that ...

Page 310: ...re met continuously for 1 second or more The HV water pump revolution number signal is 0 Hz The HV water pump revolution number signal is OFF 3 Reset condition The HV water pump revolution number signal remains higher than 1 Hz for 5 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptom...

Page 311: ...work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper contact or fitting of connector Malfunction of HV water pump Malfunction of HV ECU ...

Page 312: ... NO YES 1 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND SHTS03ZZZ0300207 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling pump connector 2nd terminal GND 10 k or more Is the measured value within the range of standard value Go to step 2 Replace the PCU wire harness lower side 2 Inspecting the signal line of PCU wire harness lowe...

Page 313: ...e vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Set the starter key to the ON position and wait for 1 minute 6 In Fault Information on the diagnosis tool screen check if P314C 82 is detected NO YES 3 Reproduction check HINO DX SHTS03ZZZ0300208 Is DTC P314C 82 detected Replace the HV ECU The inspection is completed ...

Page 314: ...ne of PCU wire har ness lower side for short circuit 1 For the 2nd terminal of inverter cooling pump connector inspect the signal line of PCU wire harness lower side for short circuit See Inspecting the PCU harness signal line for short circuit Measurement conditions Starter key LOCK Tester connections Inverter cooling pump connector 2nd terminal Each signal line Standard values 10 k or more Defec...

Page 315: ...e met continuously for 1 second or more The HV water pump revolution number signal is 0 Hz The HV water pump revolution number signal is ON 3 Reset condition The HV water pump revolution number signal remains higher than 1 Hz for 5 seconds or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms ...

Page 316: ...work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper contact or fitting of connector Malfunction of HV water pump Malfunction of HV ECU ...

Page 317: ...for any damage or water leakage NO YES 1 Remove the radiator cap and check the height from the coolant level to the filling port NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300210 Is DTC P324B 62 or P324C 61 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the coolant system route Is any defect found Repair or replace the defective part Go to step 3 3 Inspecting th...

Page 318: ... Checking the activation of inverter cooling pump HINO DX SHTS03ZZZ0300211 Measurement conditions Measured item Standard values Starter key ON HV water pump drive duty value Activation of water pump Is the activation of water pump confirmed Go to step 8 Go to step 5 5 Inspecting the vehicle wire harness VEHICLE GND SHTS03ZZZ0300212 Measurement conditions Tester connections Standard values Starter ...

Page 319: ... the 1st and 2nd terminals of inverter start relay and measure the resistance between the 3rd and 5th terminals With voltage applied NO YES 6 Inspecting the inverter start relay 3 5 1 2 SHTS03ZZZ0300213 Measurement conditions Tester connections Standard values Starter key ON Inverter start relay 3rd terminal 5th terminal Without voltage 10 k or more With voltage less than 1 Is the measured value w...

Page 320: ...ter measure the voltage between the con nector terminals of inverter cooling pump NO YES 7 Inspecting the voltage of PCU wire harness lower side SHTS03ZZZ0300214 Measurement conditions Tester connections Standard values Starter key ON Inverter cooling pump connector 1st terminal 4th terminal 9 V or more Is the measured value within the range of standard value Go to step 8 Replace the PCU wire harn...

Page 321: ...of PCU wire harness lower side SHTS03ZZZ0300215 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling pump connector HV ECU1 connec tor 2nd terminal 26th terminal Less than 1 Is the measured value within the range of standard value Go to step 9 Replace the PCU wire harness lower side 9 Inspecting the signal line of PCU wire harness lower side for short circuit...

Page 322: ...r key to the ON position 3 Clear the malfunction history 4 Set the starter key to the ON position and wait for 1 minute 5 In Fault Information on the diagnosis tool screen check if P314D 81 is detected NO YES 10 Reproduction check HINO DX SHTS03ZZZ0300216 Is DTC P314D 81 detected Replace the HV ECU The inspection is completed ...

Page 323: ... is found Go to YES Defect is not found Go to NO Repair or replace the defective part Go to step 3 3 Inspecting the coolant level 1 Remove the radiator cap and check the height from the cool ant level to the filling port Coolant level is about 10 mm from the filling port Go to YES Coolant level is not about 10 mm from the filling port Go to NO Go to step 4 Add coolant See Adding coolant After addi...

Page 324: ...e LOCK position 2 Remove the inverter start relay 3 Using the electrical tester mea sure the resistance between the 3rd and 5th terminals of inverter start relay With no voltage applied 4 Apply the voltage of 12 V between the 1st and 2nd termi nals of inverter start relay and measure the resistance between the 3rd and 5th termi nals With voltage applied Measurement conditions Starter key ON Tester...

Page 325: ...or and the HV ECU1 con nector terminal Measurement conditions Starter key LOCK Tester connections Inverter cooling pump connector HV ECU1 connector 2nd terminal 26th terminal Standard values Less than 1 The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 9 Replace the PCU wire har ness lower side 9 ...

Page 326: ... 4 Set the starter key to the ON position and wait for 1 minute 5 In Fault Information on the diagnosis tool screen check if P314D 81 is detected DTC P314D 81 is detected Go to YES DTC P314D 81 is not detected Go to NO Replace the HV ECU The inspec tion is com pleted P314D TC81 Abnormality in HV water pump revolution number signal High Inspection Procedure Step Action Description Judgement Check Y...

Page 327: ...usly for 0 1 second or more The output of inverter start relay is ON The feedback signal of inverter start relay is OFF 3 Reset condition The following conditions are met continuously for 0 1 second or more The output of inverter start relay is ON The feedback signal of inverter start relay is ON Once the abnormality is confirmed after the HV ECU is actuated next 4 Indication warning or system con...

Page 328: ...dling stop is not available The regeneration function stops which may reduce the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Imprope...

Page 329: ...1 Inspecting the inverter start relay 3 5 1 2 SHTS03ZZZ0300218 Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay relay side 1st terminal 2nd terminal 95 125 Is the measured value within the range of standard value Go to step 2 Replace the inverter start relay 2 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND SHTS03ZZZ0300219 Me...

Page 330: ...See Inspecting the PCU harness signal line for short cir cuit NO YES 3 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay connector 1st terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness lower side Replace the HV ECU ...

Page 331: ... and inverter connectors 2 Using the electrical tester mea sure the resistance between the inverter start relay connec tor relay block and the ground Measurement conditions Starter key LOCK Tester connections Inverter start relay connector 1st terminal GND Standard values 10 k or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range o...

Page 332: ...ons are met continuously for 0 1 second or more The output of inverter start relay is OFF The feedback signal of inverter start relay is ON 3 Reset condition The following conditions are met continuously for 0 1 second or more The output of inverter start relay is OFF The feedback signal of inverter start relay is OFF Once the abnormality is confirmed after the HV ECU is actuated next 4 Indication...

Page 333: ...dling stop is not available The regeneration function stops which may reduce the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Imprope...

Page 334: ...ctrical tester measure the resistance between the inverter start relay terminals NO YES 1 Inspecting the inverter start relay 3 5 1 2 SHTS03ZZZ0300221 Measurement conditions Tester connections Standard values Inverter start relay relay side 1st terminal 2nd terminal 95 125 Is the measured value within the range of standard value Go to step 2 Replace the inverter start relay ...

Page 335: ... the ground NO YES 2 Inspecting the continuity of PCU wire harness lower side VEHICLE GND SHTS03ZZZ0300222 Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay connector HV ECU2 connector 1st terminal 1st terminal Inverter start relay connector 2nd terminal GND Less than 1 Is the measured value within the range of standard value Go to step 3 Replace the P...

Page 336: ...See Inspecting the PCU harness signal line for short cir cuit NO YES 3 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay connector 1st terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness lower side Replace the HV ECU ...

Page 337: ...the resistance from the inverter start relay connector relay block to the HV ECU2 connector terminal and to the ground Measurement conditions Starter key LOCK Tester connections Inverter start relay connector HV ECU2 connector 1st terminal 1st terminal Inverter start relay connector 2nd terminal GND Standard values Less than 1 The mea sured value is within the range of stan dard value Go to YES Th...

Page 338: ...s are met continuously for 0 1 second or more The output of HV battery ECU start relay is ON The feedback signal of HV battery ECU start relay is OFF 3 Reset condition The following conditions are met continuously for 0 1 second or more The output of HV battery ECU start relay is ON The feedback signal of HV battery ECU start relay is ON Once the abnormality is confirmed after the HV ECU is actuat...

Page 339: ...stops which may reduce the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that any DTC is not detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of ...

Page 340: ...V battery start relay 3 5 1 2 SHTS03ZZZ0300224 Measurement conditions Tester connections Standard values HV battery start relay relay side 1st terminal 2nd terminal 95 125 Is the measured value within the range of standard value Go to step 2 Replace the HV battery start relay 2 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND SHTS03ZZZ0300225 Measurement conditions Tester c...

Page 341: ...for short circuit See Inspecting the PCU harness signal line for short circuit NO YES 3 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK HV battery start relay connector 1st terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness lower side Replace the HV ECU ...

Page 342: ...ester mea sure the resistance between the HV battery start relay con nector relay block and the ground Measurement conditions Starter key LOCK Tester connections HV battery start relay connector 1st terminal Ground Standard values 10 k or more The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Re...

Page 343: ...following conditions are met continuously for 0 1 second or more The output of HV battery ECU start relay is OFF The feedback signal of HV battery ECU start relay is ON 3 Reset condition The following conditions are met continuously for 0 1 second or more The output of HV battery ECU start relay is OFF The feedback signal of HV battery ECU start relay is OFF Once the abnormality is confirmed after...

Page 344: ...n stops which may reduce the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of HV ...

Page 345: ...ical tester measure the resistance between the HV battery start relay terminals NO YES 1 Inspecting the HV battery start relay 3 5 1 2 SHTS03ZZZ0300227 Measurement conditions Tester connections Standard values HV battery start relay relay side 1st terminal 2nd terminal 95 125 Is the measured value within the range of standard value Go to step 2 Replace the HV battery start relay ...

Page 346: ...und NO YES 2 Inspecting the continuity of PCU wire harness lower side VEHICLE GND SHTS03ZZZ0300228 Measurement conditions Tester connections Standard values Starter key LOCK HV battery start relay connector HV ECU2 connec tor 1st terminal 2nd terminal HV battery start relay connector 2nd terminal GND Less than 1 Is the measured value within the range of standard value Go to step 3 Replace the PCU ...

Page 347: ...See Inspecting the PCU harness signal line for short circuit NO YES 3 Inspecting the signal line of PCU wire harness lower side for short circuit Measurement conditions Tester connections Standard values Starter key LOCK HV battery start relay connector 1st terminal Each signal line 10 k or more Is any defect found Replace the PCU wire harness lower side Replace the HV ECU ...

Page 348: ... resistance from the HV battery start relay connector relay block to the HV ECU2 connector terminal and to the ground Measurement conditions Starter key LOCK Tester connections HV battery start relay connector HV ECU2 connector 1st terminal 2nd terminal HV battery start relay connector 2nd terminal GND Standard values Less than 1 The mea sured value is within the range of stan dard value Go to YES...

Page 349: ...ore in total If normal time continues for 5 seconds the accumulated time shall be reset 3 Reset condition A state in which no control CAN bus off is detected continues for 0 5 second or more Once the abnormality is confirmed the following conditions are included HV ECU runs within 0 5 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON ABS ECU CA...

Page 350: ...reduce the feeling of deceleration during deceleration The CHG AST ECO and SOC lamp go off 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting ...

Page 351: ...U and inverter 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0073 11 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduction c...

Page 352: ...he diagnosis tool screen check if DTC U0073 91 is detected in the inverter NO YES 3 Inspecting the inverter HINO DX SHTS03ZZZ0300231 Is DTC U0073 91 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV ECU ...

Page 353: ... to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history of the HV ECU and inverter 5 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0073 11 is detected DTC U0073 11 is detected Go to YES DTC U0073 11 is not detected Go to NO Go to ste...

Page 354: ... 3 Reset condition A state in which no DIAG CAN bus off is detected continues for 0 5 second or more Once the abnormality is confirmed the following conditions are included HV ECU runs within 0 5 second 9 8 CANN VCS ECU Engine ECU CANP 5 4 L H L H L H L H CANL CANH 4 3 16 5 17 6 15 14 J C CAN 2 Telematics information 17 6 2 13 4 15 J C CAN1 22P Diagnosis connector DLC ATM ECU Clutch ECU CAN H CAN ...

Page 355: ...ction becomes inoperative The regeneration function stops which may reduce the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper ...

Page 356: ...sition and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0074 16 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduction check HINO DX SHTS03ZZZ0300233 Is DTC U0074 16 detec...

Page 357: ...on items Go to step 2 2 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if ...

Page 358: ...frames from the engine ECU are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 9 8 CANN VCS ECU Engine ECU CANP 5 4 L H L H L H L H CANL CANH 4 3 16 5 17 6 15 14 J C CAN 2 Telematics information 17 6 2 13 4 15 J C CAN1 22P Diagnosis connector DLC ATM ECU Clutch ECU CAN H CAN L CAN H CAN L CAN H CAN L CAN H CAN L DCU CAL 1 CAH...

Page 359: ...ng of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness Improper connector connection or fitting Malfun...

Page 360: ...sition and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0100 13 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduction check HINO DX SHTS03ZZZ0300235 Is DTC U0100 13 detec...

Page 361: ... Go to step 2 2 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0100 13...

Page 362: ... state in which no CAN frame is received from the AT ECU continues for 0 7 seconds or more 3 Reset condition When all frames from the AT ECU are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON ABS ECU CAN H2 CAN L2 HV PCU HV ECU Inverter 7 6 CA1 CA1 3 2 CA2 CA2 9 18 7 19 8 20 J C CAN2 9 18 7 19 8 20 J C CAN1 AT ECU Clutch EC...

Page 363: ...ng of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness Improper connector connection or fitting Malfun...

Page 364: ... vehicle control ECU 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0101 18 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduc...

Page 365: ...CU CAN communication blackout U0121 ABS ECU CAN communication blackout U0110 Inverter CAN communication blackout U0155 Meter CAN communication blackout NO YES 3 Inspecting the HV ECU HINO DX SHTS03ZZZ0300238 Is DTC U0073 11 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0073 11 Step 2 and onward Go to step 4 4 Reading the DTC HINO DX Are all communication blac...

Page 366: ... check if DTC U0101 AT ECU communication blackout is detected in the vehi cle control ECU NO YES 5 Inspecting the vehicle control ECU HINO DX SHTS03ZZZ0300239 Is DTC U0101 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV ECU ...

Page 367: ...the starter key to the ON position 4 Clear the malfunction history of the HV ECU and vehicle control ECU 5 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0101 18 is detected DTC U0101 18 is detected Go to YES DTC U0101 18 is not detected Go to NO Go to step 3 The ins...

Page 368: ...to YES All communi cationblackout DTCs are not detected Go to NO Go to step 5 All communi cation black outs have been gener ated Refer to the CONTROL CAN COMMU NICATION LINE HYBRID in the chapter CONTROL SYSTEM 5 Inspecting the vehicle control ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if DTC U0101 AT ECU commu nication blackout is detected in the vehicle control ECU DTC...

Page 369: ...ed ON 1 second or more has passed 2 Judgement criteria When a state in which no CAN frame is received from the inverter continues for 0 68 second or more 3 Reset condition When all frames from the inverter are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON ABS ECU CAN H2 CAN L2 HV PCU HV ECU Inverter 7 6 CA1 CA1 3 2 CA2 CA2 ...

Page 370: ...g of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness Improper connector connection or fitting Malfunc...

Page 371: ...nd vehicle control ECU 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if DTC U0110 14 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Re...

Page 372: ...reen check if DTC U0073 91 Control CAN abnormality is detected in the inverter NO YES 3 Inspecting the HV ECU HINO DX SHTS03ZZZ0300242 Is DTC U0073 11 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0073 11 Step 2 and onward Go to step 4 4 Inspecting the inverter 1 HINO DX SHTS03ZZZ0300243 Is DTC U0073 91 detected Replace the inverter Go to step 5 ...

Page 373: ...n the HV ECU U110A Vehicle control ECU CAN communication blackout U0101 AT ECU CAN communication blackout U1136 Clutch ECU CAN communication blackout U0121 ABS ECU CAN communication blackout U0155 Meter CAN communication blackout NO YES 5 Inspecting the inverter 2 HINO DX SHTS03ZZZ0300244 Is DTC P0A1B 92 detected Replace the inverter Go to step 6 6 Reading the DTC 1 HINO DX SHTS03ZZZ0300245 Are al...

Page 374: ...Clutch ECU CAN communication blackout U0121 ABS ECU CAN communication blackout U0155 Meter CAN communication blackout NO YES 7 Inspecting the vehicle control ECU HINO DX SHTS03ZZZ0300246 Is DTC U0155 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV ECU 8 Reading the DTC 2 HINO DX SHTS03ZZZ0300247 Is any DTC other than U0110 14 detected Refe...

Page 375: ...ol screen check if DTC U0110 14 is detected DTC U0110 14 is detected Go to YES DTC U0110 14 is not detected Go to NO Go to step 3 The inspec tion is com pleted Temporary actuation of protection function due to external noise or connector terminal con tact resis tance return 3 Inspecting the HV ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if DTC U0073 11 is detected in the ...

Page 376: ...55 is detected Go to YES DTC U0155 is not detected Go to NO Refer to the CONTROL CAN COMMU NICATION LINE HYBRID in the chapter CONTROL SYSTEM Replace the HV ECU 8 Reading the DTC 2 HINO DX 1 In Fault Information on the diagnosis tool screen check if any control CAN system ECU communication blackout is detected other than U0110 14 in the HV ECU U110A Vehicle control ECU CAN communication black out ...

Page 377: ...s for 0 68 second or more 3 Reset condition When all frames from the HV battery ECU are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 9 8 CANN VCS ECU Engine ECU CANP 5 4 L H L H L H L H CANL CANH 4 3 16 5 17 6 15 14 J C CAN 2 Telematics information 17 6 2 13 4 15 J C CAN1 22P Diagnosis connector DLC ATM ECU Clutch ECU CAN ...

Page 378: ...n during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of HV batte...

Page 379: ...icle control ECU 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if DTC U0111 15 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduc...

Page 380: ...ormality is detected in the HV bat tery ECU NO YES 3 Inspecting the HV ECU HINO DX SHTS03ZZZ0300250 Is DTC U0073 11 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0073 11 Step 2 and onward Go to step 4 4 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300251 Is DTC U0074 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0074 ...

Page 381: ...Fault Information on the diagnosis tool screen check if DTC U0105 Engine ECU communication blackout is detected in the vehicle control ECU NO YES 5 Reading the DTC 1 HINO DX SHTS03ZZZ0300252 Are all communication blackout DTCs detected Go to step 6 All communication blackouts have been generated Go to step 7 6 Inspecting the vehicle control ECU HINO DX SHTS03ZZZ0300253 Is DTC U0105 detected Refer ...

Page 382: ...tion blackout U110A Vehicle control ECU CAN communication blackout NO YES 7 Reading the DTC 2 HINO DX SHTS03ZZZ0300254 Is any DTC other than U0111 15 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV battery ECU Because blackout has occurred only in the HV battery ECU CAN communication it is likely that there is an abnormality in the HV batt...

Page 383: ...inute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if DTC U0111 15 is detected DTC U0111 15 is detected Go to YES DTC U0111 15 is not detected Go to NO Go to step 3 The inspec tion is com pleted Temporary actuation of protection function due to external noise or connector terminal con tact resis tance return 3 Inspecting the HV ECU HINO DX 1 In...

Page 384: ... Go to YES DTC U0105 is not detected Go to NO Refer to the DIAGNOSIS CAN COMMU NICATION LINE HYBRID in the chapter CONTROL SYSTEM Replace the HV ECU 7 Reading the DTC 2 HINO DX 1 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 U110A Vehicle control ...

Page 385: ...state in which no CAN frame is received from the ABS ECU continues for 0 72 second or more 3 Reset condition When all frames from the ABS ECU are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON ABS ECU CAN H2 CAN L2 HV PCU HV ECU Inverter 7 6 CA1 CA1 3 2 CA2 CA2 9 18 7 19 8 20 J C CAN2 9 18 7 19 8 20 J C CAN1 AT ECU Clutch E...

Page 386: ...ection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of ABS ECU Malfunction of HV ECU Malfunctio...

Page 387: ... vehicle control ECU 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0121 24 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduc...

Page 388: ...nication blackout U1136 Clutch ECU CAN communication blackout U0110 Inverter CAN communication blackout U0155 Meter CAN communication blackout NO YES 3 Inspecting the HV ECU HINO DX SHTS03ZZZ0300257 Is DTC U0073 11 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0073 11 Step 2 and onward Go to step 4 4 Reading the DTC HINO DX SHTS03ZZZ0300258 Are all communicat...

Page 389: ... check if DTC U0121 ABS ECU communication blackout is detected in the vehi cle control ECU NO YES 5 Inspecting the vehicle control ECU HINO DX SHTS03ZZZ0300259 Is DTC U0121 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV ECU ...

Page 390: ...the starter key to the ON position 4 Clear the malfunction history of the HV ECU and vehicle control ECU 5 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0121 24 is detected DTC U0121 24 is detected Go to YES DTC U0121 24 is not detected Go to NO Go to step 3 The ins...

Page 391: ...o YES All communi cationblackout DTCs are not detected Go to NO Go to step 5 All communi cation black outs have been gener ated Refer to the CONTROL CAN COMMU NICATION LINE HYBRID in the chapter CONTROL SYSTEM 5 Inspecting the vehicle control ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if DTC U0121 ABS ECU com munication blackout is detected in the vehicle control ECU DTC...

Page 392: ...state in which no CAN frame is received from the meter ECU continues for 1 6 seconds or more 3 Reset condition When all frames from the meter ECU are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON ABS ECU CAN H2 CAN L2 HV PCU HV ECU Inverter 7 6 CA1 CA1 3 2 CA2 CA2 9 18 7 19 8 20 J C CAN2 9 18 7 19 8 20 J C CAN1 AT ECU Clut...

Page 393: ...ction work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of meter ECU Malfunction of HV ECU Malfuncti...

Page 394: ... vehicle control ECU 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0155 25 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduc...

Page 395: ...unication blackout U1136 Clutch ECU CAN communication blackout U0121 ABS CAN communication blackout U0110 Inverter CAN communication blackout NO YES 3 Inspecting the HV ECU HINO DX SHTS03ZZZ0300262 Is DTC U0073 11 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0073 11 Step 2 and onward Go to step 4 4 Reading the DTC HINO DX SHTS03ZZZ0300263 Are all communicati...

Page 396: ...check if DTC U0155 Meter ECU communication blackout is detected in the vehicle control ECU NO YES 5 Inspecting the vehicle control ECU HINO DX SHTS03ZZZ0300264 Is DTC U0155 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV ECU ...

Page 397: ... the starter key to the ON position 4 Clear the malfunction history of the HV ECU and vehicle control ECU 5 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0155 25 is detected DTC U0155 25 is detected Go to YES DTC U0155 25 is not detected Go to NO Go to step 3 The in...

Page 398: ...ES All communi cationblackout DTCs are not detected Go to NO Go to step 5 All communi cation black outs have been gener ated Refer to the CONTROL CAN COMMU NICATION LINE HYBRID in the chapter CONTROL SYSTEM 5 Inspecting the vehicle control ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if DTC U0155 Meter ECU com munication blackout is detected in the vehicle control ECU DTC ...

Page 399: ...state in which no CAN frame is received from the vehicle control ECU continues for 0 68 second or more 3 Reset condition When all frames from the vehicle control ECU are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON ABS ECU CAN H2 CAN L2 HV PCU HV ECU Inverter 7 6 CA1 CA1 3 2 CA2 CA2 9 18 7 19 8 20 J C CAN2 9 18 7 19 8 20 ...

Page 400: ... work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of vehicle control ECU Malfunction of HV ECU Malf...

Page 401: ... and engine ECU 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U110A 26 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduction ...

Page 402: ...ation blackout U0121 ABS ECU CAN communication blackout U0110 inverter CAN communication blackout U0155 meter CAN communication blackout NO YES 3 Inspecting the HV ECU HINO DX SHTS03ZZZ0300267 Is DTC U0073 11 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0073 11 Step 2 and onward Go to step 4 4 Reading the DTC HINO DX SHTS03ZZZ0300268 Are all communication bl...

Page 403: ...een check if DTC U110A vehicle control ECU communication blackout is detected in the engine ECU NO YES 5 Inspecting the engine ECU HINO DX SHTS03ZZZ0300269 Is DTC U110A detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV ECU ...

Page 404: ...cle 3 Set the starter key to the ON position 4 Clear the malfunction history of the HV ECU and engine ECU 5 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U110A 26 is detected DTC U110A 26 is detected Go to YES DTC U110A 26 is not detected Go to NO Go to step 3 The in...

Page 405: ... communi cationblackout DTCs are not detected Go to NO Go to step 5 All communi cation black outs have been gener ated Refer to the CONTROL CAN COMMU NICATION LINE HYBRID in the chapter CONTROL SYSTEM 5 Inspecting the engine ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if DTC U110A vehicle control ECU communication blackout is detected in the engine ECU DTC U110A is detect...

Page 406: ...state in which no CAN frame is received from the clutch ECU continues for 0 68 second or more 3 Reset condition When all frames from the clutch ECU are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON ABS ECU CAN H2 CAN L2 HV PCU HV ECU Inverter 7 6 CA1 CA1 3 2 CA2 CA2 9 18 7 19 8 20 J C CAN2 9 18 7 19 8 20 J C CAN1 AT ECU Cl...

Page 407: ... of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness Improper connector connection or fitting Malfunct...

Page 408: ... vehicle control ECU 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U1136 27 is detected NO YES 1 Implementation of common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduc...

Page 409: ...munication blackout U0121 ABS CAN communication blackout U0110 inverter CAN communication blackout U0155 meter ECU CAN communication blackout NO YES 3 Inspecting the HV ECU HINO DX SHTS03ZZZ0300272 Is DTC U0073 11 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0073 11 Step 2 and onward Go to step 4 4 Reading the DTC HINO DX SHTS03ZZZ0300273 Are all communicati...

Page 410: ...check if DTC U1136 clutch ECU communication blackout is detected in the vehicle control ECU NO YES 5 Inspecting the vehicle control ECU HINO DX SHTS03ZZZ0300274 Is DTC U1136 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV ECU ...

Page 411: ... the starter key to the ON position 4 Clear the malfunction history of the HV ECU and vehicle control ECU 5 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U1136 27 is detected DTC U1136 27 is detected Go to YES DTC U1136 27 is not detected Go to NO Go to step 3 The in...

Page 412: ...S All communi cationblackout DTCs are not detected Go to NO Go to step 5 All communi cation black outs have been gener ated Refer to the CONTROL CAN COMMU NICATION LINE HYBRID in the chapter CONTROL SYSTEM 5 Inspecting the vehicle control ECU HINO DX 1 In Fault Information on the diagnosis tool screen check if DTC U1136 clutch ECU com munication blackout is detected in the vehicle control ECU DTC ...

Page 413: ...MR off P0A78 21 P0604 Abnormality in internal element for control abnor mality in RAM RAM abnormality diagnosis micro processor D2 Normal control P0A78 22 P0605 Abnormality in internal element for control abnor mality in ROM ROM abnormality control micropro cessor 17 Gate block SMR off P0A78 21 P0605 Abnormality in internal element for control abnor mality in ROM ROM abnormality diagnosis micro pr...

Page 414: ...oscillation stop abnormality A2 Gate block SMR off P0A78 21 P0A1B Abnormality in inverter ECU sys tem Resolver REF sig nal cycle abnor mality A3 Gate block SMR off P0A78 21 P0A1B Abnormality in inverter ECU sys tem R D converter resolver angle abnormality A4 Gate block SMR off P0A78 21 P0A1B Abnormality in inverter ECU sys tem R D converter NM stop abnormality A5 Gate block SMR off P0A78 21 P0A1B ...

Page 415: ...r ECU sys tem CPU communica tion abnormality control micropro cessor D4 Normal control P0A78 22 P0A1B Abnormality in inverter ECU sys tem CPU communica tion abnormality diagnosis micro processor D5 Normal control P0A78 22 P0A1D HV ECU abnormal ity HV ECU operation state abnormality 21 Gate block SMR off P0A78 21 P0A2B Abnormality in characteristics of motor temperature sensor Abnormality in charac...

Page 416: ...P0A78 22 P0A78 Abnormality in inverter system DC voltage exces sively low 13 Gate block SMR off P0A78 21 P0A78 Abnormality in inverter system DC voltage exces sively high 14 Gate block SMR off P0A78 21 P0A78 Abnormality in inverter system Motor over current 15 Gate block except at 3 phase ON con trol SMR off P0A78 21 P0AA1 SMR 2 positive side contact stick ing Contact sticking D8 Normal control P0...

Page 417: ... the main circuit ele ment temperature sensor High fail ure 25 Gate block SMR off P0A78 21 P0BEA Abnormality in V phase current sen sor characteristics Offset abnormality B3 Gate block SMR off P0A78 21 P0BEA Abnormality in V phase current sen sor characteristics Deviation abnor mality B4 Gate block SMR off P0A78 21 P0BEB V phase current sensor Low abnor mality Out of range Low failure 9A Gate bloc...

Page 418: ... control CAN Communication disabled due to control CAN bus off 91 Gate block SMR off except at EMG start P0A78 21 U0074 Abnormality in CAN communica tion with inverter DIAG CAN Communication disabled due to DIAG CAN bus off 3E Normal control P0A78 22 U0293 HV ECU CAN com munication black out HV ECU CAN com munication black out 31 Gate block SMR off except at EMG start P0A78 21 DTC Name of malfunc ...

Page 419: ...ition of the HV system OFF 0 Engine startup 1 At acceleration by motor 2 Deceleration by motor retarder or foot brake 3 Deceleration by motor 4 HV battery charging 5 Engine stop 6 Forced HV battery charging 7 At manufacturing inspection 8 At EV 9 At gear shifting 10 Not defined 11 to 15 0 15 Motor control mode information Indicates a motor operating state 0 Shutdown 1 Torque control 2 Discharge pr...

Page 420: ...r control mode 0 Sine wave 1 Overmodulation 2 Square wave 0 2 Carrier frequency 0 5 kHz 1 2 5 kHz 2 1 25 kHz 0 2 Emergency start request 0 Without 1 With 0 1 Power supply voltage B power supply 0 40 V Inverter start signal voltage ON signal voltage 0 40 V System main relay SMR drive 12V voltage SMR drive 12 V voltage 0 20 V Current crowding judgment 0 Without crowding judgment 1 With crowding judg...

Page 421: ...re INV temperature 0 200 C HV control mode information Represents the operating condition of the HV system OFF 0 Engine startup 1 At acceleration by motor 2 Deceleration by motor retarder or foot brake 3 Deceleration by motor 4 HV battery charging 5 Engine stop 6 Forced HV battery charging 7 At manufacturing inspection 8 At EV 9 At gear shifting 10 Not defined 11 to 15 0 15 Motor control mode info...

Page 422: ...tem main relay 2 SMR2 0 OFF 1 ON 0 1 System main relay 3 SMR3 0 OFF 1 ON 0 1 System main relay 1 SMR1 0 OFF 1 ON 0 1 Motor control mode 0 Sine wave 1 Overmodulation 2 Square wave 0 2 Carrier frequency 0 5 kHz 1 2 5 kHz 2 1 25 kHz 0 2 Emergency start request 0 Without 1 With 0 1 Power supply voltage B power supply 0 40 V Inverter start signal voltage ON signal voltage 0 40 V System main relay SMR d...

Page 423: ...HYBRID TROUBLE SHOOTING 3 419 Shorted phase upper arm lower arm 0 Not detected 1 Upper arm 2 Lower arm 0 2 Item Description Display range Unit ...

Page 424: ... H 26 H 25 D q n k J B WATER PUMP INVERTER START RELAY INVERTER F F RAD FAN E F E L L L L 25 N P D 10 3 4 2 15 HV BATTERY EARTH W S_GND SERVICE PLUG SERVICE PLUG SWITCH SMR1 RESISTOR SMR2 SMR3 1 38 D 38 D 39 D 40 1 2 D 5 D 16 D Y 23 1 A A A A A A 8 D Y 24 2 4 D Y 12 H H H G G 1 3 2 U V W U V W 5 6 D Y 34 A B 4 B B THERMISTOR A CONNECTOR No B CONNECTOR PIN No ROTATION MACHINE RESOLVER D Y 35 8 1 2 ...

Page 425: ...FIG URE 1 CAUTION Inspect in the state that engine and hybrid motor rotor are completely assembled Never measure between each phase U V W terminal of three phase of three phase cable connector side Refer to Figure 2 ٤ INSULATION RESISTANCE MEASUREMENT MACHINE TERMINAL FIGURE 1 FIGURE 2 SECURELY SANDWICH THE MEASUREMENT MACHINE TERMINAL BY THE THERMISTER BRACKET BOLT IDENTIFICATION LABEL NO 1 IDENT...

Page 426: ...ORE 3 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 Do not touch the terminals for three minutes after measurement Do not damage connector part of wire assembly high voltage three phase cable ...

Page 427: ...h SMR power supply voltage is less than 7 5 V is detected continuously for 0 05 second 3 Reset condition The state in which SMR power supply voltage is 7 5 V or more and 16 5 V or less is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON HV ECU Inverter starter relay PCI_B_2 20A F F F M F L X L L L I H 2 2 5 1 3 F...

Page 428: ...starter Idling stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improp...

Page 429: ...ls of PCU harness 24P vehicle connector NO YES 1 Inspecting the voltage of 12 V battery SHTS03ZZZ0300278 Measurement conditions Tester connections Standard values Starter key ON PCU harness 24P vehicle connector 2nd terminal 16th terminal 10 16 V Is the measured value within the range of standard value Go to step 2 Inspect the 12 V battery and charge or replace if necessary When the battery is nor...

Page 430: ...d inverter connector NO YES 2 Inspecting the PCU wire harness lower side for continuity 1 SHTS03ZZZ0300279 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 24P lower side con nector inverter connector 2nd terminal 30th terminal 2nd terminal 31st terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 3 Replace the...

Page 431: ...ns Standard values Starter key LOCK PCU harness 24P lower side con nector 2nd terminal GND 3rd terminal GND 10 k or more No continuity Is the measured value within the range of standard value Go to step 4 Replace the PCU wire harness lower side 4 Inspecting the PCU wire harness lower side for continuity 2 SHTS03ZZZ0300281 Measurement conditions Tester connections Standard values Starter key LOCK I...

Page 432: ...5 Inspecting the inverter cooling pump and inverter cooling radiator fan for short circuit SHTS03ZZZ0300282 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling pump connector PCU harness 24P lower side con nector 4th terminal 16th terminal Inverter cooling radiator fan con nector PCU har ness 24P lower side connector 1st terminal 16th terminal 10 k or more N...

Page 433: ...ng for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0562 96 is detected NO YES 6 Inspecting the PCU wire harness lower side for short circuit 2 Vehicle GND SHTS03ZZZ0300283 Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay connector relay block side 1st terminal GND 10 k or more No continuity Is the measured value...

Page 434: ...arter key to the LOCK position 2 Disconnect the inverter con nector 3 Using the electrical tester mea sure the resistance between the terminals of PCU harness 24P lower side connector and inverter connector Measurement conditions Starter key LOCK Tester connections PCU harness 24P lower side connector inverter connector 2nd terminal 30th terminal 2nd terminal 31st terminal Standard values 1 or les...

Page 435: ... Measurement conditions Starter key LOCK Tester connections Inverter cooling pump connector PCU harness 24P lower side connector 4th terminal 16th terminal Inverter cooling radiator fan con nector PCU harness 24P lower side connector 1st terminal 16th terminal Standard values 10 k or more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not ...

Page 436: ...rform a test run accelerate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0562 96 is detected DTC P0562 96 is detected Go to YES DTC P0562 96 is not detected Go to NO Replace the inverter The inspec tion is com pleted Temporary actuation of protection function due to external noise P0562 TC96 Abnormality in power supply voltage Inspec...

Page 437: ...Judgement criteria The state in which control power supply voltage is less than 7 5 V is detected continuously for 1 second 3 Reset condition The state in which control power supply voltage is 7 5 V or more is detected continuously for 3 seconds 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON HV ECU Inverter starter relay PCI_B_2 20A F F F M F L X ...

Page 438: ...starter Idling stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improp...

Page 439: ...ls of PCU harness 24P vehicle connector NO YES 1 Inspecting the voltage of 12 V battery SHTS03ZZZ0300286 Measurement conditions Tester connections Standard values Starter key ON PCU harness 24P vehicle connector 2nd terminal 16th terminal 10 16 V Is the measured value within the range of standard value Go to step 2 Inspect the 12 V battery and charge or replace if necessary When the battery is nor...

Page 440: ...d inverter connector NO YES 2 Inspecting the PCU wire harness lower side for continuity 1 SHTS03ZZZ0300287 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 24P lower side con nector Inverter connector 2nd terminal 30th terminal 2nd terminal 31st terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 3 Replace the...

Page 441: ... Standard values Starter key LOCK PCU harness 24P lower side con nector 2nd terminal GND 3rd terminal GND 10 k or more No continuity Is the measured value within the range of standard value Go to step 4 Replace the PCU wire harness lower side 4 Inspecting the PCU wire harness lower side for continuity 2 SHTS03ZZZ0300289 Measurement conditions Tester connections Standard values Starter key LOCK Inv...

Page 442: ... Inspecting the inverter cooling pump and inverter cooling radiator fan for short circuit SHTS03ZZZ0300290 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling pump connector PCU harness 24P lower side con nector 4th connector 16th connector Inverter cooling radiator fan con nector PCU har ness 24P lower side connector 1st terminal 16th terminal 10 k or more ...

Page 443: ...ng for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0562 A0 is detected NO YES 6 Inspecting the PCU wire harness lower side for short circuit 2 Vehicle GND SHTS03ZZZ0300291 Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay connector relay block side 1st terminal GND 10 k or more No continuity Is the measured value...

Page 444: ...arter key to the LOCK position 2 Disconnect the inverter con nector 3 Using the electrical tester mea sure the resistance between the terminals of PCU harness 24P lower side connector and inverter connector Measurement conditions Starter key LOCK Tester connections PCU harness 24P lower side connector Inverter connector 2nd terminal 30th terminal 2nd terminal 31st terminal Standard values 1 or les...

Page 445: ...Measurement conditions Starter key LOCK Tester connections Inverter cooling pump connector PCU harness 24P lower side connector 4th connector 16th connector Inverter cooling radiator fan con nector PCU harness 24P lower side connector 1st terminal 16th terminal Standard values 10 k or more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not...

Page 446: ...rform a test run accelerate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0562 A0 is detected DTC P0562 A0 is detected Go to YES DTC P0562 A0 is not detected Go to NO Replace the inverter The inspec tion is com pleted Temporary actuation of protection function due to external noise P0562 TCA0 Abnormality in power supply voltage Inspec...

Page 447: ...lue is detected 3 times successively immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 448: ... actuation of protection function due to external noise P0604 TC18 Abnormality in internal element for control abnormality in RAM Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction histor...

Page 449: ...alue is detected 3 times successively immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 wit...

Page 450: ... actuation of protection function due to external noise P0604 TCD2 Abnormality in internal element for control abnormality in RAM Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction histor...

Page 451: ... data Specified value AA55 hex is detected 3 times successively immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 s...

Page 452: ... actuation of protection function due to external noise P0605 TC17 Abnormality in internal element for control abnormality in ROM Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Restoration check HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history...

Page 453: ...n data Specified value AA55 hex is detected 3 times successively immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ...

Page 454: ... actuation of protection function due to external noise P0605 TCD1 Abnormality in internal element for control abnormality in ROM Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Restoration check HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history...

Page 455: ...nverter is larger than 5 95 V A D conversion completion interrupt has not occurred 3 Reset condition The following condition continues for 0 2 second Voltage of AD converter is 4 04 V or more Voltage of AD converter is 5 95 V or less A D conversion completion interrupt has occurred 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the ve...

Page 456: ...HYBRID TROUBLE SHOOTING 3 452 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of inverter ...

Page 457: ...ation of protection function due to external noise P060B TC1A Abnormality in internal element for control abnormality in AD converter Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction hi...

Page 458: ...l width is less than 0 001 After the run pulse signal width of 0 003 second or more continues for 0 05 second reset is performed once but it is detected again 3 Reset condition When the following conditions continue for 0 1 second The run pulse signal is present The run pulse signal width is larger than 1 0 ms The run pulse signal width is smaller than 3 0 ms 4 Indication warning or system control...

Page 459: ...of protection function due to external noise P060C TC1C Abnormality in internal element for control abnormality in diagnosis microprocessor Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunct...

Page 460: ...memory is not available immediately 3 Reset condition When access to the memory is become available immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 6 Pre inspection work Check the battery voltag...

Page 461: ...emporary actuation of protection function due to external noise P062F TC41 Abnormality in inverter abnormality in memory Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 Perfo...

Page 462: ...criteria When the inverter is actuated uninserted or unlocked service plug or disconnection is detected continuously for 0 04 second 3 Reset condition Presence of service plug signal is detected continuously for 0 08 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter High voltage J B High voltage J B D 38 39 40 16 5 CON3 38 CON1 CON4 39...

Page 463: ...ith the starter Idling stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harnes...

Page 464: ...the service plug connector terminals NO YES 1 Inspecting the service plug Is any defect found Insert the service plug and lock it securely Go to step 2 2 Inspecting the continuity of service plug 1 2 SHTS03ZZZ0300301 Measurement conditions Tester connections Standard values Starter key LOCK Service plug con nector 1st terminal 2nd terminal 1 or less With continuity Is the measured value within the...

Page 465: ...de connector NO YES 3 Inspecting the PCU wire harness lower side for continuity SHTS03ZZZ0300302 Measurement conditions Tester connections Standard values Starter key LOCK Inverter connec tor PCU harness 16P lower side connector 5th terminal 5th terminal 16th terminal 1st terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 4 Replace the PCU wire h...

Page 466: ...er key to the ON position again 6 In Fault Information on the diagnosis tool screen check if P0A0D 20 is detected NO YES 4 Inspecting the PCU wire harness upper side for continuity 2 1 SHTS03ZZZ0300303 Measurement conditions Tester connections Standard values Starter key LOCK Service plug con nector PCU har ness 16P connector 1st terminal 1st terminal 2nd terminal 5th terminal 1 or less With conti...

Page 467: ... Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Replace the service plug 3 Inspecting the PCU wire har ness lower side for conti nuity 1 Disconnect the connectors of inverter and PCU harness 16P 2 Using the electrical tester mea sure the resistance be...

Page 468: ...the range of stan dard value Go to NO Go to step 5 Replace the main wire har ness in the HV battery 5 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history and set the starter key to the LOCK position 5 Set the starter key ...

Page 469: ...ality signal from the drive circuit is ON is not detected 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 sta...

Page 470: ...three phase cable motor side for failing connection looseness wear or melting damage NO YES 1 Inspecting the three phase cable 1 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is detected Go to step 2 2 Inspecting the three phase cable 2 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is dete...

Page 471: ...ies Therefore measure the resistance at least 8 hours after the vehi cle has stopped NO YES 3 Inspecting resistance between HV motor phases SHTS03ZZZ0300305 Measurement conditions Tester connections Standard values Starter key LOCK 8 hours after the vehicle has stopped HV motor U phase terminal V phase terminal U phase terminal W phase terminal V phase terminal W phase terminal 38 2 40 5 M 15 30 C...

Page 472: ...ater leakage or clogging 3 Check that the coolant level is appropriate NO YES 4 Inspecting the three phase cable 3 7 8 9 Megohmmeter Megohmmeter SHTS03ZZZ0300306 Measurement conditions Tester connections Standard values Starter key LOCK Three phase cable U terminal V terminal V terminal W terminal W terminal U terminal 10 M or more Is the measured value within the range of standard value Go to ste...

Page 473: ... Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A1B 16 is detected NO YES 6 Inspecting the inverter cooling radiator fan and inverter cooling pump Can the operating sound be checked Go to step 7 Replace the inverter cooling radiator fan or inverter cooling pump After repla...

Page 474: ...inals Replace the terminals if abnormalwear or melting damage is detected Go to step 3 3 Inspecting resistance between HV motor phases 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 Using the electrical tester mea sure the resistance between the HV motor terminals HINT If the motor temperature is too high the resistance largely...

Page 475: ...NO Repair or replace the defective part After repair or replacement add coolant and go to step 6 Go to step 6 6 Inspecting the inverter cool ing radiator fan and inverter cooling pump 1 Set the starter key to the ON position 2 Check the operating sound of inverter cooling radiator fan and inverter cooling pump Operating sound is checked Go to YES Operating sound is not checked Go to NO Go to step ...

Page 476: ...rmally during initialization after ECU activation immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 477: ...eted Temporary actuation of protection function due to external noise P0A1B TC92 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 478: ...diately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 Idling stop is not available...

Page 479: ...eted Temporary actuation of protection function due to external noise P0A1B TC97 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 480: ...ally during initialization after ECU activation immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 s...

Page 481: ...eted Temporary actuation of protection function due to external noise P0A1B TC3F Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 482: ...is 4 04 V or more and 5 95 V or less is detected continu ously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 483: ...eted Temporary actuation of protection function due to external noise P0A1B TCA1 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 484: ...tected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 I...

Page 485: ...eted Temporary actuation of protection function due to external noise P0A1B TCA2 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 486: ...kHz or less is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 w...

Page 487: ...eted Temporary actuation of protection function due to external noise P0A1B TCA3 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 488: ...rmation flag ON Building up normal confirmation flag ON 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 start...

Page 489: ...eted Temporary actuation of protection function due to external noise P0A1B TCA4 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 490: ...nds The NM signal is detected within 0 2 second of the abnormality timer counter 0 008 second of monitoring 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 491: ...eted Temporary actuation of protection function due to external noise P0A1B TCA5 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 492: ...r 0 104 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 Idling stop is not av...

Page 493: ...eted Temporary actuation of protection function due to external noise P0A1B TCA6 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 494: ...ver angle of received data is 6 or less is detected continuously for 0 104 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 wi...

Page 495: ...eted Temporary actuation of protection function due to external noise P0A1B TCA7 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 496: ...ly for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 Idling stop is not...

Page 497: ...eted Temporary actuation of protection function due to external noise P0A1B TCA8 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 498: ...or more and 450 V or less is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 wil...

Page 499: ...ted Temporary actuation of protection function due to external noise P0A1B TCA9 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 t...

Page 500: ...hout phase judgment is not confirmed When the abnormality is not confirmed inverter short circuit with phase judgment is not confirmed 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 u...

Page 501: ...ng tongue terminals of three phase cable motor side for failing connection looseness wear or melting damage NO YES 1 Inspecting the three phase cable 1 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is detected Go to step 2 ...

Page 502: ...he resistance at least 8 hours after the vehi cle has stopped NO YES 2 Inspecting resistance between the HV motor phases SHTS03ZZZ0300320 Measurement conditions Tester connections Standard values Starter key LOCK 8 hours after the vehicle has stopped Insulation resis tance U phase terminal Housing V phase terminal Housing W phase terminal Housing Interphase resis tance U phase terminal V phase ter...

Page 503: ...alfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A1B AA is detected NO YES 3 Inspecting the three phase cable 2 7 8 9 Megohmmeter Megohmmeter SHTS03ZZZ0300321 Measurement conditions Tester connections Standard values Starter key LOCK Three phase cable U terminal V terminal V terminal W...

Page 504: ...ement Check Yes No Yes No 1 Inspecting the three phase cable 1 1 Check the ring tongue termi nals of three phase cable motor side for failing connec tion looseness wear or melt ing damage Defect is found Go to YES Defect is not found Go to NO Retighten the terminals Replace the terminals if abnormalwear or melting damage is detected Go to step 2 ...

Page 505: ...ter the vehicle has stopped Measurement conditions Starter key LOCK 8 hours after the vehicle has stopped Tester connections Insulation resistance U phase terminal Housing V phase terminal Housing W phase terminal Housing Interphase resistance U phase terminal V phase terminal U phase terminal W phase terminal V phase terminal W phase terminal Standard values Insulation resistance See HV motor ins...

Page 506: ...within the range of stan dard value Go to NO Go to step 4 Replace the three phase cable 4 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 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 accelerate and decelerate running for approximately 1 hour...

Page 507: ...voltage is 21 0 V or more and 30 5 V or less is detected contin uously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 equippe...

Page 508: ...eted Temporary actuation of protection function due to external noise P0A1B TCBB Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 509: ...side voltage is 12 2 V or more and 17 7 V or less is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 equ...

Page 510: ...eted Temporary actuation of protection function due to external noise P0A1B TCBC Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 511: ...age is 2 0 V or more and 3 0 V or less is detected continu ously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 512: ...eted Temporary actuation of protection function due to external noise P0A1B TCBD Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 513: ...side voltage is 7 2 V or more and 2 82 V or less is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 equi...

Page 514: ...eted Temporary actuation of protection function due to external noise P0A1B TCBE Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 515: ... V or more and 5 95 V or less is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 516: ...eted Temporary actuation of protection function due to external noise P0A1B TCBF Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 517: ... Correct value CE hex is detected 100 times successively immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ...

Page 518: ...eted Temporary actuation of protection function due to external noise P0A1B TCD3 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 519: ...rror has occurred communication is working properly No sum error has occurred received data are valid 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ...

Page 520: ...eted Temporary actuation of protection function due to external noise P0A1B TCD4 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 521: ...r 0 2 second No receive error has occurred communication is working properly No sum error has occurred received data are valid 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 522: ...eted Temporary actuation of protection function due to external noise P0A1B TCD5 Abnormality in inverter ECU system Inspection Procedure Step Action Description Judgement Check Yes No Yes No 1 Reproduction check HINO DX 1 Set the starter key to the LOCK position 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 ...

Page 523: ...ersion signals from the HV ECU are normal 80 times successively immediately 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 s...

Page 524: ...on system is detected NO YES 1 Check that reading of DTC is available and that no DTC is detected in Fault Information on the diagnosis tool screen NO YES 1 Reading the DTC other system HINO DX SHTS03ZZZ0300331 Is any DTC related to the CAN communication system detected Perform troubleshooting for each of related DTC Go to step 2 2 Reading the DTC HV system HINO DX SHTS03ZZZ0300332 Is any DTC othe...

Page 525: ... minute 3 Set the starter key to the ON position 4 In Fault Information on the diagnosis tool screen check if P0A1D 21 is detected NO YES 3 Reproduction check HINO DX SHTS03ZZZ0300333 Is DTC P0A1D 21 detected Replace the HV ECU The inspection is completed Temporary actuation of protection function due to external noise ...

Page 526: ...shooting for each of related DTC Go to step 2 2 Reading the DTC HV sys tem HINO DX 1 Check that reading of DTC is available and that no DTC is detected in Fault Information on the diagnosis tool screen DTC other than P0A1D 21 is detected Go to YES DTC other than P0A1D 21 is not detected Go to NO Perform trou bleshooting for each of related DTC Go to step 3 3 Reproduction check HINO DX 1 Clear the ...

Page 527: ...d twice 2 Judgement criteria The motor coil temperature deviation Max Min of 2 0 C 35 6 F or less is met twice in 480 seconds 3 Reset condition The motor coil temperature deviation Max Min of more than 2 0 C 35 6 F is met twice in 480 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on th...

Page 528: ...HYBRID TROUBLE SHOOTING 3 524 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of inverter ...

Page 529: ...ical tester measure the resistance between the terminals of PCU harness 12P vehicle side connector NO YES 1 Inspecting the vehicle wire harness SHTS03ZZZ0300335 Measurement conditions Tester connections Standard values Starter key LOCK Motor tempera ture equivalent to the ambient temperature PCU harness 12P vehicle side con nector 4th terminal 8th terminal 16 18 184 1 k 0 50 C 32 122 F Is the meas...

Page 530: ...or temperature sensor connector NO YES 2 Inspecting the motor temperature sensor SHTS03ZZZ0300336 Measurement conditions Tester connections Standard values Starter key LOCK Motor tempera ture sensor con nector sensor side 1st terminal 2nd terminal 16 18 184 1 k 0 50 C 32 122 F Is the measured value within the range of standard value Go to step 3 Replace the HV motor ...

Page 531: ...of PCU harness 12P vehicle side connector NO YES 3 Inspecting the vehicle wire harness for short circuit Vehicle GND SHTS03ZZZ0300337 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector 4th terminal GND 8th terminal GND 4th terminal 8th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to s...

Page 532: ...nspecting the vehicle wire harness for continuity SHTS03ZZZ0300338 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector motor temperature sen sor connector 4th terminal 1st terminal 8th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 5 Replace the vehicle wire harness ...

Page 533: ...e terminals of PCU harness 12P lower side connector NO YES 5 Inspecting the PCU wire harness lower side for short circuit Vehicle GND SHTS03ZZZ0300339 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P lower side con nector 4th terminal GND 8th terminal GND 4th terminal 8th terminal 10 k or more No continuity Is the measured value within the range of standar...

Page 534: ...Fault Information on the diagnosis tool screen check if P0A2B E9 is detected NO YES 6 Inspecting the PCU wire harness lower side for continuity SHTS03ZZZ0300340 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P lower side con nector inverter connector 4th terminal 34th terminal 8th terminal 35th terminal 1 or less With continuity Is the measured value withi...

Page 535: ...ctions PCU harness 12P vehicle side connector 4th terminal 8th terminal Standard values 16 18 184 1 k 0 50 C 32 122 F The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 4 Go to step 2 2 Inspecting the motor temper ature sensor 1 Disconnect the connector of motor temperature sensor 2 Using the elect...

Page 536: ...ange of stan dard value Go to NO Go to step 4 Replace the vehicle wire harness 4 Inspecting the vehicle wire harness for continuity 1 Using the electrical tester mea sure the resistance between the terminals of PCU harness 12P vehicle side connector and motor temperature sensor connector Measurement conditions Starter key LOCK Tester connections PCU harness 12P vehicle side connector Motor tempera...

Page 537: ... inverter connector Measurement conditions Starter key LOCK Tester connections PCU harness 12P lower side connector inverter connector 4th terminal 34th terminal 8th terminal 35th terminal Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 7 Replace the PCU...

Page 538: ...ent criteria The motor coil temperature deviation Max Min of 16 0 C 60 8 F or more is met twice when 480 seconds have passed 3 Reset condition The motor coil temperature deviation Max Min of less than 16 0 C 60 8 F is met twice when 480 seconds have passed 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set ...

Page 539: ...HYBRID TROUBLE SHOOTING 3 535 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of inverter ...

Page 540: ...ical tester measure the resistance between the terminals of PCU harness 12P vehicle side connector NO YES 1 Inspecting the vehicle wire harness SHTS03ZZZ0300343 Measurement conditions Tester connections Standard values Starter key LOCK Motor tempera ture equivalent to the ambient temperature PCU harness 12P vehicle side con nector 4th terminal 8th terminal 16 18 184 1 k 0 50 C 32 122 F Is the meas...

Page 541: ...or temperature sensor connector NO YES 2 Inspecting the motor temperature sensor SHTS03ZZZ0300344 Measurement conditions Tester connections Standard values Starter key LOCK Motor tempera ture sensor con nector sensor side 1st terminal 2nd terminal 16 18 184 1 k 0 50 C 32 122 F Is the measured value within the range of standard value Go to step 3 Replace the HV motor ...

Page 542: ...of PCU harness 12P vehicle side connector NO YES 3 Inspecting the vehicle wire harness for short circuit Vehicle GND SHTS03ZZZ0300345 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector 4th terminal GND 8th terminal GND 4th terminal 8th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to s...

Page 543: ...nspecting the vehicle wire harness for continuity SHTS03ZZZ0300346 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector motor temperature sen sor connector 4th terminal 1st terminal 8th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 5 Replace the vehicle wire harness ...

Page 544: ...e terminals of PCU harness 12P lower side connector NO YES 5 Inspecting the PCU wire harness lower side for short circuit VEHICLE GND SHTS03ZZZ0300347 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P lower side con nector 4th terminal GND 8th terminal GND 4th terminal 8th terminal 10 k or more No continuity Is the measured value within the range of standar...

Page 545: ...Fault Information on the diagnosis tool screen check if P0A2B ED is detected NO YES 6 Inspecting the PCU wire harness lower side for continuity SHTS03ZZZ0300348 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P lower side con nector inverter connector 4th terminal 34th terminal 8th terminal 35th terminal 1 or less With continuity Is the measured value withi...

Page 546: ...ctions PCU harness 12P vehicle side connector 4th terminal 8th terminal Standard values 16 18 184 1 k 0 50 C 32 122 F The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 4 Go to step 2 2 Inspecting the motor temper ature sensor 1 Disconnect the connector of motor temperature sensor 2 Using the elect...

Page 547: ...ange of stan dard value Go to NO Go to step 4 Replace the vehicle wire harness 4 Inspecting the vehicle wire harness for continuity 1 Using the electrical tester mea sure the resistance between the terminals of PCU harness 12P vehicle side connector and motor temperature sensor connector Measurement conditions Starter key LOCK Tester connections PCU harness 12P vehicle side connector Motor tempera...

Page 548: ... inverter connector Measurement conditions Starter key LOCK Tester connections PCU harness 12P lower side connector Inverter connector 4th terminal 34th terminal 8th terminal 35th terminal Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 7 Replace the PCU...

Page 549: ...e and 4 86 V or less for 4 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 Afte...

Page 550: ...ical tester measure the resistance between the terminals of PCU harness 12P vehicle side connector NO YES 1 Inspecting the vehicle wire harness SHTS03ZZZ0300351 Measurement conditions Tester connections Standard values Starter key LOCK Motor tempera ture Equivalent to the ambient temperature PCU harness 12P vehicle side con nector 4th terminal 8th terminal 16 18 184 1 k 0 50 C 32 122 F Is the meas...

Page 551: ...or temperature sensor connector NO YES 2 Inspecting the motor temperature sensor SHTS03ZZZ0300352 Measurement conditions Tester connections Standard values Starter key LOCK Motor tempera ture sensor con nector sensor side 1st terminal 2nd terminal 16 18 184 1 k 0 50 C 32 122 F Is the measured value within the range of standard value Go to step 3 Replace the HV motor ...

Page 552: ...of PCU harness 12P vehicle side connector NO YES 3 Inspecting the vehicle wire harness for short circuit Vehicle GND SHTS03ZZZ0300353 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector 4th terminal GND 8th terminal GND 4th terminal 8th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to s...

Page 553: ...nspecting the vehicle wire harness for continuity SHTS03ZZZ0300354 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector motor temperature sen sor connector 4th terminal 1st terminal 8th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 5 Replace the vehicle wire harness ...

Page 554: ...e terminals of PCU harness 12P lower side connector NO YES 5 Inspecting the PCU wire harness lower side for short circuit Vehicle GND SHTS03ZZZ0300355 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P lower side con nector 4th terminal GND 8th terminal GND 4th terminal 8th terminal 10 k or more No continuity Is the measured value within the range of standar...

Page 555: ...Fault Information on the diagnosis tool screen check if P0A2C DA is detected NO YES 6 Inspecting the PCU wire harness lower side for continuity SHTS03ZZZ0300356 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P lower side con nector inverter connector 4th terminal 34th terminal 8th terminal 35th terminal 1 or less With continuity Is the measured value withi...

Page 556: ...U harness 12P vehicle side connector 4th terminal 8th terminal Standard values 16 18 184 1 k 0 50 C 32 122 F The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 4 Go to step 2 2 Inspecting the motor temper ature sensor 1 Disconnect the connector of motor temperature sensor 2 Using the electrical tes...

Page 557: ...hin the range of stan dard value Go to NO Go to step 4 Replace the vehicle wire harness 4 Inspecting the vehicle wire harness for continuity 1 Using the electrical tester mea sure the resistance between the terminals of PCU harness 12P vehicle side connector and motor temperature sensor connector Measurement conditions Starter key LOCK Tester connections PCU harness 12P vehicle side connector Moto...

Page 558: ...ector and inverter connector Measurement conditions Starter key LOCK Tester connections PCU harness 12P lower side connector Inverter connector 4th terminal 34th terminal 8th terminal 35th terminal Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 7 Replac...

Page 559: ... Motor temperature thermistor voltage remains at 4 86 V or more short circuit or disconnection of control power supply for 2 seconds 3 Reset condition Motor temperature thermistor voltage remains at 0 19 V or more and 4 86 V or less for 4 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms o...

Page 560: ...YBRID TROUBLE SHOOTING 3 556 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of motor temperature sensor Malfunction of inverter ...

Page 561: ...ical tester measure the resistance between the terminals of PCU harness 12P vehicle side connector NO YES 1 Inspecting the vehicle wire harness SHTS03ZZZ0300359 Measurement conditions Tester connections Standard values Starter key LOCK Motor tempera ture Equivalent to the ambient temperature PCU harness 12P vehicle side con nector 4th terminal 8th terminal 16 18 184 1 k 0 50 C 32 122 F Is the meas...

Page 562: ...or temperature sensor connector NO YES 2 Inspecting the motor temperature sensor SHTS03ZZZ0300360 Measurement conditions Tester connections Standard values Starter key LOCK Motor tempera ture sensor con nector sensor side 1st terminal 2nd terminal 16 18 184 1 k 0 50 C 32 122 F Is the measured value within the range of standard value Go to step 3 Replace the HV motor ...

Page 563: ...of PCU harness 12P vehicle side connector NO YES 3 Inspecting the vehicle wire harness for short circuit Vehicle GND SHTS03ZZZ0300361 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector 4th terminal GND 8th terminal GND 4th terminal 8th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to s...

Page 564: ...nspecting the vehicle wire harness for continuity SHTS03ZZZ0300362 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector motor temperature sen sor connector 4th terminal 1st terminal 8th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 5 Replace the vehicle wire harness ...

Page 565: ...e terminals of PCU harness 12P lower side connector NO YES 5 Inspecting the PCU wire harness lower side for short circuit Vehicle GND SHTS03ZZZ0300363 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P lower side con nector 4th terminal GND 8th terminal GND 4th terminal 8th terminal 10 k or more No continuity Is the measured value within the range of standar...

Page 566: ...Fault Information on the diagnosis tool screen check if P0A2D DB is detected NO YES 6 Inspecting the PCU wire harness lower side for continuity SHTS03ZZZ0300364 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P lower side con nector inverter connector 4th terminal 34th terminal 8th terminal 35th terminal 1 or less With continuity Is the measured value withi...

Page 567: ...CU harness 12P vehicle side connector 4th terminal 8th terminal Standard values 16 18 184 1 k 0 50 C 32 122 F The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 4 Go to step 2 2 Inspecting the motor temper ature sensor 1 Disconnect the connector of motor temperature sensor 2 Using the electrical te...

Page 568: ...hin the range of stan dard value Go to NO Go to step 4 Replace the vehicle wire harness 4 Inspecting the vehicle wire harness for continuity 1 Using the electrical tester mea sure the resistance between the terminals of PCU harness 12P vehicle side connector and motor temperature sensor connector Measurement conditions Starter key LOCK Tester connections PCU harness 12P vehicle side connector Moto...

Page 569: ...ector and inverter connector Measurement conditions Starter key LOCK Tester connections PCU harness 12P lower side connector Inverter connector 4th terminal 34th terminal 8th terminal 35th terminal Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 7 Replac...

Page 570: ...etected continuously for 5 seconds 3 Reset condition The state in which the HV motor coil temperature is less than 140 C 284 F is detected continuously for 10 sec onds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ma...

Page 571: ...HYBRID TROUBLE SHOOTING 3 567 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of HV motor ...

Page 572: ... DX to the vehicle 3 Set the starter key to the ON position 4 In Fault Information on the diagnosis tool screen check if any of the following DTC other than P0A2F 33 is detected P0A2C P0A2D NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300367 Is any DTC other than P0A2F 33 detected Perform troubleshooting for each of related DTC Go to step 2 ...

Page 573: ...ition 2 Check the operating sound of HV motor NO YES 2 Inspecting resistance between the HV motor phases SHTS03ZZZ0300368 Measurement conditions Tester connections Standard values Starter key LOCK 8 hours after the vehicle has stopped HV motor U phase terminal V phase terminal U phase terminal W phase terminal V phase terminal W phase terminal 38 2 40 5 M 30 15 C 86 59 F Is the measured value with...

Page 574: ...unction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A2F 33 is detected HINT Monitor Motor temperature on the data monitor to check that the temperature is less than 100 C 212 F NO YES 4 Reproduction check HINO DX SHTS03ZZZ0300369 Is DTC P0A2F 33 detected Replace the inverter The inspection i...

Page 575: ...rom the HV motor 3 Using the electrical tester mea sure the resistance between the HV motor terminals HINT If the motor temperature is too high the resistance will largely vary Therefore measure the resistance at least 8 hours after the vehicle has stopped Measurement conditions Starter key LOCK 8 hours after the vehicle has stopped Tester connections HV motor U phase terminal V phase terminal U p...

Page 576: ...rate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A2F 33 is detected HINT Monitor Motor temperature on the data monitor to check that the temperature is less than 100 C 212 F DTC P0A2F 33 is detected Go to YES DTC P0A2F 33 is not detected Go to NO Replace the inverter The inspec tion is com pleted P0A2F TC33 Abnormality in motor tem...

Page 577: ...2 Judgement criteria The state in which the main circuit element temperature is 122 C 251 6 F or more is detected continuously for 0 2 second 3 Reset condition The state in which the main circuit element temperature is less than 122 C 251 6 F is detected continuously for 0 4 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter starter rel...

Page 578: ...n work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of inverter cooling radiator fan Malfunction of water pump Disconnection or short circuit of harness Improper connector connection or fitting Insufficient coolant or clogging Ma...

Page 579: ...07 P0A93 P0C73 P3128 P3129 P314C P314D NO YES 1 Remove the bottom cover of the PCU 2 Check the inverter radiator inverter cooling radiator fan and the hose for water leakage or clogging 3 Check that the coolant level is appropriate NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300371 Is any DTC other than P03AC 34 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the ...

Page 580: ...rter cooling radiator fan 1 Can the operating sound be checked Go to step 4 Replace the inverter cooling radiator fan After replacement go to step 4 4 Inspecting the voltage of 12 V battery SHTS03ZZZ0300372 Measurement conditions Tester connections Standard values Starter key ON PCU harness 24P vehicle connector 2nd terminal 16th terminal 10 16 V Is the measured value within the range of standard ...

Page 581: ...373 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 24P lower side con nector Inverter start relay connec tor relay block side 3rd terminal 3rd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 6 Replace the PCU wire harness lower side 6 Inspecting the PCU wire harness lower side for short circuit 1 Vehicle...

Page 582: ...ween the 2nd terminal of inverter cooling radiator fan connector and the ground NO YES 7 Inspecting the PCU wire harness lower side for continuity 2 Vehicle GND SHTS03ZZZ0300375 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling radiator fan con nector Inverter start relay connec tor relay block side 1st terminal 5th terminal Inverter cooling radiator fan c...

Page 583: ...pump connector and the ground NO YES 8 Inspecting the PCU wire harness lower side for continuity 3 Vehicle GND SHTS03ZZZ0300376 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling pump connector Inverter start relay connector relay block side 4th terminal 5th terminal Inverter cooling pump connector 1st terminal GND 1 or less With continuity Is the measured ...

Page 584: ...ay connector and the ground NO YES 9 Inspecting the PCU wire harness lower side for continuity 4 Vehicle GND SHTS03ZZZ0300377 Measurement conditions Tester connections Standard values Starter key LOCK Inverter start relay connector relay block side Inverter connector 1st terminal 25th terminal Inverter start relay connector 2nd terminal GND 1 or less With continuity Is the measured value within th...

Page 585: ...s Standard values Starter key LOCK Inverter start relay connector relay block side HV ECU2 connector 1st terminal 27th terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 11 Replace the PCU wire harness lower side 11 Inspecting the PCU wire harness lower side for short circuit 2 Vehicle GND SHTS03ZZZ0300379 Measurement conditions Tester connection...

Page 586: ...rt relay Vehicle GND SHTS03ZZZ0300380 Measurement conditions Tester connections Standard values Starter key ON HV ECU2 connec tor 27th terminal GND 10 16 V Is the measured value within the range of standard value Go to step 13 Replace the HV ECU After replacement go to step 13 13 Inspecting the inverter start relay Vehicle GND SHTS03ZZZ0300381 Measurement conditions Tester connections Standard val...

Page 587: ...Set the starter key to the ON position and check the operating sound of inverter cooling pump NO YES 14 Inspecting the inverter cooling radiator fan 2 Can the operating sound be checked Go to step 15 Replace the inverter cooling radiator fan After replacement go to step 15 15 Inspecting the inverter cooling pump 1 Can the operating sound be checked Go to step 16 Replace the inverter cooling pump A...

Page 588: ...er cooling pump connector and HV ECU2 con nector NO YES 16 Inspecting the PCU wire harness lower side for continuity SHTS03ZZZ0300382 Measurement conditions Tester connections Standard values Starter key LOCK Inverter cooling pump connector HV ECU2 connec tor 3rd terminal 43rd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 17 Replace the PCU ...

Page 589: ...nd decelerate running for approxi mately 1 hour 4 In Fault Information on the diagnosis tool screen check if P0A3C 34 is detected HINT In Data Monitor monitor Coolant temperature and Internal temperature of inverter to check that there is no abnormality NO YES 17 Inspecting the inverter cooling pump 2 HINO DX SHTS03ZZZ0300383 Measurement conditions Measured item Standard values Starter key ON HV w...

Page 590: ...fect is not found Go to NO Repair or replace the defective part After repair or replacement add coolant and go to step 3 Go to step 3 3 Inspecting the inverter cool ing radiator fan 1 1 Set the starter key to the ON position 2 Check the operating sound of inverter cooling radiator fan Operating sound is checked Go to YES Operating sound is not checked Go to NO Go to step 4 Replace the inverter coo...

Page 591: ...a sured value is not within the range of stan dard value Go to NO Go to step 6 Replace the PCU wire har ness lower side 6 Inspecting the PCU wire har ness lower side for short circuit 1 1 Using the electrical tester mea sure the resistance between the 3rd terminal of inverter start relay connector relay block side and the ground Measurement conditions Starter key LOCK Tester connections Inverter s...

Page 592: ...mea sured value is not within the range of stan dard value Go to NO Go to step 8 Replace the PCU wire har ness lower side 8 Inspecting the PCU wire har ness lower side for conti nuity 3 1 Using then electrical tester measure the resistance between the terminals of inverter cooling pump connec tor and inverter start relay con nector relay block side 2 Using the electrical tester mea sure the resist...

Page 593: ...inals of inverter start relay connector relay block side and HV ECU2 connector Measurement conditions Starter key LOCK Tester connections Inverter start relay connector relay block side HV ECU2 connector 1st terminal 27th terminal Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard v...

Page 594: ...1st terminal GND 5th terminal GND Standard values 10 16 V The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 14 Replace the inverter start relay After replacement go to step 14 14 Inspecting the inverter cool ing radiator fan 2 1 Set the starter key to the LOCK position 2 Set the starter key to the...

Page 595: ...o NO Go to step 17 Replace the PCU wire har ness lower side 17 Inspecting the inverter cool ing pump 2 HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Set the starter key to the ON position 3 In Activation Test on the diag nosis tool screen select HV water pump drive duty value 4 Change the operation duty value of inverter cooling pump to check that the wat...

Page 596: ...tool screen check if P0A3C 34 is detected HINT In Data Monitor monitor Coolant temperature and Internal temperature of inverter to check that there is no abnormality DTC P0A3C 34 is detected Go to YES DTC P0A3C 34 is not detected Go to NO Replace the inverter The inspec tion is com pleted Temporary actuation of protection function due to external noise P0A3C TC34 Abnormality in inverter cooling sy...

Page 597: ... High is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 th...

Page 598: ...ear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of resolver position detector Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of inverter ...

Page 599: ...resolver connector NO YES 1 Inspecting the resolver sensor SHTS03ZZZ0300386 Measurement conditions Tester connections Standard values Starter key LOCK Resolver connec tor 8th terminal 4th terminal 6th terminal 2nd terminal 7th terminal 3rd terminal All are equivalent to ambient tem perature 25 C 77 F 7 2 1 44 26 8 5 36 28 5 5 7 Is the measured value within the range of standard value Go to step 2 ...

Page 600: ...vehicle side con nector 1st terminal 2nd 5th 6th 9th 10th 11th terminal 2nd terminal 1st 5th 6th 8th 10th 11th terminal 5th terminal 1st 2nd 6th 9th 10th 11th terminal 6th terminal 1st 2nd 5th 9th 10th 11th terminal 10th terminal 1st 2nd 5th 6th 9th 11th terminal 11th terminal 1st 2nd 5th 6th 9th 10th terminal PCU harness 12P vehicle side con nector GND 1st terminal GND 2nd terminal GND 5th termin...

Page 601: ...wer side con nector 1st terminal 2nd 5th 6th 9th 10th 11th terminal 2nd terminal 1st 5th 6th 8th 10th 11th terminal 5th terminal 1st 2nd 6th 9th 10th 11th terminal 6th terminal 1st 2nd 5th 9th 10th 11th terminal 10th terminal 1st 2nd 5th 6th 9th 11th terminal 11th terminal 1st 2nd 5th 6th 9th 10th terminal PCU harness 12P lower side con nector GND 1st terminal GND 2nd terminal GND 5th terminal GND...

Page 602: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A3F B7 is detected NO YES 4 Reproduction check HINO DX SHTS03ZZZ0300389 Is DTC P0A3F B7 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 603: ...rical tester mea sure the resistance between the terminals of resolver con nector Measurement conditions Starter key LOCK Tester connections Resolver connector 1 8th terminal 4th terminal 2 6th terminal 2nd terminal 3 7th terminal 3rd terminal Standard values All are equivalent to ambient temperature 25 C 77 F 1 7 2 1 44 2 26 8 5 36 3 28 5 5 7 The mea sured value is within the range of stan dard v...

Page 604: ...h 9th 10th 11th terminal 6th terminal 1st 2nd 5th 9th 10th 11th terminal 10th terminal 1st 2nd 5th 6th 9th 11th terminal 11th terminal 1st 2nd 5th 6th 9th 10th terminal PCU harness 12P vehicle side connector GND 1st terminal GND 2nd terminal GND 5th terminal GND 6th terminal GND 10th terminal GND 11th terminal GND Standard values 10 k or more No continuity The mea sured value is within the range o...

Page 605: ...11th terminal GND Standard values 10 k or more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 4 Replace the PCU wire har ness lower side 4 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Connect the diagnosis tool HINO DX...

Page 606: ...he determination condition cos2 sin2 1 378V2 is met in a control cycle Ts ms the 2 ms counter is incremented When the counter exceeds 30 times successively the abnormality is confirmed 3 Reset condition When the following conditions continue for 3 seconds COS2 SIN2 1 378V2 COS2 SIN2 8 511V2 Smoothed absolute revolution value for determining recovery of resolver diagnosis Revolution of 40 r min 4 I...

Page 607: ...er Idling stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of resolver position detector Disconnecti...

Page 608: ...resolver connector NO YES 1 Inspecting the resolver sensor SHTS03ZZZ0300391 Measurement conditions Tester connections Standard values Starter key LOCK Resolver connec tor 8th terminal 4th terminal 6th terminal 2nd terminal 7th terminal 3rd terminal All are equivalent to ambient tem perature 25 C 77 F 7 2 1 44 26 8 5 36 28 5 5 7 Is the measured value within the range of standard value Go to step 2 ...

Page 609: ...vehicle side con nector 1st terminal 2nd 5th 6th 9th 10th 11th terminal 2nd terminal 1st 5th 6th 8th 10th 11th terminal 5th terminal 1st 2nd 6th 9th 10th 11th terminal 6th terminal 1st 2nd 5th 9th 10th 11th terminal 10th terminal 1st 2nd 5th 6th 9th 11th terminal 11th terminal 1st 2nd 5th 6th 9th 10th terminal PCU harness 12P vehicle side con nector GND 1st terminal GND 2nd terminal GND 5th termin...

Page 610: ...S03ZZZ0300393 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector resolver connector 1st terminal 8th terminal 2nd terminal 4th terminal 5th terminal 6th terminal 6th terminal 7th terminal 10th terminal 2nd terminal 11th terminal 3rd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step ...

Page 611: ...wer side con nector 1st terminal 2nd 5th 6th 9th 10th 11th terminal 2nd terminal 1st 5th 6th 8th 10th 11th terminal 5th terminal 1st 2nd 6th 9th 10th 11th terminal 6th terminal 1st 2nd 5th 9th 10th 11th terminal 10th terminal 1st 2nd 5th 6th 9th 11th terminal 11th terminal 1st 2nd 5th 6th 9th 10th terminal PCU harness 12P lower side con nector GND 1st terminal GND 2nd terminal GND 5th terminal GND...

Page 612: ...ZZZ0300395 Measurement conditions Tester connections Standard values PCU harness 12P lower side con nector Inverter 1st terminal 23rd terminal 2nd terminal 24th terminal 5th terminal 12th terminal 6th terminal 14th terminal 10th terminal 13th terminal 11th terminal 15th terminal 9th terminal 27th terminal 1 or less With continuity Is the measured value within the range of standard value Go to step...

Page 613: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A41 C0 is detected NO YES 6 Reproduction check HINO DX SHTS03ZZZ0300396 Is DTC P0A41 C0 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 614: ...er mea sure the resistance between the terminals of resolver con nector Measurement conditions Starter key LOCK Tester connections Resolver connector 1 8th terminal 4th terminal 2 6th terminal 2nd terminal 3 7th terminal 3rd terminal Standard values All are equivalent to ambient temperature 25 C 77 F 1 7 2 1 44 2 26 8 5 36 3 28 5 5 7 The mea sured value is within the range of stan dard value Go to...

Page 615: ...more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Replace the vehicle wire harness 3 Inspecting the vehicle wire harness for continuity 1 Using the electrical tester mea sure the resistance between the terminals of PCU harness 12P vehicle side connector and resolver connector ...

Page 616: ...ity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 5 Replace the PCU wire har ness lower side 5 Inspecting the PCU wire har ness lower side for conti nuity 1 Using the electrical tester mea sure the resistance between the terminals of PCU harness 12P lower side connector and inverter connector ...

Page 617: ... Perform a test run accelerate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A41 C0 is detected DTC P0A41 C0 is detected Go to YES DTC P0A41 C0 is not detected Go to NO Replace the inverter The inspec tion is com pleted Temporary actuation of protection function due to external noise P0A41 TCC0 Resolver range Low abnormality Inspecti...

Page 618: ...he determination condition cos2 sin2 8 511V2 is met in the control cycle Ts ms the 2 ms counter is incremented When the counter exceeds 30 times successively the abnormality is confirmed 3 Reset condition When the following conditions continue for 3 seconds COS2 SIN2 1 378V2 COS2 SIN2 8 511V2 Smoothed absolute revolution value for determining recovery of revolver diagnosis Revolution of 40 r min 4...

Page 619: ...d with the starter Idling stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected 8 Estimated failure factors Malfunction of resolver position detector Disconnection or short cir...

Page 620: ...resolver connector NO YES 1 Inspecting the resolver sensor SHTS03ZZZ0300398 Measurement conditions Tester connections Standard values Starter key LOCK Resolver connec tor 8th terminal 4th terminal 6th terminal 2nd terminal 7th terminal 3rd terminal All are equivalent to ambient tem perature 25 C 77 F 7 2 1 44 26 8 5 36 28 5 5 7 Is the measured value within the range of standard value Go to step 2 ...

Page 621: ...vehicle side con nector 1st terminal 2nd 5th 6th 9th 10th 11th terminal 2nd terminal 1st 5th 6th 8th 10th 11th terminal 5th terminal 1st 2nd 6th 9th 10th 11th terminal 6th terminal 1st 2nd 5th 9th 10th 11th terminal 10th terminal 1st 2nd 5th 6th 9th 11th terminal 11th terminal 1st 2nd 5th 6th 9th 10th terminal PCU harness 12P vehicle side con nector GND 1st terminal GND 2nd terminal GND 5th termin...

Page 622: ...S03ZZZ0300400 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 12P vehicle side con nector Resolver connector 1st terminal 8th terminal 2nd terminal 4th terminal 5th terminal 6th terminal 6th terminal 7th terminal 10th terminal 2nd terminal 11th terminal 3rd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step ...

Page 623: ...wer side con nector 1st terminal 2nd 5th 6th 9th 10th 11th terminal 2nd terminal 1st 5th 6th 8th 10th 11th terminal 5th terminal 1st 2nd 6th 9th 10th 11th terminal 6th terminal 1st 2nd 5th 9th 10th 11th terminal 10th terminal 1st 2nd 5th 6th 9th 11th terminal 11th terminal 1st 2nd 5th 6th 9th 10th terminal PCU harness 12P lower side con nector GND 1st terminal GND 2nd terminal GND 5th terminal GND...

Page 624: ...ZZZ0300402 Measurement conditions Tester connections Standard values PCU harness 12P lower side con nector Inverter 1st terminal 23rd terminal 2nd terminal 24th terminal 5th terminal 12th terminal 6th terminal 14th terminal 10th terminal 13th terminal 11th terminal 15th terminal 9th terminal 27th terminal 1 or less With continuity Is the measured value within the range of standard value Go to step...

Page 625: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A42 C1 is detected NO YES 6 Reproduction check HINO DX SHTS03ZZZ0300403 Is DTC P0A42 C1 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 626: ...ter mea sure the resistance between the terminals of resolver con nector Measurement conditions Starter key LOCK Tester connections Resolver connector 1 8th terminal 4th terminal 2 6th terminal 2nd terminal 3 7th terminal 3rd terminal Standard values All are equivalent to ambient temperature 25 C 77 F 1 7 2 1 44 2 26 8 5 36 3 28 5 5 7 The mea sured value is within the range of stan dard value Go t...

Page 627: ...more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Replace the vehicle wire harness 3 Inspecting the vehicle wire harness for continuity 1 Using the electrical tester mea sure the resistance between the terminals of PCU harness 12P vehicle side connector and resolver connector ...

Page 628: ...ty The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 5 Replace the PCU wire har ness lower side 5 Inspecting the PCU wire har ness lower side for conti nuity 1 Using the electrical tester mea sure the resistance between the terminals of PCU harness 12P lower side connector and inverter connector M...

Page 629: ...Perform a test run accelerate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A42 C1 is detected DTC P0A42 C1 is detected Go to YES DTC P0A42 C1 is not detected Go to NO Replace the inverter The inspec tion is com pleted Temporary actuation of protection function due to external noise P0A42 TCC1 Resolver range High abnormality Inspecti...

Page 630: ...f V phase current value low resolution V phase current value high resolution is more than 75 A 3 Reset condition The following conditions continue for 0 2 second V phase current sensor value high resolution is 0 30 V or more V phase current sensor value high resolution is 4 40 V or less V phase current value low resolution V phase current value high resolution is 75 A or less 4 Indication warning ...

Page 631: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0A51 D6 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300404 Is DTC P0A51 D6 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 632: ... DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0A51 D6 is detected DTC P0A51 D6 is detected Go to YES DTC P0A51 D6 is not detected Go to NO Replace the inverter The inspec ...

Page 633: ...f W phase current value low resolution W phase current value high resolution is more than 75 A 3 Reset condition The following conditions continue for 0 2 second W phase current sensor value high resolution is 0 30 V or more W phase current sensor value high resolution is 4 40 V or less W phase current value low resolution W phase current value high resolution is 75 A or less 4 Indication warning ...

Page 634: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0A51 D7 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300405 Is DTC P0A51 D7 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 635: ... DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0A51 D7 is detected DTC P0A51 D7 is detected Go to YES DTC P0A51 D7 is not detected Go to NO Replace the inverter The inspec ...

Page 636: ... ON Since the SMR 3 side is turned ON 260 seconds or more have passed SMR 1 side control signal is ON 2 Judgement criteria The state in which the inverter DC voltage is less than 100 V is detected continuously for 0 2 second 3 Reset condition When the abnormality is not confirmed the state in which the inverter DC voltage is 100 V or more is detected con tinuously for 0 4 second 4 Indication warni...

Page 637: ...stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of HV motor Malfunction of three phase cable Malfun...

Page 638: ...he HV battery line is detected NO YES 1 In Fault Information on the diagnosis tool screen check if any of the following DTC other than P0A78 13 is detected P0ADC P0ADB P0AE7 P0AE0 P0AE6 P0ADF NO YES 1 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300407 Is DTC P0A95 detected Perform troubleshooting for each of related DTC Go to step 2 2 Reading the DTC HINO DX SHTS03ZZZ0300408 Is any DTC other t...

Page 639: ...ing the DC high voltage cable for continuity 1 INV 2 1 INV SHTS03ZZZ0300409 Measurement conditions Tester connections Standard values Starter key LOCK Inverter high volt age terminal high voltage J B in ECU box P 1 terminal INV terminal N 2 terminal INV terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 4 Replace the DC high voltage cable between...

Page 640: ...oseness wear or melting damage BATT terminal BATT terminal INV terminal INV terminal NO YES 5 Inspecting the high voltage J B in the ECU box BATT BATT INV INV SHTS03ZZZ0300410 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is detected Go to step 6 ...

Page 641: ...continuity 2 BATT BATT BATT OUT BATT OUT SHTS03ZZZ0300411 Measurement conditions Tester connections Standard values Starter key LOCK High voltage J B in battery pack High voltage J B in ECU box BATT OUT ter minal BATT terminal BATT OUT ter minal BATT terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 7 Replace the DC high voltage cable between th...

Page 642: ...3ZZZ0300412 Measurement conditions Tester connections Standard values SMR 1 terminal switch side 3rd terminal 5th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to step 8 Replace the SMR 1 After replacement go to step 8 8 Inspecting the SMR 2 SHTS03ZZZ0300413 Measurement conditions Tester connections Standard values SMR 2 terminal switch side 3rd te...

Page 643: ...3 terminal switch side 3rd terminal 5th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to step 10 Replace the SMR 3 After replacement go to step 10 10 Checking the high voltage J B in the battery pack for short circuit BATT OUT 6 BATT OUT 5 BATT IN 4 BATT IN 3 SHTS03ZZZ0300415 Measurement conditions Tester connections Standard values High voltage J ...

Page 644: ...unction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if DTC P0A78 13 is detected HINT Monitor DC voltage on the data monitor NO YES 11 Reproduction check HINO DX SHTS03ZZZ0300416 Is DTC P0A78 13 detected Replace the inverter The inspection is completed Temporary actuation of protection function du...

Page 645: ... to step 3 3 Inspecting the DC high volt age cable for continuity 1 1 Set the starter key to the LOCK position 2 Remove the inverter terminal block cover and the ECU box terminal block cover 3 Using the electrical tester mea sure the resistance between the terminals of inverter and high voltage J B in the ECU box Measurement conditions Starter key LOCK Tester connections Inverter high voltage term...

Page 646: ...T terminal BATT OUT terminal BATT terminal Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 7 Replace the DC high volt age cable between the high voltage J B in the bat tery pack and the high volt age J B in the ECU box 7 Inspecting the SMR 1 1 Remove the...

Page 647: ...inal 5th terminal Standard values 10 k or more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 10 Replace the SMR 3 After replace ment go to step 10 10 Checking the high voltage J B in the bat tery pack for short circuit 1 Using the electrical tester mea sure the resistance between...

Page 648: ...lerate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis tool screen check if DTC P0A78 13 is detected HINT Monitor DC voltage on the data monitor DTC P0A78 13 is detected Go to YES DTC P0A78 13 is not detected Go to NO Replace the inverter The inspec tion is com pleted Temporary actuation of protection function due to external noise P0A78 TC13 Abnormality in ...

Page 649: ...teria Over voltage signal from the drive circuit ON DC voltage typ 439 V is detected continuously for 0 07 sec ond 3 Reset condition The following condition continues for 0 14 second When the abnormality is not confirmed over voltage signal from the drive circuit ON is not detected 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter High voltag...

Page 650: ...stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of HV motor Malfunction of three phase cable Malfun...

Page 651: ...S 1 Inspecting the DC high voltage cable for continuity 1 INV 2 1 INV SHTS03ZZZ0300418 Measurement conditions Tester connections Standard values Starter key LOCK Inverter high volt age terminal High voltage J B in ECU box P 1 terminal INV terminal N 2 terminal INV terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 2 Replace the DC high voltage ca...

Page 652: ...SHTS03ZZZ0300419 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is detected Go to step 4 4 Inspecting the DC high voltage cable for continuity 2 BATT BATT BATT OUT BATT OUT SHTS03ZZZ0300420 Measurement conditions Tester connections Standard values Starter key LOCK High voltage J B in battery pack High voltage J B in ECU box BATT OUT ter minal B...

Page 653: ...J B in the battery pack for failing connection loose ness wear or damage NO YES 5 Inspecting the DC high voltage cable 2 BATT OUT BATT OUT SHTS03ZZZ0300421 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is detected Go to step 6 6 Inspecting the DC high voltage cable 3 BATT IN BATT IN SHTS03ZZZ0300422 Is any defect found Retighten the terminals ...

Page 654: ...wer side connector NO YES 7 Inspecting the PCU wire harness lower side for continuity 1 SHTS03ZZZ0300423 Measurement conditions Tester connections Standard values Starter key LOCK Inverter connec tor PCU harness 16P lower side connector 38th terminal 2nd terminal 39th terminal 3rd terminal 40th terminal 4th terminal 1 or less With continuity Is the measured value within the range of standard value...

Page 655: ...r side connector NO YES 8 Inspecting the PCU wire harness lower side for continuity 2 SHTS03ZZZ0300424 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P lower side con nector PCU har ness 24P lower side connector 15th terminal 16th terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 9 Replace the PCU wire h...

Page 656: ...ess in the HV battery for continuity SHTS03ZZZ0300425 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P upper side con nector SMR drive connector 2nd terminal 3rd terminal SMR 1 3rd terminal 4th terminal SMR 2 4th terminal 1st terminal SMR 3 15th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to s...

Page 657: ... the high voltage J B SHTS03ZZZ0300426 Measurement conditions Tester connections Standard values Starter key LOCK SMR drive con nector 3rd terminal 2nd terminal SMR 1 4th terminal 2nd terminal SMR 2 1st terminal 2nd terminal SMR 3 SMR 1 70 190 SMR 2 SMR 3 19 50 Is the measured value within the range of standard value Go to step 14 Go to step 11 ...

Page 658: ...als NO YES 11 Inspecting the SMR 1 SHTS03ZZZ0300427 Measurement conditions Tester connections Standard values SMR 1 1st terminal 2nd terminal 70 190 Is the measured value within the range of standard value Go to step 12 Replace the SMR 1 After replacement go to step 12 12 Inspecting the SMR 2 SHTS03ZZZ0300428 Measurement conditions Tester connections Standard values SMR 2 1st terminal 2nd terminal...

Page 659: ...ester measure the resistance between the SMR 3 terminals NO YES 13 Inspecting the SMR 3 SHTS03ZZZ0300429 Measurement conditions Tester connections Standard values SMR 3 1st terminal 2nd terminal 19 50 Is the measured value within the range of standard value Go to step 14 Replace the SMR 3 After replacement go to step 14 ...

Page 660: ...ing the inverter SHTS03ZZZ0300430 Measurement conditions Tester connections Standard values Inverter connec tor unit side 38th terminal 30th terminal 39th terminal 30th terminal 40th terminal 30th terminal 38th terminal 31st terminal 39th terminal 31st terminal 40th terminal 31st terminal 4 0 6 2 k Is the measured value within the range of standard value Go to step 15 Replace the inverter ...

Page 661: ...m a test run accelerate and decelerate running for approxi mately 1 hour 3 In Fault Information on the diagnosis tool screen check if P0A78 14 is detected HINT Monitor DC voltage on the data monitor NO YES 15 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300431 Is any DTC related to the HV battery line detected Perform troubleshooting for each of related DTC Go to step 16 16 Reproduction check H...

Page 662: ...the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 2 Replace the DC high volt age cable between the terminals of inverter and high voltage JB in the ECU box 2 Inspecting the DC high volt age cable 1 1 Check the P and N termi nals of DC high voltage cable inverter side for failing con nection looseness wear or damage Defect is f...

Page 663: ...igh voltage J B in the bat tery pack and the high volt age J B in the ECU box 5 Inspecting the DC high volt age cable 2 1 Check the BATT OUT termi nal and BATT OUT terminal of the high voltage J B in the battery pack for failing connec tion looseness wear or dam age Defect is found Go to YES Defect is not found Go to NO Retighten the terminals Replace the terminals if abnormalwear or melting damag...

Page 664: ...hin the range of stan dard value Go to NO Go to step 8 Replace the PCU wire har ness lower side 8 Inspecting the PCU wire har ness lower side for conti nuity 2 1 Disconnect the connector of PCU harness 24P 2 Using the electrical tester mea sure the resistance between the terminals of PCU harness 16P lower side connector and PCU harness 24P lower side connector Measurement conditions Starter key LO...

Page 665: ... J B 1 Using the electrical tester mea sure the resistance between the SMR 1 terminals Measurement conditions Starter key LOCK Tester connections SMR drive connector 3rd terminal 2nd terminal SMR 1 4th terminal 2nd terminal SMR 2 1st terminal 2nd terminal SMR 3 Standard values SMR 1 70 190 SMR 2 SMR 3 19 50 The mea sured value is within the range of stan dard value Go to YES The mea sured value is...

Page 666: ...dard values 19 50 The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 14 Replace the SMR 3 After replace ment go to step 14 14 Inspecting the inverter 1 Disconnect the inverter con nector 2 Using the electrical tester mea sure the resistance between the terminals of inverter unit side connector Meas...

Page 667: ... detected Go to NO Perform trou bleshooting for each of related DTC Go to step 16 16 Reproduction check HINO DX 1 Clear the malfunction history 2 Perform a test run accelerate and decelerate running for approximately 1 hour 3 In Fault Information on the diagnosis tool screen check if P0A78 14 is detected HINT Monitor DC voltage on the data monitor DTC P0A78 14 is detected Go to YES DTC P0A78 14 is...

Page 668: ... 0 08 seconds 3 Reset condition The state in which the phase currents monitored in control cycles are 415 A or less is detected continuously for 0 16 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ...

Page 669: ...orded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of HV motor Malfunction of three phase cable Malfunction of SMR 1 Malfunction of SMR 2 Malfunction of SMR 3 Blown fuse Disconnection of DC high voltage cable ...

Page 670: ...three phase cable motor side for failing connection looseness wear or melting damage NO YES 1 Inspecting the three phase cable 1 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is detected Go to step 2 2 Inspecting the three phase cable 2 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is dete...

Page 671: ...ies Therefore measure the resistance at least 8 hours after the vehi cle has stopped NO YES 3 Inspecting resistance between HV motor phases SHTS03ZZZ0300434 Measurement conditions Tester connections Standard values Starter key LOCK 8 hours after the vehicle has stopped HV motor U phase terminal V phase terminal U phase terminal W phase terminal V phase terminal W phase terminal 38 2 40 5 M 15 30 C...

Page 672: ...alfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0A78 15 is detected NO YES 4 Inspecting the three phase cable 3 7 8 9 Megohmmeter Megohmmeter SHTS03ZZZ0300435 Measurement conditions Tester connections Standard values Starter key LOCK Three phase cable U terminal V terminal V terminal W...

Page 673: ...als Replace the terminals if abnormalwear or melting damage is detected Go to step 3 3 Inspecting resistance between HV motor phases 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 Using the electrical tester mea sure the resistance between the HV motor terminals HINT If the motor temperature is too high the resistance largely v...

Page 674: ... The mea sured value is not within the range of stan dard value Go to NO Go to step 5 Replace the three phase cable 5 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 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 accelerate and decelerate runn...

Page 675: ...ria When DC voltage does not drop to 100 V or less even after 1 second has passed since discharge is started timeout occurs 3 Reset condition Immediately when discharge is successfully completed 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe Sympto...

Page 676: ... to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of SMR 2 positive terminal side Malfunction of high voltage J B Malfunction of inverter ...

Page 677: ...ve the PCU top cover 4 Using the electrical tester measure the resistance between the terminals of high voltage J B in the battery pack NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300438 Is any DTC other than P0AA1 D8 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the PN cable for short circuit BATT OUT BATT IN SHTS03ZZZ0300439 Measurement conditions Tester conne...

Page 678: ... Standard values SMR 2 terminal switch side 3rd terminal 5th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to step 4 Replace the SMR 2 After replacement go to step 4 4 Inspecting the high voltage J B in the battery pack BATT OUT BATT IN SHTS03ZZZ0300441 Measurement conditions Tester connections Standard values High voltage J B in battery pack BATT ...

Page 679: ...nction history 4 Perform a test run accelerate and decelerate running for approxi mately 1 hour 5 In Fault Information on the diagnosis tool screen check if P0AA1 D8 is detected NO YES 5 Restoration check HINO DX SHTS03ZZZ0300442 Is DTC P0AA1 D8 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 680: ...er 4 Using the electrical tester mea sure the resistance between the terminals of high voltage J B in the battery pack Measurement conditions Starter key LOCK Tester connections High voltage J B in battery pack BATT OUT terminal BATT IN terminal Standard values 10 k or more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the rang...

Page 681: ...lace the high voltage J B in the bat tery pack After replace ment go to step 5 5 Restoration check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Set the starter key to the ON position 3 Clear the malfunction history 4 Perform a test run accelerate and decelerate running for approximately 1 hour 5 In Fault Information on the diagnosis tool screen check if ...

Page 682: ...less 2 Judgement criteria DC voltage DC voltage value obtained at the timing of SMR 2 being turned ON 30 V is detected contin uously for 0 01 second 3 Reset condition DC voltage DC voltage value obtained at the timing of SMR 2 being turned ON Threshold value 30 V is detected continuously for 0 01 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light O...

Page 683: ...lfunction 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Malfunction of SMR 1 precharge Malfunction of SMR 3 negative terminal side Malfunction of high voltage J B Malfunction of inverter ...

Page 684: ... Remove the PCU top cover 4 Remove the system main resistor 5 Using the electrical tester measure the resistance between the terminals of system main resistor NO YES 1 Reading the DTC HINO DX SHTS03ZZZ0300444 Is any DTC other than P0AA4 D9 detected Perform troubleshooting for each of related DTC Go to step 2 2 Inspecting the system main resistor SHTS03ZZZ0300445 Measurement conditions Tester conne...

Page 685: ...for short circuit BATT OUT BATT IN SHTS03ZZZ0300446 Measurement conditions Tester connections Standard values High voltage J B in battery pack BATT OUT ter minal BATT IN terminal 29 5 30 5 Is the measured value within the range of standard value Go to step 4 Go to step 5 4 Inspecting the SMR 1 SHTS03ZZZ0300447 Measurement conditions Tester connections Standard values SMR 1 terminal switch side 3rd...

Page 686: ...ditions Tester connections Standard values SMR 3 terminal switch side 3rd terminal 5th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to step 6 Replace the SMR 3 After replacement go to step 6 6 Inspecting the high voltage J B in the battery pack BATT OUT BATT IN SHTS03ZZZ0300449 Measurement conditions Tester connections Standard values High voltage...

Page 687: ...nction history 4 Perform a test run accelerate and decelerate running for approxi mately 1 hour 5 In Fault Information on the diagnosis tool screen check if P0AA4 D9 is detected NO YES 7 Reproduction check HINO DX SHTS03ZZZ0300450 Is DTC P0AA4 D9 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 688: ...er 4 Remove the system main resis tor 5 Using the electrical tester mea sure the resistance between the terminals of system main resistor Measurement conditions Tester connections Between the terminals of system main resistor Standard values 29 5 30 5 The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to s...

Page 689: ...l Standard values 10 k or more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 6 Replace the SMR 3 After replace ment go to step 6 6 Inspecting the high voltage J B in the bat tery pack 1 Remove SMR 1 or SMR 3 from the high voltage J B in the battery pack 2 Using the electrical tes...

Page 690: ...nd decelerate running for approximately 1 hour 5 In Fault Information on the diagnosis tool screen check if P0AA4 D9 is detected DTC P0AA4 D9 is detected Go to YES DTC P0AA4 D9 is not detected Go to NO Replace the inverter The inspec tion is com pleted Temporary actuation of protection function due to external noise P0AA4 TCD9 SMR 1 and 3 negative side contact sticking Inspection Procedure Step Ac...

Page 691: ...wer supply voltage is 8 V or more 2 Judgement criteria A load short in the SMR 2 signal line is detected continuously for 0 06 seconds 3 Reset condition Normal output of SMR 2 is detected continuously for 0 06 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter High voltage J B High voltage J B D 38 39 40 CON3 38 CON1 CON4 39 CON2 CON4 ...

Page 692: ... is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connec...

Page 693: ... the ground NO YES 1 Inspecting the PCU wire harness lower side for short circuit Vehicle GND SHTS03ZZZ0300452 Measurement conditions Tester connections Standard values Starter key LOCK Inverter connector 39th terminal GND 10 k or more No continuity Is the measured value within the range of standard value Go to step 2 Replace the PCU wire harness lower side 2 Inspecting the wire harness in the HV ...

Page 694: ... SHTS03ZZZ0300454 Measurement conditions Tester connections Standard values Starter key LOCK SMR drive con nector 4th terminal GND 10 k or more No continuity Is the measured value within the range of standard value Go to step 5 Go to step 4 4 Inspecting the SMR 2 SHTS03ZZZ0300455 Measurement conditions Tester connections Standard values SMR 2 terminal exciting coil side 1st terminal 2nd terminal 1...

Page 695: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0ADB 1F is detected NO YES 5 Reproduction check HINO DX SHTS03ZZZ0300456 Is DTC P0ADB 1F detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 696: ...top cover 2 Disconnect the SMR drive con nector from the high voltage J B in the battery pack 3 Using the electrical tester mea sure the resistance between the 3rd terminal of PCU har ness 16P upper side connec tor and the ground Measurement conditions Starter key LOCK Tester connections PCU harness 16P upper side connector 3rd terminal GND Standard values 10 k or more No continuity The mea sured ...

Page 697: ...lace the SMR 2 After replace ment go to step 5 5 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 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 accelerate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis ...

Page 698: ...ol power supply voltage is 8 V or more 2 Judgement criteria A disconnection in SMR 2 output is detected continuously for 0 06 seconds 3 Reset condition Normal output of SMR 2 is detected continuously for 0 06 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter High voltage J B High voltage J B D 38 39 40 CON3 38 CON1 CON4 39 CON2 CON4 4...

Page 699: ... is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connec...

Page 700: ... side for continuity 1 SHTS03ZZZ0300458 Measurement conditions Tester connections Standard values Starter key LOCK Inverter connec tor PCU harness 16P lower side connector 39th terminal 3rd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 2 Replace the PCU wire harness lower side 2 Inspecting the PCU wire harness lower side for continuity 2 VEH...

Page 701: ...drive connector NO YES 3 Inspecting the wire harness in the HV battery for continuity SHTS03ZZZ0300460 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P upper side con nector SMR drive connector 3rd terminal 4th terminal 15th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 4 Replace the mai...

Page 702: ...itions Tester connections Standard values SMR drive con nector high volt age J B side 4th terminal 2nd terminal 19 50 Is the measured value within the range of standard value Go to step 6 Go to step 5 5 Inspecting the SMR 2 SHTS03ZZZ0300461 Measurement conditions Tester connections Standard values SMR 2 terminal exciting coil side 1st terminal 2nd terminal 19 50 Is the measured value within the ra...

Page 703: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0ADC 93 is detected NO YES 6 Reproduction check HINO DX SHTS03ZZZ0300462 Is DTC P0ADC 93 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 704: ... the 15th terminal of PCU har ness 16P lower side connec tor and the ground Measurement conditions Starter key LOCK Tester connections PCU harness 16P lower side connector 15th terminal GND Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Replace the PC...

Page 705: ...a sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Replace the high voltage J B in the bat tery pack After replace ment go to step 6 Replace the SMR 2 After replace ment go to step 6 6 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Connect the diagnosis t...

Page 706: ...wer supply voltage is 8 V or more 2 Judgement criteria A load short circuit in the SMR 3 signal line is detected continuously for 0 06 seconds 3 Reset condition Normal output of SMR 3 is detected continuously for 0 06 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter High voltage J B High voltage J B D 38 39 40 CON3 38 CON1 CON4 39 CO...

Page 707: ... is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connec...

Page 708: ... the ground NO YES 1 Inspecting the PCU wire harness lower side for short circuit Vehicle GND SHTS03ZZZ0300464 Measurement conditions Tester connections Standard values Starter key LOCK Inverter connector 40th terminal GND 10 k or more No continuity Is the measured value within the range of standard value Go to step 2 Replace the PCU wire harness lower side 2 Inspecting the wire harness in the HV ...

Page 709: ... SHTS03ZZZ0300466 Measurement conditions Tester connections Standard values Starter key LOCK SMR drive con nector 1st terminal GND 10 k or more No continuity Is the measured value within the range of standard value Go to step 5 Go to step 4 4 Inspecting the SMR 3 SHTS03ZZZ0300467 Measurement conditions Tester connections Standard values SMR 3 terminal exciting coil side 1st terminal 2nd terminal 1...

Page 710: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0ADF 1E is detected NO YES 5 Reproduction check HINO DX SHTS03ZZZ0300468 Is DTC P0ADF 1E detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 711: ...r 2 Disconnect the SMR drive con nector from the high voltage J B in the battery pack 3 Using the electrical tester mea sure the resistance between the 4th terminal of PCU har ness 16P upper side connec tor and the ground Measurement conditions Starter key LOCK Tester connections PCU harness 16P upper side connector 4th terminal GND Standard values 10 k or more No continuity The mea sured value is...

Page 712: ...lace the SMR 3 After replace ment go to step 5 5 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 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 accelerate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis ...

Page 713: ...ol power supply voltage is 8 V or more 2 Judgement criteria A disconnection in SMR 3 output is detected continuously for 0 06 seconds 3 Reset condition Normal output of SMR 3 is detected continuously for 0 06 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter High voltage J B High voltage J B D 38 39 40 CON3 38 CON1 CON4 39 CON2 CON4 4...

Page 714: ... is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connec...

Page 715: ... side for continuity 1 SHTS03ZZZ0300470 Measurement conditions Tester connections Standard values Starter key LOCK Inverter connec tor PCU harness 16P lower side connector 40th terminal 4th terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 2 Replace the PCU wire harness lower side 2 Inspecting the PCU wire harness lower side for continuity 2 Veh...

Page 716: ...drive connector NO YES 3 Inspecting the wire harness in the HV battery for continuity SHTS03ZZZ0300472 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P upper side con nector SMR drive connector 4th terminal 1st terminal 15th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 4 Replace the mai...

Page 717: ...itions Tester connections Standard values SMR drive con nector high volt age J B side 1st terminal 2nd terminal 19 50 Is the measured value within the range of standard value Go to step 6 Go to step 5 5 Inspecting the SMR 3 SHTS03ZZZ0300473 Measurement conditions Tester connections Standard values SMR 3 terminal exciting coil side 1st terminal 2nd terminal 19 50 Is the measured value within the ra...

Page 718: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0AE0 95 is detected NO YES 6 Reproduction check HINO DX SHTS03ZZZ0300474 Is DTC P0AE0 95 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 719: ... the 15th terminal of PCU har ness 16P lower side connec tor and the ground Measurement conditions Starter key LOCK Tester connections PCU harness 16P lower side connector 15th terminal GND Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Replace the PC...

Page 720: ...a sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Replace the high voltage J B in the bat tery pack After replace ment go to step 6 Replace the SMR 3 After replace ment go to step 6 6 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Connect the diagnosis t...

Page 721: ...ply voltage is 8 V or more 2 Judgement criteria A load short circuit in the SMR 1 signal line is detected continuously for 0 06 seconds 3 Reset condition Normal output of SMR 1 is detected continuously for 0 06 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter High voltage J B High voltage J B D 38 39 40 CON3 38 CON1 CON4 39 CON2 CON4...

Page 722: ...stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector co...

Page 723: ... the ground NO YES 1 Inspecting the PCU wire harness lower side for short circuit Vehicle GND SHTS03ZZZ0300476 Measurement conditions Tester connections Standard values Starter key LOCK Inverter connector 38th terminal GND 10 k or more No continuity Is the measured value within the range of standard value Go to step 2 Replace the PCU wire harness lower side 2 Inspecting the wire harness in the HV ...

Page 724: ... SHTS03ZZZ0300478 Measurement conditions Tester connections Standard values Starter key LOCK SMR drive con nector 3rd terminal GND 10 k or more No continuity Is the measured value within the range of standard value Go to step 5 Go to step 4 4 Inspecting the SMR 1 SHTS03ZZZ0300479 Measurement conditions Tester connections Standard values SMR 1 terminal exciting coil side 1st terminal 2nd terminal 7...

Page 725: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0AE6 1D is detected NO YES 5 Reproduction check HINO DX SHTS03ZZZ0300480 Is DTC P0AE6 1D detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 726: ...r 2 Disconnect the SMR drive con nector from the high voltage J B in the battery pack 3 Using the electrical tester mea sure the resistance between the 2nd terminal of PCU har ness 16P upper side connec tor and the ground Measurement conditions Starter key LOCK Tester connections PCU harness 16P upper side connector 2nd terminal GND Standard values 10 k or more No continuity The mea sured value is...

Page 727: ...lace the SMR 1 After replace ment go to step 5 5 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 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 accelerate and decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis ...

Page 728: ...er supply voltage is 8 V or more 2 Judgement criteria A disconnection in SMR 1 output is detected continuously for 0 06 seconds 3 Reset condition Normal output of SMR 1 is detected continuously for 0 06 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON Inverter High voltage J B High voltage J B D 38 39 40 CON3 38 CON1 CON4 39 CON2 CON4 40 CON3...

Page 729: ...stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector co...

Page 730: ... side for continuity 1 SHTS03ZZZ0300482 Measurement conditions Tester connections Standard values Starter key LOCK Inverter connec tor PCU harness 16P lower side connector 38th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 2 Replace the PCU wire harness lower side 2 Inspecting the PCU wire harness lower side for continuity 2 Veh...

Page 731: ...drive connector NO YES 3 Inspecting the wire harness in the HV battery for continuity SHTS03ZZZ0300484 Measurement conditions Tester connections Standard values Starter key LOCK PCU harness 16P upper side con nector SMR drive connector 2nd terminal 3rd terminal 15th terminal 2nd terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 4 Replace the mai...

Page 732: ...itions Tester connections Standard values SMR drive con nector high volt age J B side 3rd terminal 2nd terminal 19 50 Is the measured value within the range of standard value Go to step 6 Go to step 5 5 Inspecting the SMR 1 SHTS03ZZZ0300485 Measurement conditions Tester connections Standard values SMR 1 terminal exciting coil side 1st terminal 2nd terminal 19 50 Is the measured value within the ra...

Page 733: ...position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if P0AE7 94 is detected NO YES 6 Reproduction check HINO DX SHTS03ZZZ0300486 Is DTC P0AE7 94 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to external noise ...

Page 734: ... the 15th terminal of PCU har ness 16P lower side connec tor and the ground Measurement conditions Starter key LOCK Tester connections PCU harness 16P lower side connector 15th terminal GND Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 3 Replace the PC...

Page 735: ...a sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Replace the high voltage J B in the bat tery pack After replace ment go to step 6 Replace the SMR 1 After replace ment go to step 6 6 Reproduction check HINO DX 1 Connect all the connectors that have been disconnected to restore the system 2 Connect the diagnosis t...

Page 736: ...ne intake air temperature 20 C 68 F 2 Judgement criteria A state in which the deviation Max Min of main circuit element temperature 2 0 C 35 6 F is met 3 times in 120 seconds 3 Reset condition When the abnormality is not confirmed a state in which the deviation Max Min of variable main circuit element temperature 2 0 C 35 6 F is met 3 times in 120 seconds 4 Indication warning or system control reg...

Page 737: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0AEE 22 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300487 Is DTC P0AEE 22 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 738: ...s 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 accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0AEE 22 is detected DTC P0AEE 22 is detected Go to YES DTC P0AEE 22 is not detected Go to NO Replace the inverter ...

Page 739: ...Max Min of main circuit element temperature 18 0 C 64 4 F is met 3 times in 120 seconds 3 Reset condition When the abnormality is not confirmed the state in which the deviation Max Min of variable main circuit element temperature 18 0 C 64 4 F is met 3 times in 120 seconds 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle whe...

Page 740: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0AEE 23 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300488 Is DTC P0AEE 23 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 741: ...s 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 accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0AEE 23 is detected DTC P0AEE 23 is detected Go to YES DTC P0AEE 23 is not detected Go to NO Replace the inverter ...

Page 742: ...s 8 V or more Inverter start signal is ON 2 Judgement criteria A state in which input voltage is less than 0 19 V is detected continuously for 0 1 second 3 Reset condition A state in which input voltage is 0 19 V or more and 4 86 V or less is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON D D D H H H Y Y B B Y D...

Page 743: ...vehicles equipped with a starter will be started with the starter Idling stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failur...

Page 744: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0AEF 24 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300490 Is DTC P0AEF 24 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 745: ...NO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0AEF 24 is detected DTC P0AEF 24 is detected Go to YES DTC P0AEF 24 is not detected Go to NO Replace the inverter The inspe...

Page 746: ...ON 2 Judgement criteria The state in which the voltage of main circuit element temperature sensor is more than 4 86 V is detected for 0 1 second or more 3 Reset condition The state in which the voltage of main circuit element temperature sensor is 0 19 V or more and 4 86 V or less is detected continuously for 0 2 second 4 Indication warning or system control regulation when the DTC is set MIL ON H...

Page 747: ...vehicles equipped with a starter will be started with the starter Idling stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failur...

Page 748: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0AF0 25 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300492 Is DTC P0AF0 25 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 749: ...INO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0AF0 25 is detected DTC P0AF0 25 is detected Go to YES DTC P0AF0 25 is not detected Go to NO Replace the inverter The insp...

Page 750: ... condition When one of the following conditions continues for 0 4 second V phase current sensor value low resolution Ach or Bch is 539 LSB or less V phase current sensor value low resolution Ach or Bch is 482 LSB or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backu...

Page 751: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEA B3 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300493 Is DTC P0BEA B3 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 752: ...ol HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEA B3 is detected DTC P0BEA B3 is detected Go to YES DTC P0BEA B3 is not detected Go to NO Replace the inverter The ...

Page 753: ... V phase current deviation absolute value filtering is Deviation threshold Revolution correction item Offset or less At the same time the final torque command value is less than 111 2 Nm 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe Symptoms on th...

Page 754: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEA B4 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300494 Is DTC P0BEA B4 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 755: ...ol HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEA B4 is detected DTC P0BEA B4 is detected Go to YES DTC P0BEA B4 is not detected Go to NO Replace the inverter The ...

Page 756: ...tage low resolution Ach or Bch is 0 29 V or more and 4 71 V or less is detected continuously for 0 2 second for each ch 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ...

Page 757: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEB 9A is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300495 Is DTC P0BEB 9A detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 758: ... DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEB 9A is detected DTC P0BEB 9A is detected Go to YES DTC P0BEB 9A is not detected Go to NO Replace the inverter The inspec ...

Page 759: ...ltage low resolution Ach or Bch is 0 29 V or more and 4 71 V or less is detected continuously for 0 2 second for each ch 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 760: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEC 9B is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300496 Is DTC P0BEC 9B detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 761: ... DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEC 9B is detected DTC P0BEC 9B is detected Go to YES DTC P0BEC 9B is not detected Go to NO Replace the inverter The inspec ...

Page 762: ... condition When one of the following conditions continues for 0 4 second W phase current sensor value low resolution Ach or Bch is 539 LSB or less W phase current sensor value low resolution Ach or Bch is 482 LSB or more 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backu...

Page 763: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEE B5 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300497 Is DTC P0BEE B5 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 764: ...ol HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEE B5 is detected DTC P0BEE B5 is detected Go to YES DTC P0BEE B5 is not detected Go to NO Replace the inverter The ...

Page 765: ...ed the value after W phase current deviation absolute value filtering is Devi ation threshold value Revolution correction item Offset or less At the same time the final torque command value is less than 111 2 Nm 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control...

Page 766: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEE B6 is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300498 Is DTC P0BEE B6 detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 767: ...ol HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEE B6 is detected DTC P0BEE B6 is detected Go to YES DTC P0BEE B6 is not detected Go to NO Replace the inverter The ...

Page 768: ...w resolution Ach or Bch is 0 29 V or more and 4 71 V or less is detected continuously for 0 2 second for each ch 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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 ho...

Page 769: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEF 9C is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300499 Is DTC P0BEF 9C detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 770: ... DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BEF 9C is detected DTC P0BEF 9C is detected Go to YES DTC P0BEF 9C is not detected Go to NO Replace the inverter The inspec ...

Page 771: ...ltage low resolution Ach or Bch is 0 29 V or more and 4 71 V or less is detected continuously for 0 2 second for each ch 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON 5 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...

Page 772: ...lfunction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BF0 9D is detected NO YES 1 Reproduction check HINO DX SHTS03ZZZ0300500 Is DTC P0BF0 9D detected Replace the inverter The inspection is completed Temporary actuation of protection function due to e...

Page 773: ... DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history 5 Perform a test run accelerate and decelerate running for approximately 1 hour 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if P0BF0 9D is detected DTC P0BF0 9D is detected Go to YES DTC P0BF0 9D is not detected Go to NO Replace the inverter The inspec ...

Page 774: ...signal is ON Since the SMR 3 side is turned ON 260 seconds or more have passed SMR 1 side control signal is ON 2 Judgement criteria The state in which the inverter DC voltage is less than 100 V is detected continuously for 0 2 second 3 Reset condition When the abnormality is not confirmed the state in which the inverter DC voltage is 100 V or more is detected con tinuously for 0 4 second 4 Indicat...

Page 775: ...ontrol fail safe Symptoms on the vehicle due to malfunction 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Reduction in HV battery voltage ...

Page 776: ...he HV battery line is detected NO YES 1 In Fault Information on the diagnosis tool screen check if any of the following DTCs other than P3126 12 is detected P0ADC P0ADB P0AE7 P0AE0 P0AE6 P0ADF NO YES 1 Inspecting the HV battery ECU HINO DX SHTS03ZZZ0300502 Is DTC P0A95 detected Perform troubleshooting for each of related DTC Go to step 2 2 Reading the DTC HINO DX SHTS03ZZZ0300503 Is any DTC other ...

Page 777: ...ing the DC high voltage cable for continuity 1 INV 2 1 INV SHTS03ZZZ0300504 Measurement conditions Tester connections Standard values Starter key LOCK Inverter high volt age terminal High voltage J B in ECU box P 1 terminal INV terminal N 2 terminal INV terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 4 Replace the DC high voltage cable between...

Page 778: ...ction looseness wear or melting damage BATT terminal BATT terminal INV terminal INV terminal NO YES 5 Inspecting the high voltage J B in the ECU box BATT BATT INV INV SHTS03ZZZ0300505 Is any defect found Retighten the terminals Replace the terminals if abnormal wear or melting damage is detected Go to step 6 ...

Page 779: ...continuity 2 BATT BATT BATT OUT BATT OUT SHTS03ZZZ0300506 Measurement conditions Tester connections Standard values Starter key LOCK High voltage J B in battery pack High voltage J B in ECU box BATT OUT ter minal BATT terminal BATT OUT ter minal BATT terminal 1 or less With continuity Is the measured value within the range of standard value Go to step 7 Replace the DC high voltage cable between th...

Page 780: ...3ZZZ0300507 Measurement conditions Tester connections Standard values SMR 1 terminal switch side 3rd terminal 5th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to step 8 Replace the SMR 1 After replacement go to step 8 8 Inspecting the SMR 2 SHTS03ZZZ0300508 Measurement conditions Tester connections Standard values SMR 2 terminal switch side 3rd te...

Page 781: ...3 terminal switch side 3rd terminal 5th terminal 10 k or more No continuity Is the measured value within the range of standard value Go to step 10 Replace the SMR 3 After replacement go to step 10 10 Checking the high voltage J B in the battery pack for short circuit BATT OUT 6 BATT OUT 5 BATT IN 4 BATT IN 3 SHTS03ZZZ0300510 Measurement conditions Tester connections Standard values High voltage J ...

Page 782: ...unction history 5 Perform a test run accelerate and decelerate running for approxi mately 1 hour 6 In Fault Information on the diagnosis tool screen check if DTC P3126 12 is detected HINT Monitor DC voltage on the data monitor NO YES 11 Reproduction check HINO DX SHTS03ZZZ0300511 Is DTC P3126 12 detected Replace the inverter The inspection is completed Temporary actuation of protection function du...

Page 783: ...elated DTC Go to step 3 3 Inspecting the DC high volt age cable for continuity 1 1 Set the starter key to the LOCK position 2 Remove the inverter terminal block cover and the ECU box terminal block cover 3 Using the electrical tester mea sure the resistance between the terminals of inverter and high voltage J B in the ECU box Measurement conditions Starter key LOCK Tester connections Inverter high...

Page 784: ...erminal BATT OUT terminal BATT terminal Standard values 1 or less With continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 7 Replace the DC high volt age cable between the high voltage J B in the bat tery pack and the high volt age J B in the ECU box 7 Inspecting the SMR 1 1 Remove the SM...

Page 785: ...rminal Standard values 10 k or more No continuity The mea sured value is within the range of stan dard value Go to YES The mea sured value is not within the range of stan dard value Go to NO Go to step 10 Replace the SMR 3 After replace ment go to step 10 10 Checking the high voltage J B in the bat tery pack for short circuit 1 Using the electrical tester mea sure the resistance between the termin...

Page 786: ... decelerate running for approximately 1 hour 6 In Fault Information on the diagnosis tool screen check if DTC P3126 12 is detected HINT Monitor DC voltage on the data monitor DTC P3126 12 is detected Go to YES DTC P3126 12 is not detected Go to NO Replace the inverter The inspec tion is com pleted Temporary actuation of protection function due to external noise P3126 TC12 Abnormality in inverter s...

Page 787: ...more has passed 2 Judgement criteria Detection of control CAN bus off continues for 0 5 second in total 3 Reset condition A communication available state continues for 1 second 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON ABS ECU CAN H2 CAN L2 HV PCU HV ECU Inverter 7 6 CA1 CA1 3 2 CA2 CA2 9 18 7 19 8 20 J C CAN2 9 18 7 19 8 20 J C CAN1 AT ECU Cl...

Page 788: ... Idling stop is not available The regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper conn...

Page 789: ... ECU and inverter 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0073 91 is detected NO YES 1 Implementing common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduction che...

Page 790: ...reen check if DTC U0073 11 abnormality in control CAN communication is detected in the HV ECU NO YES 3 Inspecting the HV ECU HINO DX SHTS03ZZZ0300514 Is DTC U0073 11 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the inverter ...

Page 791: ...the starter key to the ON position 4 Clear the malfunction history of the HV ECU and inverter 5 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0073 91 is detected DTC U0073 91 is detected Go to YES DTC U0073 91 is not detected Go to NO Go to step 3 The inspec tion is...

Page 792: ...state continues for 1 second 4 Indication warning or system control regulation when the DTC is set MIL OFF HV warning light ON 9 8 CANN VCS ECU Engine ECU CANP 5 4 L H L H L H L H CANL CANH 4 3 16 5 17 6 15 14 J C CAN 2 Telematics information 17 6 2 13 4 15 J C CAN1 22P Diagnosis connector DLC ATM ECU Clutch ECU CAN H CAN L CAN H CAN L CAN H CAN L CAN H CAN L DCU CAL 1 CAH 1 14 6 4 15 CAN H CAN L ...

Page 793: ... 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Disconnection or short circuit of harness Improper connector connection or fitting Malfunction of inverter Malfunction of ECU connected with DIAG CAN ...

Page 794: ...position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if U0074 3E is detected NO YES 1 Implementing common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Reproduction check HINO DX SHTS03ZZZ0300516 Is DTC U0074 3E detected...

Page 795: ...tep 2 2 Reproduction check HINO DX 1 Set the starter key to the LOCK position 2 Connect the diagnosis tool HINO DX to the vehicle 3 Set the starter key to the ON position 4 Clear the malfunction history of the HV ECU and inverter 5 Set the starter key to the LOCK position and wait for approximately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool scree...

Page 796: ...ca tion judgment time 0 6 second Reception cycle 10 In case of command value information Continuously for 0 68 second In case of sync task signal Continuously for 1 1 second 3 Reset condition Immediately when all frames from the HV ECU are normally received twice 4 Indication warning or system control regulation when the DTC is set MIL ON HV warning light ON ABS ECU CAN H2 CAN L2 HV PCU HV ECU Inv...

Page 797: ...e regeneration function stops reducing the feeling of deceleration during deceleration 6 Pre inspection work Check the battery voltage to make sure that there is no abnormality 7 After inspection work Clear the recorded DTC Check that no DTC is detected after test driving the vehicle 8 Estimated failure factors Temporary communication blackout due to noise Disconnection or short circuit of harness...

Page 798: ...r and vehicle control ECU 5 Set the starter key to the LOCK position and wait for approxi mately 1 minute 6 Set the starter key to the ON position 7 In Fault Information on the diagnosis tool screen check if DTC U0293 31 is detected NO YES 1 Implementing common inspection items Is any defect found Repair or replace the malfunctioning part detected by the common inspection items Go to step 2 2 Repr...

Page 799: ... Fault Information on the diagnosis tool screen check if P0A1B 92 Control CAN register stuck is detected in the inverter NO YES 3 Inspecting the HV ECU CAN register HINO DX SHTS03ZZZ0300519 Is DTC P0A1D 12 detected Replace the HV ECU Go to step 4 4 Inspecting the inverter CAN register HINO DX SHTS03ZZZ0300520 Is DTC P0A1B 92 detected Replace the inverter Go to step 5 ...

Page 800: ...communication is detected in the inverter NO YES 5 Inspecting the HV ECU communication abnormality HINO DX SHTS03ZZZ0300521 Is DTC U0073 11 detected Perform troubleshooting for each of related DTC Perform troubleshooting of U0073 11 Step 2 and onward Go to step 6 6 Inspecting the inverter communication abnormality HINO DX SHTS03ZZZ0300522 Is DTC U0073 91 detected Perform troubleshooting for each o...

Page 801: ...0110 14 in the HV ECU U110A Vehicle control ECU CAN communication blackout U0101 AT ECU CAN communication blackout U1136 Clutch ECU CAN communication blackout U0121 ABS ECU CAN communication blackout U0155 Meter CAN communication blackout NO YES 7 Inspecting the HV ECU communication blackout HINO DX SHTS03ZZZ0300523 Is DTC U0110 14 detected Go to step 8 Go to step 10 8 Reading the DTC 1 HINO DX SH...

Page 802: ...ol screen check if DTC U0293 HV ECU CAN communication blackout is detected in the vehicle control ECU NO YES 9 Inspecting the vehicle control ECU 1 HINO DX SHTS03ZZZ0300525 Is DTC U0155 detected Refer to the CONTROL CAN COMMUNICA TION LINE HYBRID in the chapter CON TROL SYSTEM Replace the HV ECU 10 Inspecting the vehicle control ECU 2 HINO DX SHTS03ZZZ0300526 Is DTC U0293 detected Replace the HV E...

Page 803: ... detected Go to YES DTC U0293 31 is not detected Go to NO Go to step 3 The inspec tion is com pleted Temporary actuation of protection function due to external noise or connector terminal con tact resis tance return 3 Inspecting the HV ECU CAN register HINO DX 1 In Fault Information on the diagnosis tool screen check if DTC P0A1D 12 Control CAN register stuck is detected in the HV ECU DTC P0A1D 12...

Page 804: ...communication black out U0101 AT ECU CAN com munication blackout U1136 Clutch ECU CAN communication blackout U0121 ABS ECU CAN communication blackout U0155 Meter CAN commu nication blackout All communi cationblackout DTCs are detected Go to YES All communi cationblackout DTCs are not detected Go to NO Go to step 9 All communi cation black outs have been occurred Go to step 10 9 Inspecting the vehi...

Page 805: ...Hino Motors Sales U S A Inc 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 41180 Bridge Street Novi MI 48375 Telephone 248 699 9300 ...

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Hino 195h Series, Workshop Manual

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Summary of Contents for 195h Series

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