Hino 238 Workshop Manual Download Page 570

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DEF SCR SYSTEM (DCU)

5–4

SYSTEM BLOCK DIAGRAM

EN01H16F02040F03001002

Diagnostic tool

diagnosis

FUSE

DEF pump

Exhaust gas temperature sensor (SCR Inlet)

Key Switch signal

DEF pump motor drive power

H
E
R
S

CAN communication(Engine ECU, NOx sensor)

T
P

Battery

N
P
U

SCR

Muffler

Power source

DEF injector drive signal

DEF injector

DEF pump temperature sensor 1

DEF pump motor drive signal

Reverting valve drive signal

DEF tank heater valve drive signal

DEF tank heater valve

DEF tank temperature
sensor

DEF tank level sensor

DEF tank

Ambient air temperature sensor

DEF pump temperature sensor 2

DCU
temperature
sensor 1
(DCU built-in)

DCU
temperature
sensor 2
(DCU built-in)

DEF line pressure sensor

Engine ECU

I/F

CAN communication(Diagnosis, Engine ECU)

NOx sensor (SCR upstream)

NOx sensor (SCR downstream)

SAPH16F020400002

Summary of Contents for 238

Page 1: ...information and specifications in this manual are based upon the latest product information available at the time of printing Hino Motors Sales U S A Inc reserves the right to make changes at any time without prior notice Please note that the publications below have also been prepared as relevant workshop manuals for the components and systems in these vehicles Manual Name Pub No Chassis Workshop ...

Page 2: ...ODELS HINO 238 258LP 268 338 358 Production Code NE8J NF8J NJ8J NV8J GENERAL INTRODUCTION 1 001 TROUBLE SHOOTING COMPONENTS 2 001 TROUBLE SHOOTING ELECTRICAL CONTROL SYSTEM 3 001 ENGINE CONTROL SYSTEM J08E 4 001 DEF SCR SYSTEM DCU 5 001 BURNER CONTROL SYSTEM BCU 6 001 BRAKE CONTROL SYSTEM 9 001 ABS HYDRAULIC E VERSION 9 002 ABS FULL AIR VEHICLE CONTROL SYSTEM VCS 11 001 CAN COMMUNICATION 12 001 DX...

Page 3: ...ANUAL GENERAL INTRODUCTION TROUBLE SHOOTING COMPONENTS TROUBLE SHOOTING ENGINE CONTROL SYSTEM J08E DEF SCR SYSTEM DCU BURNER CONTROL SYSTEM BCU BRAKE CONTROL SYSTEM VEHICLE CONTROL SYSTEM VCS CAN COMMUNICATION ELECTRICAL CONTROL SYSTEM ...

Page 4: ...C P0115 4 219 DTC P0117 and P0118 4 231 DTC P011A 4 241 DTC P011C 4 252 DTC P0122 and P0123 4 260 DTC P0128 4 273 DTC P016E and P016F 4 280 DTC P0182 and P0183 4 304 DTC P0191 4 313 DTC P0192 and P0193 4 335 DTC P01A5 4 346 DTC P01A6 4 355 DTC P0200 4 364 DTC P0201 P0202 P0203 P0204 P0205 and P0206 4 367 DTC P0217 4 376 DTC P0219 4 383 DTC P0222 and P0223 4 390 DTC P0234 4 402 DTC P0237 4 409 DTC ...

Page 5: ...1 DTC P20EE 4 943 DTC P2100 4 955 DTC P2101 4 962 DTC P2103 4 970 DTC P2120 4 977 DTC P2122 and P2123 4 982 DTC P2127 and P2128 4 991 DTC P2135 4 1002 DTC P2138 4 1009 DTC P2146 4 1015 DTC P2147 and P2148 4 1023 DTC P2149 4 1032 DTC P2150 and P2151 4 1040 DTC P2184 and P2185 4 1049 DTC P2214 4 1058 DTC P2227 4 1072 DTC P2228 and P2229 4 1077 DTC P2269 4 1082 DTC P226C 4 1088 DTC P22D3 4 1097 DTC P...

Page 6: ... conditions described above remain for 5 seconds or longer 2 Judgement criteria Output of the starter cut relay remains at 10 V or less for 3 seconds or longer 3 Reset condition Just after restoration to normal condition 4 Indication warning or system control regulation when the DTC is set MIL OFF Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup con...

Page 7: ...After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Harness disconnection or short circuit Looseness or poor contact of connector starter cut relay failure Engine ECU failure ...

Page 8: ... YES 1 Check the connection of the starter cut relay connector Loose ness and poor contact NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300633 Has DTC P081A been detected Go to step 2 Replace the starter cut relay Perform After inspection work of INFOR MATION section 2 Inspect the starter cut relay connector Was any failure found Connect securely repair if needed Perf...

Page 9: ...O YES 3 Inspect for disconnection in wire harness of starter cut relay A B V2 V80 SAPH16F010300634 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness STCR V2 PGD4 V80 Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perform After inspection work of INFOR MATION section 4 Check the DTC detected Engine ECU...

Page 10: ...orm After inspection work of INFORMA TION section Go to step 3 3 Inspect for dis connection in wire harness of starter cut relay Connect the signal check harness to the engine ECU and measure the resistance between the termi nals of the engine ECU signal check harness Tester connections Engine ECU signal check har ness STCR V2 PGD4 V80 Standard values The measure ments meet the standard value Go t...

Page 11: ...5 seconds 2 Judgement criteria Output of the starter cut relay remains at 10 V or more for 3 seconds or longer 3 Reset condition After restoration to normal condition 4 Indication warning or system control regulation when the DTC is set MIL OFF Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to...

Page 12: ...After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Harness disconnection or short circuit Looseness or poor contact of connector Starter cut relay failure Engine ECU failure ...

Page 13: ...he engine ECU signal check harness NO YES 1 Inspect the starter cut relay connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect for disconnection in wire harness of starter cut relay A B V2 V80 SAPH16F010300637 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check ...

Page 14: ... P081B has been detected in Fault Information NO YES 3 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300638 Has DTC P081B been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 15: ...k harness to the engine ECU and measure the resistance between the termi nals of the engine ECU signal check harness Tester connections Engine ECU signal check har ness STCR V2 PGD4 V80 Standard values 3 V or less The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Repair or replace the harness Perform After inspection work of...

Page 16: ...d below remains for 10 seconds Vehicle speed is 31 25 miles h or higher Battery voltage is in the range of 10 V to 16 V After that vehicle speed is 0 miles h 2 Judgement criteria The neutral switch cannot be switched twice 3 Reset condition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Cruise control is not...

Page 17: ...ise control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Harness disconnection or short circuit Malfunction of neutral switch Malfunction of ECU ...

Page 18: ...ral switch 1 Inspect the neutral switch Was any failure found Adjust the neutral switch Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the neutral switch connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 3 Inspect the neutral switch unit NRF NRE SAPH16F010300640 Measurement conditions T...

Page 19: ...ace the neutral switch Perform After inspection work of INFOR MATION section 4 Inspect the power supply of the neutral switch NRE NRF SAPH16F010300641 Measurement conditions Tester connections Standard values Starter switch ON Neutral switch vehi cle side connector NRE Ground More than 10 V Do the measurements meet the standard value Go to step 5 Repair the neutral switch power circuit Perform Aft...

Page 20: ... the termi nals of the engine ECU signal check harness and ground NO YES 5 Inspect the neutral switch harness A V11 SAPH16F010300642 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness NUSW V11 Ground Shift lever in N posi tion 10 V Shift lever in any other position 0 5 V Do the measurements meet the standard value Replace the engine ECU Perf...

Page 21: ...al switch unit Measure the resistance between the terminals of the neutral switch Tester connections Neutral switch NRE NRF Standard values Shift lever in N position 1 Shift lever in any other position The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Replace the neutral switch Perform After inspection work of INFORMA TION s...

Page 22: ...ness NUSW V11 Ground Standard values Shift lever in N position 10 V Shift lever in any other position 0 5 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Replace the engine ECU Perform After inspection work of INFORMA TION section Repair or replace the harness Perform After inspection work of INFORMA TION section DTC P0850 Neutral sw...

Page 23: ...witch ON Battery voltage is in the range of 10 V to 16 V The conditions described above remain for 5 seconds or longer 2 Judgement criteria Sensor voltage remains at 4 82 V or higher for 3 seconds or longer 3 Reset condition After normal operation is restored and starter switch is turned LOCK Engine ECU PTO accelerator sensor K95 ET4 ET2 EXPS ADG9 AVC5 LCG KR4 GND3 TEX3 KUH LCT KUQ VOUT GND KSK KS...

Page 24: ...cle due to backup control fail safe function Body mounting control is not working Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Faulty harness B short circuit Malfunction of sensor Failure in engine ECU sensor ...

Page 25: ... dirt or damage to the PTO accelerator sen sor NO YES 1 Inspect the PTO accelerator sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the PTO accelerator sensor Was any failure found Clean the PTO accelerator sensor and install it properly If damaged replace the sensor Perform After inspection work ...

Page 26: ...terminals of the PTO accelerator sensor NO YES 3 Inspect the PTO accelerator sensor unit VCC SIG GND SIG SAPH16F010300644 Measurement conditions Tester connections Standard values Starter switch LOCK PTO accelerator sensor SIG VCC SIG GND More than 2 Do the measurements meet the standard value Go to step 4 Replace the PTO accelerator sensor Perform After inspection work of INFOR MATION section ...

Page 27: ...heck harness and ground NO YES 4 Inspect for short circuit of the PTO accelerator sensor harness B B V71 V68 V45 SAPH16F010300645 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness ASCS V68 Ground AVC5 V71 Ground ADG7 V45 Ground Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection ...

Page 28: ...r sensor harness B B V45 V68 V71 V68 SAPH16F010300646 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness ASCS V68 AVC5 V71 ASCS V68 ADG7 V45 More than 2 Do the measurements meet the standard value Go to step 6 Repair or replace the harness Perform After inspection work of INFOR MATION section 6 Check the DTC detected Engine ECU Hino DX Sel...

Page 29: ...NFORMA TION section Go to step 3 3 Inspect the PTO accelera tor sensor unit Disconnect the PTO accelerator sensor connector and measure the resistance between the termi nals of the PTO accelerator sen sor Tester connections PTO accelerator sensor SIG VCC SIG GND Standard values More than 2 The measure ments meet the standard value Go to YES Go to step 4 Replace the sensor Perform After inspection ...

Page 30: ...measure ments do not meet the stan dard value Go to NO Go to step 6 Repair or replace the harness Perform After inspection work of INFORMA TION section 6 Check the DTC detected Engine ECU Hino DX Check if P1133 has been detected in Engine DTC P1133 has been detected Go to YES No DTC has beendetected Go to NO Replace the engine ECU Perform After inspection work of INFORMA TION section Procedure com...

Page 31: ... to 2 Judgement criteria P119F is detected under the conditions described below 1 and 2 represent the order of priority 1 A difference in voltage remains higher than 1 06 V for 3 seconds or longer 2 A difference in voltage remains less than 0 04 V for 3 seconds or longer 3 Reset condition After normal operation is restored and starter switch LOCK 4 Indication warning or system control regulation w...

Page 32: ... Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Sensor disconnected from measuring site Harness disconnection or short circuit Abnormal resistance of sensor Malfunction of ECU ...

Page 33: ...n Fault Information NO YES 1 Check the connection of the common rail pressure sensor connec tor Looseness and poor contact NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300649 Has a DTC other than P119F been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the common rail pressure sensor connector Was any failure found Connect securely ...

Page 34: ...s of the engine ECU signal check harness NO YES 3 Inspect the sensor power supply C D D E13 E33 E76 E56 E49 E56 E68 E64 E76 E65 SAPH16F010300650 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness AVC1 E13 AGD1 E56 PCR1 E49 AGD1 E56 PCR2 E68 AGD1 E56 AVC2 E33 AGD2 E76 PCR3 E64 AGD2 E76 PCR4 E65 AGD2 E76 4 5 5 5 V Do the measurements meet the ...

Page 35: ...ation NO YES 4 Inspect the signal of the common rail pressure sensor D E49 E68 E65 E64 SAPH16F010300651 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness PCR1 E49 PCR3 E64 PCR1 E49 PCR4 E65 PCR2 E68 PCR3 E64 PCR2 E68 PCR4 E65 0 3 0 7 V Do the measurements meet the standard value Go to step 5 Replace the common rail pressure sensor Perform A...

Page 36: ...tor Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the sensor power supply 1 Connect the signal check harness to the engine and disconnect the common rail pressure sensor connector 2 Measure the voltage between the terminals of the engine ECU signal check har...

Page 37: ...e ments do not meet the stan dard value Go to NO Go to step 5 Replace the sensor Perform After inspection work of INFORMA TION section 5 Check the DTC detected 2 Engine ECU Hino DX 1 Perform engine warm up engine coolant tempera ture 60 C 140 F or more 2 Check if P119F has been detected in Engine DTC P119F has been detected Go to YES No DTC has beendetected Go to NO Replace the engine ECU Perform ...

Page 38: ...teria 3 Reset condition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Chec...

Page 39: ...tarter switch to the ON position 4 Select Engine and check if P141F has been detected in Fault Information NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300653 Has DTC P141F been detected Go to DTC separate trouble diagnosis of the burner system BCU Procedure completed Perform After inspection work of INFOR MATION section ...

Page 40: ...ion Judgement Check Yes No Yes No 1 Check the DTC detected Engine ECU Hino DX Check if P141F has been detected in Engine DTC P141F has been detected Go to YES No DTC has beendetected Go to NO Go to DTC separate trou ble diagnosis of the burner system BCU Procedure completed Perform After inspection work of INFORMA TION section ...

Page 41: ...s are present 2 Judgement criteria Differential pressure remains less than 2 kPa 0 3 psi or higher than 2 kPa 0 3 psi for 2 seconds 3 Reset condition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function E...

Page 42: ...tage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Loose disconnected sensor and failure in sensing area contamination or clogging Abnormality in resistance of sensor Malfunction of engine ECU sensor power supply or internal circuit ...

Page 43: ... the differential pressure hose and pipe Was any failure found Clean or replace the differential pressure hose and pipe Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the differential pressure sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 3 Inspect the differential pressure s...

Page 44: ... ECU signal check harness and ground 4 Inspect the differential pressure sensor unit GND VCC GND VOUT SAPH16F010300655 Measurement conditions Tester connections Standard values Starter switch LOCK Differential pres sure sensor VCC GND VOUT GND 2 15 k Do the measurements meet the standard value Go to step 5 Replace the differential pressure sensor Perform After inspection work of INFOR MATION secti...

Page 45: ...ess Perform After inspection work of INFOR MATION section 6 Inspect disconnection of the differential pressure sensor harness B B V70 V71 V70 V46 SAPH16F010300657 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness AVC5 V71 EXPS V70 AGD9 V46 EXPS V70 2 15 k Do the measurements meet the standard value Go to step 7 Repair or replace the harne...

Page 46: ...e to Hino DX 4 Set the starter switch to the ON position 5 Select Engine and check if P1426 has been detected in Fault Information NO YES 7 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300658 Has DTC P1426 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 47: ... After inspection work of INFORMA TION section Go to step 3 3 Inspect the dif ferential pres sure sensor 1 Check the installation of the differential pressure sensor 2 Make sure there is no dirt or damage to the differential pressure sensor Failure found Go to YES No failure found Go to NO Clean the dif ferential pres sure sensor and install it properly If damaged replace the sensor Perform After ...

Page 48: ... connector and measure the resistance between the termi nals of the engine ECU signal check harness Tester connections Engine ECU signal check har ness AVC5 V71 EXPS V70 AGD9 V46 EXPS V70 Standard values 2 15 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 7 Repair or replace the harness Perform After inspection work of IN...

Page 49: ...ditions Starter switch ON Battery voltage is in the range of 10 V to 16 V The conditions described above remain for 5 seconds or longer 2 Judgement criteria Output of the sensor remains less than 0 5 V 6 41 kPa 0 93 psi for 3 seconds 3 Reset condition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF ET4 ET2 EX...

Page 50: ...alfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Abnormal resistance of sensor Harness disconnection or short circuit Looseness or poor contact of connector Malfunction of engine ECU sensor power supply or internal circuit ...

Page 51: ...to the differential pressure sensor NO YES 1 Inspect the differential pressure sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the differential pressure sensor Was any failure found Clean the differential pressure sensor and install it properly If damaged replace the differential pressure sensor P...

Page 52: ... differential pressure sensor unit GND VCC GND VOUT SAPH16F010300660 Measurement conditions Tester connections Standard values Starter switch LOCK Differential pres sure sensor VCC GND VOUT GND 2 15 k Do the measurements meet the standard value Go to step 4 Replace the differential pressure sensor Perform After inspection work of INFOR MATION section 4 Inspect the power supply of the differential ...

Page 53: ...nals of the engine ECU signal check harness and ground NO YES 5 Inspect for short circuit of the differential pressure sensor harness B V70 V71 V46 SAPH16F010300662 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness AVC5 V71 Ground EXPS V70 Ground ADG9 V46 Ground Do the measurements meet the standard value Go to step 6 Repair or replace th...

Page 54: ...n Fault Information NO YES 6 Inspect disconnection of the differential pressure sensor harness B B V70 V71 V70 V46 SAPH16F010300663 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness AVC5 V71 EXPS V70 ADG9 V46 EXPS V70 2 15 k Do the measurements meet the standard value Go to step 7 Repair or replace the harness Perform After inspection wor...

Page 55: ...ure sensor and install it properly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the dif ferential pres sure sensor unit Measure the resistance between the terminals of the differential pressure sensor Tester connections Differential pressure sensor VCC GND VOUT GND Standard values 2 15 k The measure ments meet the standard value Go to Y...

Page 56: ...ance between the termi nals of the engine ECU signal check harness Tester connections Engine ECU signal check har ness AVC5 V71 XPS V70 ADG9 V46 EXPS V70 Standard values 2 15 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 7 Repair or replace the harness Perform After inspection work of INFORMA TION section 7 Check the DTC...

Page 57: ...r switch ON Battery voltage is in the range of 10 V to 16 V The conditions described above remain for 5 seconds or longer 2 Judgement criteria Output of the sensor remains greater than 4 46 V 95 1 kPa 13 8 psi for 3 seconds 3 Reset condition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF ET4 ET2 EXPS ADG9 AV...

Page 58: ...alfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Abnormal resistance of sensor Harness disconnection or short circuit Looseness or poor contact of connector Malfunction of engine ECU sensor power supply or internal circuit ...

Page 59: ...to the differential pressure sensor NO YES 1 Inspect the differential pressure sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the differential pressure sensor Was any failure found Clean the differential pressure sensor and install it properly If damaged replace the differential pressure sensor P...

Page 60: ...ntial pressure sensor vehicle side connector NO YES 3 Inspect the differential pressure sensor power supply VCC GND GND VOUT SAPH16F010300666 Measurement conditions Tester connections Standard values Starter switch ON Differential pres sure sensor vehicle side connector VCC GND VOUT GND 4 5 5 5 V Do the measurements meet the standard value Go to step 7 Go to step 4 ...

Page 61: ...he differential pressure sensor NO YES 4 Inspect the differential pressure sensor unit VOUT VCC GND VOUT SAPH16F010300667 Measurement conditions Tester connections Standard values Starter switch LOCK Differential pres sure sensor con nector VCC VOUT VOUT GND 2 15 k Do the measurements meet the standard value Go to step 5 Replace the differential pressure sensor Perform After inspection work of INF...

Page 62: ...nals of the engine ECU signal check harness and ground NO YES 5 Inspect for short circuit of the differential pressure sensor harness B V70 V71 V46 SAPH16F010300668 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness AVC5 V71 Ground EXPS V70 Ground AGD9 V46 Ground Do the measurements meet the standard value Go to step 6 Repair or replace th...

Page 63: ... Fault Information NO YES 6 Inspect disconnection of the differential pressure sensor harness B B V70 V71 V70 V46 SAPH16F010300669 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness AVC5 V71 EXPS V70 AGD9 V46 EXPS V70 2 15 k Do the measurements meet the standard value Go to step 7 Repair or replace the harness Perform After inspection work...

Page 64: ...all it properly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect of the differential pressure power supply Measure the voltage between the terminals of the differential pres sure sensor vehicle side connec tor Tester connections Differential sensor vehicle side connector VCC GND VOUT GND Standard values 4 5 5 5 V The measure ments meet the ...

Page 65: ... connector and measure the resistance between the termi nals of the engine ECU signal check harness Tester connections Engine ECU signal check har ness AVC5 V71 EXPS V70 AGD9 V46 EXPS V70 Standard values 2 15 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 7 Repair or replace the harness Perform After inspection work of IN...

Page 66: ...in harness connected to EGR valve Starter switch ON Not related to engine speed 2 Judgement criteria Actual actuator temperature is 165 C 329 F and this condition continues for 0 6 sec 3 Reset condition Normal operation is restored and accelerator is not being operated 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted VNT control...

Page 67: ...Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Abnormal engine room interior temperature Abnormal heat rise in motor or element inside EGR actuator Soot adhesion and damage due to hard foreign substances on EGR valve sealing face and gas passageway Hardened carbon may peel ...

Page 68: ...eway for soot accu mulation and damage due to foreign substances 2 Check if there is soot obstructing the exhaust gas passageway inlet or outlet NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300672 Has a DTC other than P1458 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the EGR valve Was any failure found Remove foreign substances...

Page 69: ...S 3 Inspect the EGR valve connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the EGR power supply EGRV EGRG SAPH16F010300673 Measurement conditions Tester connections Standard values Starter switch ON EGR valve vehicle side connector EGRV EGRG 8 16 V Do the measurements meet the standard value Go to step 5 ...

Page 70: ...l EGR position from 0 to 100 5 Select EGR opening DOWN Inspect the response delay at each step of the Target EGR posi tion and Actual EGR position from 100 to 0 HINT The EGR opening position changes of around 10 per step between 0 100 NO YES 5 Inspect the response delay of the EGR valve Hino DX 4 5 3 1 2 SAPH16F010300674 Standard values From the Target EGR position to the Actual EGR position the r...

Page 71: ...NO Remove for eign sub stances and clean the valve Replace the EGR valve if it is damaged Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the EGR valve connector Check the connection of the EGR valve connector Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION sect...

Page 72: ...nspect the response delay at each step of the Target EGR position and Actual EGR position from 100 to 0 HINT The EGR opening position changes of around 10 per step between 0 100 Standard values From the Target EGR position to the Actual EGR position the response delay should be within 5 seconds The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go...

Page 73: ...tarter switch ON Not related to engine speed 2 Judgement criteria Actual actuator temperature is 150 C 302 F or greater and under 165 C 329 F and this condition continues for 0 6 sec 3 Reset condition Normal operation is restored and accelerator is not being operated 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted VNT controlle...

Page 74: ...heck that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Abnormal engine room interior temperature Abnormal heat rise in motor or element inside EGR actuator Soot adhesion and damage due to hard foreign substances on EGR valve sealing face and gas passageway Hard ened carbon may peel ...

Page 75: ...eway for soot accu mulation and damage due to foreign substances 2 Check if there is soot obstructing the exhaust gas passageway inlet or outlet NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300676 Has a DTC other than P1459 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the EGR valve Was any failure found Remove foreign substances...

Page 76: ...3 Inspect the EGR valve connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 4 4 Check the EGR valve power supply EGRV EGRG SAPH16F010300677 Measurement conditions Tester connections Standard values Starter switch ON EGR valve vehicle side connector EGRV EGRG 8 16 V Do the measurements meet the standard value Go to step ...

Page 77: ...l EGR position from 0 to 100 5 Select EGR opening DOWN Inspect the response delay at each step of the Target EGR posi tion and Actual EGR position from 100 to 0 HINT The EGR opening position changes of around 10 per step between 0 100 NO YES 5 Inspect the response delay of the EGR valve Hino DX 4 5 3 1 2 SAPH16F010300678 Standard values From the Target EGR position to the Actual EGR position the r...

Page 78: ...b stances and clean the valve Replace the EGR valve if it is damaged Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the EGR valve connector Check the connection of the EGR valve connector Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 4 4 Ch...

Page 79: ...EGR opening DOWN Inspect the response delay at each step of the Target EGR position and Actual EGR position from 100 to 0 HINT The EGR opening position changes of around 10 per step between 0 100 Standard values From the Target EGR position to the Actual EGR position the response delay should be within 5 seconds The measure ments meet the standard value Go to YES The measure ments do not meet the ...

Page 80: ... in harness connected to EGR valve Starter switch ON Not related to engine speed 2 Judgement criteria When data stored in actuator cannot be correctly read 3 Reset condition When power is supplied again and judgment criteria are resolved 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted VNT controller VNT actuator ENG No 1 SUB W ...

Page 81: ...ail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Damaged element inside EGR valve actuator ...

Page 82: ...cted in Fault Information NO YES 1 Check the connection of the EGR valve connector Looseness and poor contact NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300680 Has a DTC other than P14B0 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the EGR valve connector Was any failure found Connect securely repair if needed Perform After ...

Page 83: ...V EGRG SAPH16F010300681 Measurement conditions Tester connections Standard values Starter switch ON EGR valve vehicle side connector EGRV EGRG 8 16 V Do the measurements meet the standard value Replace the EGR valve go to step 4 Check the wire harness actuator power sup ply and ground and battery voltage Repair or replace parts as needed Perform After inspection work of INFOR MATION section 4 Chec...

Page 84: ...TION section Go to step 3 3 Inspect the EGR valve power supply Disconnect the EGR valve con nector and measure the voltage between the terminals of the EGR valve vehicle side connector Tester connections EGR valve vehicle side connector EGRV EGRG Standard values 8 16 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Replace the EGR val...

Page 85: ...nected to EGR valve Starter switch ON Not related to engine speed 2 Judgement criteria When difference in power supply voltage input with 2 systems is at least 1 V and this condition continues for 1 second 3 Reset condition Normal operation is restored and accelerator is not being operated 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF VNT controller VNT...

Page 86: ...mptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Damaged substrate or element inside EGR valve actuator Abnormal battery voltage Faulty contact in EGR actuator connector Disconnection or short circuit in sensor ha...

Page 87: ...cted in Fault Information NO YES 1 Check the connection of the EGR valve connector Looseness and poor contact NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300684 Has a DTC other than P14B2 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the EGR valve connector Was any failure found Connect securely repair if needed Perform After ...

Page 88: ... EGRG SAPH16F010300685 Measurement conditions Tester connections Standard values Starter switch ON EGR valve vehicle side connector EGRV EGRG 8 16 V Do the measurements meet the standard value Replace the EGR valve go to step 4 Check the wire harness actuator power sup ply and ground and battery voltage Repair or replace parts as needed Perform After inspection work of INFOR MATION section 4 Check...

Page 89: ...ORMA TION section Go to step 3 3 Inspect the EGR valve power supply Disconnect the EGR valve con nector and measure the voltage between the terminals of the EGR valve vehicle side connector Tester connections EGR valve vehicle side connector EGRV EGRG Standard values 8 16 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Replace the EG...

Page 90: ...to 16 V There is no disconnection in harness connected to EGR valve Starter switch ON Not related to engine speed 2 Judgement criteria When power supply voltage is 7 V or less and this condition continues for 1 second 3 Reset condition After restoration to normal condition 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted VNT con...

Page 91: ... is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Abnormal battery voltage Faulty contact in EGR actuator connector Harness disconnection or short circuit ...

Page 92: ...nnection in harness connected to EGR valve Starter switch ON Not related to engine speed 2 Judgement criteria When power supply voltage is 7 V or less and this condition continues for 60 ms 3 Reset condition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted VNT controller VNT actuato...

Page 93: ...nsufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Abnormal battery voltage Faulty contact in EGR actuator connector Disconnection or short circuit in sensor harness ...

Page 94: ...en detected in Fault Information NO YES 1 Check the connection of the EGR valve connector Looseness and poor contact NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300689 Has a DTC other than DTC P14B3 or P14B4 been detected Go to diagnosis procedure of a related DTC Go to step 2 2 Inspect the EGR valve connector Was any failure found Connect securely repair if needed...

Page 95: ...ower supply EGRV EGRG SAPH16F010300690 Measurement conditions Tester connections Standard values Starter switch ON EGR valve vehicle side connector EGRV EGRG 8 16 V Do the measurements meet the standard value Replace the EGR valve and go to step 4 Check the wire harness actuator power sup ply and ground Repair or replace parts as needed Perform After inspection work of INFOR MATION section 4 Check...

Page 96: ...rm After inspection work of INFORMA TION section Go to step 3 3 Inspect the EGR valve power supply Disconnect the EGR valve con nector and measure the voltage between the terminals of the EGR valve vehicle side connector Tester connections EGR valve vehicle side connector EGRV EGRG Standard values 8 16 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dar...

Page 97: ...rness connected to EGR valve Starter switch ON Not related to engine speed 2 Judgement criteria When temperature of temperature sensor 1 FET side inside actuator is 50 C 58 F or less and this condi tion continues for 1 second 3 Reset condition Normal operation is restored and accelerator is not being operated 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OF...

Page 98: ...ckup control fail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Damaged element inside EGR valve actuator ...

Page 99: ... switch ON Not related to engine speed 2 Judgement criteria When temperature of temperature sensor 1 FET side inside actuator is at least 200 C 392 F and this condi tion continues for 1 second 3 Reset condition Normal operation is restored and accelerator is not being operated 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted VNT...

Page 100: ...ail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Damaged element inside EGR valve actuator ...

Page 101: ... detected in Fault Information NO YES 1 Check the connection of the EGR valve connector Looseness and poor contact NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300694 Has a DTC other than DTC P14B7 or P14B8 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the EGR valve connector Was any failure found Connect securely repair if nee...

Page 102: ...GRV EGRG SAPH16F010300695 Measurement conditions Tester connections Standard values Starter switch ON EGR valve vehicle side connector EGRV EGRG 8 16 V Do the measurements meet the standard value Replace the EGR valve go to step 4 Check the wire harness actuator power sup ply and ground and battery voltage Repair or replace parts as needed Perform After inspection work of INFOR MATION section 4 Ch...

Page 103: ...onnect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 3 3 Check the EGR valve power supply Disconnect the EGR valve con nector and measure the voltage between the terminals of the EGR valve vehicle side connector Tester connections EGR valve vehicle side connector EGRV EGRG Standard values 8 16 V The measure ments meet the standard value Go to YES The me...

Page 104: ...rness connected to EGR valve Starter switch ON Not related to engine speed 2 Judgement criteria When temperature of temperature sensor 2 CPU side inside actuator is 50 C 58 F or less and this condi tion continues for 1 second 3 Reset condition Normal operation is restored and accelerator is not being operated 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OF...

Page 105: ...ckup control fail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Damaged element inside EGR valve actuator ...

Page 106: ... switch ON Not related to engine speed 2 Judgement criteria When temperature of temperature sensor 2 CPU side inside actuator is at least 200 C 392 F and this condi tion continues for 1 second 3 Reset condition Normal operation is restored and accelerator is not being operated 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted VNT...

Page 107: ...ail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Damaged element inside EGR valve actuator ...

Page 108: ... detected in Fault Information NO YES 1 Check the connection of the EGR valve connector Looseness and poor contact NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300699 Has a DTC other than DTC P14BC or P14BD been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the EGR valve connector Was any failure found Connect securely repair if nee...

Page 109: ...EGRV EGRG SAPH16F010300700 Measurement conditions Tester connections Standard values Starter switch ON EGR valve vehicle side connector EGRV EGRG 8 16 V Do the measurements meet the standard value Replace the EGR valve go to step 4 Check the wire harness actuator power sup ply and ground and battery voltage Repair or replace parts as needed Perform After inspection work of INFOR MATION section 4 C...

Page 110: ...Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the EGR valve power supply Disconnect the EGR valve con nector and measure the voltage between the terminals of the EGR valve vehicle side connector Tester connections EGR valve vehicle side connector EGRV EGRG Standard values 8 16 V The measure ments meet the standard value Go to YES The...

Page 111: ...nnection in harness connected to EGR valve Starter switch ON Not related to engine speed 2 Judgement criteria When temperature of temperature sensor 1 inside actuator is between 20 C 4 F and 170 C 338 F and difference between temperature sensors 1 and 2 is at least 30 C 86 F this condition continues for 1 second 3 Reset condition Immediately after normal operation is restored 4 Indication warning ...

Page 112: ...ated failure factors Damaged element inside EGR valve actuator Soot adhesion to EGR valve sealing face and gas passageway and motor abnormal heat rise due to damage caused by hard foreign substances Hardened carbon may peel off from EGR cooler upstream of EGR valve 1 If there is no problem with the above foreign substance damage occurred when the MIL was ON but at present the foreign substances ar...

Page 113: ...and gas passageway for soot buildup or damage due to foreign substances 2 Check if there is soot obstructing the exhaust gas passageway inlet or outlet NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300703 Has a DTC other than P14BF been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the EGR valve Was any failure found Removing foreign m...

Page 114: ... Inspect the EGR valve connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the EGR valve power supply EGRV EGRG SAPH16F010300704 Measurement conditions Tester connections Standard values Starter switch ON EGR valve vehicle side connector EGRV EGRG 8 16 V Do the measurements meet the standard value Go to step...

Page 115: ...al EGR position from 0 to 100 5 Select EGR opening DOWN Inspect the response delay at each step of the Target EGR posi tion and Actual EGR position from 100 to 0 HINT The EGR opening position changes of around 10 per step between 0 100 NO YES 5 Check the response delay of the EGR valve Hino DX 4 5 3 1 2 SAPH16F010300705 Standard values From the Target EGR position to the Actual EGR position the re...

Page 116: ... Go to NO Removing for eign matter and clean If damaged replace the EGR valve Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the EGR valve connector Check the connection of the EGR valve connector Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to st...

Page 117: ...spect the response delay at each step of the Target EGR position and Actual EGR position from 100 to 0 HINT The EGR opening position changes of around 10 per step between 0 100 Standard values From the Target EGR position to the Actual EGR position the response delay should be within 5 seconds The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go ...

Page 118: ...o normal condition 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DT...

Page 119: ...clogging in the air cleaner ele ment NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300706 Has a DTC other than P1515 for example P0096 P0106 P011C P2227 P0101 P2457 been detected Go to diagnosis procedure of a related DTC Go to step 2 2 Inspect the radiator curtain Was any failure found Open the radiator curtain Perform After inspection work of INFOR MATION section Go ...

Page 120: ... or cracked 4 Inspect the radiator fan Was any failure found Replace the radiator fan Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the fan clutch Was any failure found Replace the fan clutch Perform After inspection work of INFOR MATION section Go to step 6 6 Inspect the intercooler Was any failure found Replace the intercooler Perform After inspection work of INFOR...

Page 121: ...d NO YES Replace the intercooler tube Perform After inspection work of INFOR MATION section Go to step 8 8 Inspect the radiator Was any failure found Replace the radiator Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 122: ... ment Check there is no dirt damage or clogging in the air cleaner ele ment Failure found Go to YES No failure found Go to NO Clean or replace the air cleaner ele ment Perform After inspection work of INFORMA TION section Go to step 4 4 Inspect the radiator fan Check that the radiator fan fan blades was damaged Failure found Go to YES No failure found Go to NO Replace the radiator fan Perform Afte...

Page 123: ...on work of INFORMA TION section Go to step 8 8 Inspect the radiator Check if the radiator outer fins are clogged or damaged Failure found Go to YES No failure found Go to NO Replace the radiator Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P1515 Charge air undercooling Inspection procedure Step Action Descriptio...

Page 124: ...OCK 4 Indication warning or system control regulation when the DTC is set MIL OFF Diag lamp OFF Engine stop switch is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine stop switch cannot be used Symptoms on the vehicle due to malfunction Engine cannot start 6 Pre inspection work Check that the battery voltage is in t...

Page 125: ...erform a unit test of the engine stop switch NO YES 1 Inspect the engine stop switch Was any failure found Install the engine stop switch correctly Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the engine stop switch connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 3 Inspect the engin...

Page 126: ...the engine stop switch A B V80 V32 SAPH16F010300708 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness STOP V32 PGD4 V80 Less than 1 V Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Inspect for disconnection in the wire harness of the engine stop ...

Page 127: ... to step 3 3 Inspect the engine stop switch unit Disconnect the engine stop switch connector to perform a unit test of the engine stop switch Failure found Go to YES No failure found Go to NO Replace the engine stop switch Perform After inspection work of INFORMA TION section Go to step 4 4 Inspect for power supply short circuit in the wire har ness of the engine stop switch Connect the signal che...

Page 128: ...signal check har ness STOP V32 terminal Engine stop switch vehicle side connec tor Standard values Less than 1 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Replace the engine ECU Perform After inspection work of INFORMA TION section Repair or replace the harness Perform After inspection work of INFORMA TION section DTC P1530 Engin...

Page 129: ...injector manufacturing process Description of malfunction Faulty injector correction value is detected 2 DTC set condition 1 DTC detection condition Calibration data QR codes are not written Calibration data are 127 or more Calibration data are 128 or less Improper checksum of calibration data EEPROM memory failure 2 Judgement criteria Either of these conditions described above remains for 3 secon...

Page 130: ...fe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Inconsistent with calibration data QR codes stored in the server Malfunction of ECU ...

Page 131: ...TC code Check that DTC code P1601 is not displayed NO YES 1 Check the injector replaced record Has the injector been replaced in the past Replacement history exists or is unclear Go to step 3 No replacement history Go to step 2 2 Check the injector calibration data QR CODE 1 Hino DX Select Engine SAPH16F010300711 Has DTC P1601 been detected Go to step 3 Procedure completed Perform After inspection...

Page 132: ...se the DTC memory and check again DTC code Check that DTC code P1601 is not displayed NO YES 3 Check the injector calibration data QR CODE 2 Hino DX Select Engine SAPH16F010300712 Has DTC P1601 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 133: ...k again DTC code Check that DTC code P1601 is not displayed DTC P1601 has been detected Go to YES No DTC has beendetected Go to NO Go to step 3 Procedure completed Perform After inspection work of INFORMA TION section 3 Check the injector cali bration data QR CODE 2 Hino DX 1 Read the injector calibration data QR CODE of the injectors using Hino DX re input injector calibration data QR CODE 2 Eras...

Page 134: ...of DPR it will be judged as an error 2 DTC set condition 1 DTC detection condition The engine must not be stopped 2 Judgement criteria Judge a reading taken by the DPR downstream DOC outlet exhaust gas temperature sensor by referencing to a value specified below Immediately judge when 965 C 1 769 F is exceeded for continuous 5 minutes Engine ECU PTO accelerator sensor K95 ET4 ET2 EXPS ADG9 AVC5 LC...

Page 135: ... data Maximum exhaust temperature 1 2 for monitor 8 Estimated failure factors If malfunction in the burner system also exists Abnormal control of the burner system temperature Judged by the abnormal temperature rise at regeneration due to excessive soot emission Injector Characteristic abnormality of injection volume SCV Faulty control of common rail pressure EGR valve Faulty control of EGR openin...

Page 136: ...r failures or for other reasons P200C may have been detected First perform the diagnostics related to the other DTCs such as sensors and engine related DTCs Refer to Estimated failure fac tors in the previous pages NO YES 1 Check for dirt or soot in the exhaust pipe NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300714 Has a DTC other than P200C been detected Go to diag...

Page 137: ...njection quantity 3 Select Engine speed from the Data Monitor menu and measure the rotational fluctuation 3 Inspection of the exhaust gas temperature Hino DX Select Engine SAPH16F010300715 Standard values Exhaust gas temperature below 800 C 1 472 F Do the measurements meet the standard value Go to step 4 Go to step 10 4 Inspect the injector Hino DX Engine Ne r min NE Rotational fluctuation 1 500 r...

Page 138: ...ion quantity and the rotational fluctuation are within the standard values Go to step 5 Replace the injector Perform After inspection work of INFOR MATION section 5 Perform engine basic inspection Hino DX Select Engine SAPH16F010300718 Was any failure found Repair or replace the faulty part Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of I...

Page 139: ...as temperature sensor DOC outlet Was any failure found Clean the exhaust gas temperature sensor DOC outlet and install it properly If damaged replace the exhaust gas temper ature sensor DOC outlet Perform After inspection work of INFOR MATION section Go to step 8 8 Inspect the exhaust gas temperature sensor DOC outlet unit GND1 TEX1 SAPH16F010300719 Measurement conditions Tester connections Standa...

Page 140: ...sor connec tor burner outlet Looseness and poor contact NO YES 9 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300720 Has DTC P200C been detected Go to step 3 Procedure completed Perform After inspection work of INFOR MATION section 10 Inspect the exhaust gas temperature sensor burner outlet connector Was any failure found Connect securely Repair if needed Perform After inspect...

Page 141: ...r burner outlet Was any failure found Clean the exhaust gas temperature sensor burner outlet and install it properly If damaged replace the exhaust gas temper ature sensor burner outlet Perform After inspection work of INFOR MATION section Go to step 12 12 Inspect the exhaust gas temperature sensor burner outlet unit DIT DIT SAPH16F010300721 Measurement conditions Tester connections Standard value...

Page 142: ... HINT When replacing the DPR filter replace the burner nozzle and clean the igniter When replac ing the DPR filter replace the burner nozzle and clean the igniter Standard values Exhaust gas temperature below 800 C The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Go to step 10 4 Inspect the injector Hino DX Start the engine...

Page 143: ...sor DOC outlet Failure found Go to YES No failure found Go to NO Clean the exhaust gas temperature sensor DOC outlet and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 8 8 Inspect the exhaust gas temperature sensor DOC outlet unit Disconnect the connector of the exhaust gas temperature sensor DOC outlet and measure the resistance...

Page 144: ...Go to YES No failure found Go to NO Clean the exhaust gas temperature sensor burner outlet and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 12 12 Inspect the exhaust gas temperature sensor burner outlet unit Disconnect the connector of the exhaust gas temperature sensor burner outlet and measure the resistance between the termi...

Page 145: ...3 Reset condition Just after restoration to normal condition 4 Indication warning or system control regulation when the DTC is set Diag lamp ON Remaining DEF level lamp Engine output is restricted Vehicle speed is restricted DEF sensor DEF tank level sensor Common rail_CAN J C1 Common rail_CAN J C3 H L LEK LEJ CANL CANH KP KN CA3H CA3L NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L 12 CA2L CA3...

Page 146: ...ngine output is insufficient Vehicle does not speed up Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Remaining DEF level is low DEF tank level sensor failure ...

Page 147: ...ES 1 Inspect the DEF tank Did the DEF level indicator indicate 100 Procedure completed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DEF tank level sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 3 Inspect the DEF tank level sensor Was any failure found Replace the DEF tan...

Page 148: ...gine and check if P203F has been detected in Fault Information NO YES 4 Check the DTC detected Engine Hino DX Select Engine SAPH16F010300723 Had DTC U02A2 been detected Go to the diagnostic procedure of a related DTC Replace the DEF tank level sensor and go to step 5 5 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300724 Has DTC P203F been detected Replace the engine ECU Perfor...

Page 149: ... 3 3 Inspect the DEF tank level sensor Check if the DEF tank level sen sor float is disconnected stuck or damaged Failure found Go to YES No failure found Go to NO Replace the DEF tank level sensor Perform After inspection work of INFORMA TION section Go to step 4 4 Check the DTC detected Engine Hino DX Check if a CAN communication system malfunction U02A2 has been detected in Engine DTC U02A2 has...

Page 150: ... lamp OFF Engine output is restricted Vehicle speed is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Vehicle does not speed up NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L 12 CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L L...

Page 151: ... Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors When a malfunction of the DEF SCR system has occurred repeatedly P204F may not extinguish when executing a standard DTC Clear even when a normal fault recovery has been performed In such a case perform a DTC Clear after setting Release repeat offense in Activation Test to Release ...

Page 152: ...starter switch to the ON position 4 Select Engine and check if P204F has been detected in Fault Information NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300726 Has DTC P204F been detected Go to the DTC separate diagnosis of the DEF SCR system DCU Procedure completed Perform After inspection work of INFOR MATION section ...

Page 153: ...ption Judgement Check Yes No Yes No 1 Check the DTC detected Engine ECU Hino DX Check if P204F has been detected in Engine DTC P204F has been detected Go to YES No DTC has beendetected Go to NO Go to the DTC separate diag nosis of the DEF SCR sys tem DCU Procedure completed Perform After inspection work of INFORMA TION section ...

Page 154: ...e NOx conversion efficiency from NOx sensor upstream and downstream and Exhaust gas mass flow Target NOx conversion efficiency from DCU Average NOx conversion efficiency 0 457 Supply module DEF pump Air flow sensor DEF sensor Exhaust gas temperature sensor SCR inlet LFQ PSR LFR LGD PSRS PSR PSRS LFP LGF PSR PSR LFJ PMP LFL LG8 PMPS PMP PMPS LFM LGB PMV PMV LFN LGC PMV PMV LFK LGA PMP PMP LGE LG9 L...

Page 155: ... Vehicle speed is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Vehicle does not speed up Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test ...

Page 156: ...32 5 2 5 Do the measurements meet the standard value Go to step 2 Replace the DEF solution If the DEF concentration is below the stan dard drain the DEF solution through the tank drain with the starter switch ON and then refill the tank with at least 5 liters 1 3 gal lons of DEF Afterward drive the vehicle and confirm that the problem does not recur under driving conditions Perform After inspectio...

Page 157: ...ny failure found If damaged replace the air flow sensor Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the exhaust gas temperature sensor SCR inlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the exhaust gas temperature sensor SCR inlet Was any failure found Clean the ex...

Page 158: ...g corrosion or cracks NO YES 6 Inspect the exhaust gas temperature sensor SCR inlet unit FAT FAT SAPH16F010300729 Measurement conditions Tester connections Standard values Starter switch LOCK Exhaust gas tem perature sensor SCR inlet FAT FAT 20 C 68 F 220 Do the measurements meet the standard value Go to step 7 Replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of I...

Page 159: ...a tion of the DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank temperature is 5 C 23 F or lower perform warm up to raise it to 10 C 50 F or higher HINT Refer to the section System individual function in the chapter HINO Diagnostic eXplorer for detail ...

Page 160: ...r about 10 min and on Hino DX Data Monitor verify that the DEF solution is stable between 800 kPa 116 psi and 1 051 kPa 152 psi Perform After inspection work of INFOR MATION section Replace the DEF pipe pressure line After replacing the pipe idle the engine for about 10 min and on Hino DX Data Moni tor verify that the DEF solution is stable between 800 kPa 116 psi and 1 051 kPa 152 psi Perform Aft...

Page 161: ...xecute a forced DPR regeneration 6 Select Engine and check if P207F has been detected in Fault Information NO YES 11 Inspect the SCR catalyst Hino DX Select Engine SAPH16F010300733 Has DTC P207F been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed SCR catalyst is faulty Perform After inspection work of INFOR MATION section ...

Page 162: ... 3 gallons of DEF Afterward drive the vehi cle and con firm that the problem does not recur under driving conditions Perform After inspection work of INFORMA TION section 2 Perform a basic engine check Perform a basic engine check using the Engine Basic Check sheet HINT Refer to ENGINE INSPECTION CHECK SHEET Failure found Go to YES No failure found Go to NO Repair or replace the faulty part Perfor...

Page 163: ...amaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 6 6 Inspect the exhaust gas temperature sensor SCR inlet unit Disconnect the exhaust gas tem perature sensor SCR inlet con nector and measure the resistance between the terminals of the sensor FAT FAT Standard values 20 C 68 F 220 The measure ments meet the standard value Go to YES The measure ments do not m...

Page 164: ...o step 9 9 Inspect the DEF injector 2 Hino DX Replace the DEF injector with a new one Do not install it on the muffler and perform DEF addi tion test as same as step 8 Operation nor mal Go to YES Operation not normal Go to NO Install the new injector on the muffler and complete the check After installing the injector idle the engine for about 10 min and on Hino DX Data Monitor verify that the DEF ...

Page 165: ...lty Perform After inspection work of INFORMA TION section 11 Inspect the SCR catalyst Hino DX Replace the SCR catalyst and erase the trouble history and exe cute a forced DPR regeneration Check if P207F has been detected in Engine DTC P207F has been detected Go to YES No DTC has beendetected Go to NO Replace the engine ECU Perform After inspection work of INFORMA TION section Procedure completed S...

Page 166: ...ersion efficiency from NOx sensor upstream and downstream and Exhaust gas mass flow Target NOx conversion efficiency from DCU Average NOx conversion efficiency 1 0 at SCR catalyst tempera ture 200 C 392 F Supply module DEF pump Air flow sensor DEF sensor Exhaust gas temperature sensor SCR inlet LFQ PSR LFR LGD PSRS PSR PSRS LFP LGF PSR PSR LFJ PMP LFL LG8 PMPS PMP PMPS LFM LGB PMV PMV LFN LGC PMV ...

Page 167: ... backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Faulty DEF solution reduction Harness disconnection or short circuit NOx sensor failure Air flow sensor failure Exhaust gas tem...

Page 168: ...standard value Go to step 2 Replace the DEF solution If the DEF concentration is below the stan dard drain the DEF solution through the tank drain with the starter switch ON and then refill the tank with at least 5 liters 1 3 gal lons of DEF Afterward drive the vehicle and confirm that the problem does not recur under driving conditions Perform After inspection work of INFOR MATION section 2 Perfo...

Page 169: ...O YES If damaged replace the air flow sensor Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the exhaust gas temperature sensor SCR inlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the exhaust gas temperature sensor SCR inlet Was any failure found Clean the exhaust gas t...

Page 170: ...rosion or cracks NO YES 6 Inspect the exhaust gas temperature sensor SCR inlet unit FAT FAT SAPH16F010300735 Measurement conditions Tester connections Standard values Starter switch LOCK Exhaust gas tem perature sensor SCR inlet FAT FAT 20 C 68 F 220 Do the measurements meet the standard value Go to step 7 Replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of INFOR ...

Page 171: ...ra tion of the DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank temperature is 5 C 23 F or lower perform warm up to raise it to 10 C 50 F or higher HINT Refer to the section System individual function in the chapter HINO Diagnostic eXplorer for detail...

Page 172: ...tor verify that the DEF solution is stable between 800 kPa 116 psi and 1 051 kPa 152 psi Perform After inspection work of INFOR MATION section Re install the DEF injector and replace the DEF pipe pressure line After replacing the pipe idle the engine for about 10 min and on Hino DX Data Moni tor verify that the DEF solution is stable between 800 kPa 116 psi and 1 051 kPa 152 psi Perform After insp...

Page 173: ... P20EE has been detected in Fault Information NO YES Go to step 12 Procedure completed NOx sensor 1 and NOx sensor 2 are faulty Perform After inspection work of INFOR MATION section 12 Inspect the SCR catalyst Hino DX Select Engine SAPH16F010300739 Has DTC P20EE been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed SCR catalyst is faulty Per...

Page 174: ...ank with at least 5 liters 1 3 gallons of DEF Afterward drive the vehi cle and con firm that the problem does not recur under driving conditions Perform After inspection work of INFORMA TION section 2 Perform a basic engine check Hino DX Perform a basic engine check using the Engine Basic Check sheet Failure found Go to YES No failure found Go to NO Repair or replace the faulty part Perform After ...

Page 175: ...ensor Perform After inspection work of INFORMA TION section Go to step 6 6 Inspect the exhaust gas temperature sensor SCR inlet unit Disconnect the exhaust gas tem perature sensor SCR inlet con nector and measure the resistance between the terminals of the sensor FAT FAT Standard values 20 C 68 F 220 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard va...

Page 176: ...to step 9 9 Inspect the DEF injector 2 Hino DX Replace the DEF injector with a new one Do not install it on the muffler and perform DEF addi tion test as same as step 8 Operation nor mal Go to YES Operation not normal Go to NO Install the new injector on the muffler and complete the check After installing the injector idle the engine for about 10 min and on Hino DX Data Monitor verify that the DEF...

Page 177: ... in Engine DTC P20EE has been detected Go to YES No DTC has beendetected Go to NO Go to step 12 Procedure completed NOx sensor 1 and NOx sen sor 2 are faulty Perform After inspection work of INFORMA TION section 12 Inspect the SCR catalyst Hino DX 1 Replace the SCR catalyst and erase the trouble history and execute a forced DPR regeneration 2 Check if P20EE has been detected in Engine DTC P20EE ha...

Page 178: ...ottle drive current has continued to be below 0 3 A for six seconds 3 Reset condition After normal operation is restored and engine is restarted after engine stall 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to mal...

Page 179: ... of diesel throttle connector Harness disconnection GND short circuit between diesel throttle and engine ECU HINT You can check the diesel throttle intake throttle for mechanical damage by checking if the diesel throttle intake throttle valve is actuated when starter switch is turned ON and then LOCK without starting the engine ...

Page 180: ...r to measure the voltage of the diesel throt tle vehicle side connector terminals 1 Inspect the diesel throttle connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the diesel throttle Was any failure found Clean the diesel throttle If necessary replace it Perform After inspection work of INFOR MATION section...

Page 181: ...NO YES Go to step 5 Go to step 4 4 Inspect the diesel throttle power supply harness C E1 E21 SAPH16F010300742 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness MOT E1 MOT E21 8 16 V Do the measurements meet the standard value Repair or replace the harness Perform After inspection work of INFOR MATION section Replace the engine ECU Perform A...

Page 182: ...the operation of the throttle valve HINT The throttle valve opening position changes of around 10 per step between 0 100 NO YES 1 Warm up the engine engine coolant temperature 60 C 140 F or more 2 Stop the engine 3 Select Engine and check if P2100 has been detected in Fault Information NO YES 4 5 3 1 2 SAPH16F010300743 Is the throttle valve operating normally Go to step 6 Replace the diesel thrott...

Page 183: ...ailure found Go to NO Clean the die sel throttle If necessary replace it Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the diesel throttle power supply Measure the voltage of the diesel throttle vehicle side connector ter minals MOT and MOT Standard values 8 16 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go ...

Page 184: ...hanges of around 10 per step between 0 100 Operation nor mal Go to YES Operation not normal Go to NO Go to step 6 Replace the diesel throttle Perform After inspection work of INFORMA TION section 6 Check the DTC detected Engine ECU Hino DX Perform engine warm up engine coolant temperature 60 C 140 F or more and check if P2100 has been detected in Engine DTC P2100 has been detected Go to YES No DTC...

Page 185: ...nd Target is more than 10 for 80 seconds 3 Reset condition After normal operation is restored and engine is restarted after engine stall 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Idling stop system is not available Cruise control function is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehic...

Page 186: ...ENGINE CONTROL SYSTEM J08E 4 963 Throttle valve malfunction Battery Decrease in voltage Harnesses Decrease in source voltage Short circuit to GND ...

Page 187: ...uptures or cracks 1 Inspect the air cleaner element Check indicator Check for dirt clogging and original parts SAPH16F010300745 Was any failure found Clean or replace the air cleaner element Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the air hose and air pipe Check tightness and no bending Check tightness no bending and no leak Check tightness no bending and no le...

Page 188: ...ipe Perform After inspection work of INFOR MATION section Go to step 3 3 Inspect the exhaust muffler exhaust pipe Was any failure found Repair or replace the muffler pipe Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the exhaust brake valve SAPH16F010300747 Was any failure found Clean the exhaust brake valve If necessary replace the exhaust brake valve Perform After ...

Page 189: ...throttle valve can be manually moved when it is not energized 2 Make sure there is no looseness between the throttle valve and shaft NO YES 5 Inspect the diesel throttle Was any failure found Clean the intake passage Perform After inspection work of INFOR MATION section Go to step 6 6 Inspect the diesel throttle Incorrect SAPH16F010300748 Was any failure found Clean the diesel throttle If necessar...

Page 190: ...he operation of the throttle valve 5 Select Valve DOWN Check the operation of the throttle valve HINT The throttle valve opening position changes of around 10 per step between 0 100 NO YES 7 Check the operation of the diesel throttle valve Hino DX 4 5 3 1 2 SAPH16F010300749 Is the throttle valve operating normally Check that again that P2101 is not detected to complete the inspection procedure Per...

Page 191: ...rform After inspection work of INFORMA TION section Go to step 3 3 Inspect the exhaust muf fler exhaust pipe Check that the air hose and pipe have no disconnections clogging ruptures or cracks Failure found Go to YES No failure found Go to NO Repair or replace the muffler pipe Perform After inspection work of INFORMA TION section Go to step 4 4 Inspect the exhaust brake valve Make sure the exhaust...

Page 192: ...eration of the diesel intake throttle valve CAUTION Make sure the engine is stopped otherwise the engine may be damaged Inspection procedure 1 Select Check functions 2 Select Intake throttle valve check 3 Click Check start 4 Select Valve UP Check the operation of the throttle valve 5 Select Valve DOWN Check the operation of the throttle valve HINT The throttle valve opening posi tion changes of ar...

Page 193: ...bove 12 A for 112 msec 3 Reset condition After normal operation is restored and engine is restarted after engine stall 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Symptoms on the vehic...

Page 194: ...ery voltage Water intrusion inside the harness between the diesel throttle and the engine ECU Extra electronic hardware is connected HINT You can check the diesel throttle for mechanical damage by checking if the diesel throttle intake throttle valve is actuated when starter switch is turned ON and then LOCK without starting the engine ...

Page 195: ...ure the voltage of the diesel throt tle vehicle side connector terminals 1 Inspect the diesel throttle connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the diesel throttle Was any failure found Clean the diesel throttle If necessary replace the diesel throttle Perform After inspection work of INFOR MATION...

Page 196: ...le valve NO YES Go to step 5 Go to step 4 4 Inspect the diesel throttle power supply harness C E1 E21 SAPH16F010300752 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness MOT E1 MOT E21 8 16 V Do the measurements meet the standard value Repair or replace the harness Perform After inspection work of INFOR MATION section Replace the engine ECU ...

Page 197: ... Engine and check if P2103 has been detected in Fault Information NO YES 6 Inspect the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300754 Has DTC P2103 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 198: ... the diesel throttle con nector and measure the voltage of the diesel throttle vehicle side connector terminals MOT MOT Standard values 8 16 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 5 Go to step 4 4 Inspect the diesel throttle power supply harness Connect the signal check harness to the engine ECU and measure the vo...

Page 199: ... Engine DTC P2103 has been detected Go to YES No DTC has beendetected Go to NO Replace the engine ECU Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P2103 DC motor for intake throttle valve circuit Short circuit circuit high Inspection procedure Step Action Description Judgement Check Yes No Yes No ...

Page 200: ...when the DTC is set MIL ON Diag lamp OFF Cruise control function is not available Idling stop system is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Cruise control does not work Idling stop system does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the nor...

Page 201: ...ENGINE CONTROL SYSTEM J08E 4 978 Harness disconnection or short circuit ...

Page 202: ...arter switch to the ON position 4 Select Engine and check if P2120 has been detected in Fault Information NO YES 1 Check the DTC detected Engine ECU 1 Hino DX Select Engine SAPH16F010300756 Has a DTC other than P2120 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Check the DTC detected Engine ECU 2 Hino DX Select Engine SAPH16F010300757 Has DTC P2120 been detected Res...

Page 203: ...4 Select Engine and check if P2120 has been detected in Fault Information NO YES 3 Check the DTC detected Engine ECU 3 Hino DX Select Engine SAPH16F010300758 Has DTC P2120 been detected Inspect the accelerator sensor harness Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 204: ...ECU 2 Hino DX Replace the accelerator sensor with a new one and check if P2120 detected in Fault Informa tion DTC P2120 has been detected Go to YES No DTC has beendetected Go to NO Restore the accelerator sensor to its original condi tion and then go to step 3 Procedure completed Perform After inspection work of INFORMA TION section 3 Check the DTC detected Engine ECU 3 Hino DX Replace the engine ...

Page 205: ...ion warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Cruise control function is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Cruise control does not work Symptoms on the vehicle due to malfunction Cruise control does not work 6 Pre inspection work Check that the battery voltage is in the no...

Page 206: ... set MIL ON Diag lamp OFF Cruise control function is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Cruise control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored af...

Page 207: ...re the resistance between the terminals of the accelerator sensor 1 1 Inspect the accelerator sensor 1 connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the accelerator sensor 1 unit VCC1 SIG1 VCC1 GND1 GND1 SIG1 SAPH16F010300761 Measurement conditions Tester connections Standard values Starter switch LOCK...

Page 208: ...form After inspection work of INFOR MATION section 3 Inspect the power supply of the accelerator sensor 1 VCC1 GND1 SAPH16F010300762 Measurement conditions Tester connections Standard values Starter switch ON Accelerator sensor 1 vehicle side connector VCC1 GND1 4 5 5 5 V Do the measurements meet the standard value Go to step 4 Go to step 5 4 Inspect the signal circuit of the accelerator sensor 1 ...

Page 209: ...ECU signal check harness and ground NO YES 5 Inspect for short circuit of the accelerator sensor 1 harness B V47 V50 V45 SAPH16F010300764 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness ADG7 V45 Ground ACS1 V47 Ground AVC3 V50 Ground Do the measurements meet the standard value Go to step 6 Repair or replace the harness Perform After ins...

Page 210: ...ct disconnection of the accelerator sensor 1 harness B V50 V45 B V50 V47 B V47 V45 SAPH16F010300765 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness AVC3 V50 ACS1 V47 AVC3 V50 ADG7 V45 ACS1 V47 ADG7 V45 2 Do the measurements meet the standard value Go to step 7 Repair or replace the harness Perform After inspection work of INFOR MATION s...

Page 211: ...k if the DTC P2122 or P2123 has been detected in Fault Information NO YES 7 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300766 Has DTC P2122 or P2123 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 212: ...2 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Replace the sensor Perform After inspection work of INFORMA TION section 3 Inspect the power supply of the acceler ator sensor 1 Measure the voltage between the terminals of the accelerator sen sor 1 vehicle side connector Tester connections Accelerator sensor vehicle side ...

Page 213: ... ECU signal check harness Tester connections Engine ECU signal check har ness AVC3 V50 ACS1 V47 AVC3 V50 ADG7 V45 ACS1 V47 ADG7 V45 Standard values 2 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 7 Repair or replace the harness Perform After inspection work of INFORMA TION section 7 Check the DTC detected Engine ECU Hino D...

Page 214: ...tion Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Cruise control is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Cruise control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the batte...

Page 215: ...ENGINE CONTROL SYSTEM J08E 4 992 Malfunction of sensor 2 Malfunction of engine ECU ...

Page 216: ...lation when the DTC is set MIL ON Diag lamp OFF Cruise control is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Cruise control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC...

Page 217: ...s no dirt or damage to the accelerator sensor NO YES 1 Inspect the accelerator sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the accelerator sensor Was any failure found Clean the accelerator sensor and install it properly If damaged replace the accelerator sensor Perform After inspection work o...

Page 218: ...minals of the accelerator sensor NO YES 3 Inspect the accelerator sensor unit VCC2 SIG2 VCC2 GND2 GND2 SIG2 SAPH16F010300769 Measurement conditions Tester connections Standard values Starter switch LOCK Accelerator sensor VCC2 SIG2 VCC2 GND2 SIG2 GND2 2 Do the measurements meet the standard value Go to step 4 Replace the accelerator sensor Perform After inspection work of INFOR MATION section ...

Page 219: ...4 Inspect the power supply of the accelerator sensor GND2 VCC2 SAPH16F010300770 Measurement conditions Tester connections Standard values Starter switch ON Accelerator sensor vehicle side con nector VCC2 GND2 4 5 5 5 V Do the measurements meet the standard value Go to step 5 Go to step 6 5 Inspect the signal circuit of the accelerator sensor SIG2 GND2 SAPH16F010300771 Measurement conditions Tester...

Page 220: ... ECU signal check harness and ground NO YES 6 Inspect for short circuit of the accelerator sensor harness B V51 V65 V67 SAPH16F010300772 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness AVC4 V51 Ground ADG8 V65 Ground ACS2 V67 Ground Do the measurements meet the standard value Go to step 7 Repair or replace the harness Perform After insp...

Page 221: ...ect disconnection of the accelerator sensor harness B V51 V67 B V51 V65 B V65 V67 SAPH16F010300773 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness AVC4 V51 ACS2 V67 AVC4 V51 ADG8 V65 ACS2 V67 ADG8 V65 2 Do the measurements meet the standard value Go to step 8 Repair or replace the harness Perform After inspection work of INFOR MATION se...

Page 222: ...k if the DTC P2127 or P2128 has been detected in Fault Information NO YES 8 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300774 Has DTC P2127 or P2128 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 223: ...failure found Go to NO Clean the accelerator sensor and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the accelerator sensor unit Measure the resistance between the terminals of the accelerator sensor Tester connections Accelerator sensor VCC2 SIG2 VCC2 GND2 SIG2 GND2 Standard values 2 The measure ments meet the stan...

Page 224: ... of INFORMA TION section 7 Inspect dis connection of theaccelerator sensor har ness Connect the accelerator sensor connector measure the resis tance between the terminals of the engine ECU signal check harness Tester connections Engine ECU signal check har ness AVC4 V51 ACS2 V67 AVC4 V51 ADG8 V65 ACS2 V67 ADG8 V65 Standard values 2 The measure ments meet the standard value Go to YES The measure me...

Page 225: ...The engine has stopped or runs at 500 r min or higher for continuous 5 seconds 2 Judgement criteria A difference between throttle position sensors 1 and 2 remains at 5 degrees or greater for 3 seconds 3 Reset condition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is s...

Page 226: ... is stored after test drive 8 Estimated failure factors Harness disconnection or short circuit Irregular contact disconnection or poor fit of connector Malfunction of diesel throttle throttle position sensor Malfunction of engine ECU sensor power supply ...

Page 227: ...e sensor and common rail pressure sensor connectors 3 Set the starter switch to the ON position 4 Select Engine and check if any DTC other than P2135 has been detected in Fault Information NO YES 1 Check the DTC detected Engine ECU 1 Hino DX Select Engine SAPH16F010300776 Has a DTC other than P2135 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Check the DTC detected ...

Page 228: ...ine ECU signal check harness NO YES 3 Inspect the intake throttle valve position sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the signal wire harness of the diesel throttle D E62 E46 SAPH16F010300778 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal c...

Page 229: ...e engine ECU signal check harness NO YES 5 Inspect the engine ECU D E62 E46 SAPH16F010300779 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness DTS1 E62 DTS2 E46 0 V Do the measurements meet the standard value Procedure completed Clear and check again the DTC Perform After inspection work of INFOR MATION section Replace the engine ECU Perfor...

Page 230: ...to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Go to step 3 3 Inspect the intake throttle valve position sensor con nector Check the connection of the intake throttle valve position sen sor connector Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely Repair if needed Perform After inspection work of INFORMA TION ...

Page 231: ...The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Procedure completed Clear and check again the DTC Perform After inspection work of INFORMA TION section Replace the engine ECU Perform After inspection work of INFORMA TION section DTC P2135 Intake throttle valve position sensor rationality Inspection procedure Step Action Description Jud...

Page 232: ...ndition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Cruise control function is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Cruise control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check th...

Page 233: ...ection of the accelerator sensor connector Loose ness and poor contact NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300781 Has a DTC other than P2138 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Inspect the PTO accelerator sensor Was any failure found Repair the GND circuit of the PTO accelerator sensor Perform After inspection work of ...

Page 234: ... check harness and ground NO YES 4 Inspect the accelerator sensor signal B V67 V47 SAPH16F010300782 Measurement conditions Tester connections Standard values Starter switch ON Depress the accelerator pedal from 0 to 100 Engine ECU signal check harness ACS1 V47 Ground ACS2 V67 Ground Difference in volt age between ter minals 0 4 1 2 V Do the measurements meet the standard value Go to step 5 Replace...

Page 235: ...U signal check harness and ground NO YES 5 Inspect the engine ECU B V67 V47 SAPH16F010300783 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU signal check harness ACS1 V47 Ground ACS2 V67 Ground 0 V Do the measurements meet the standard value Procedure completed Clear and check again the DTC Perform After inspection work of INFOR MATION section Replace the eng...

Page 236: ...TO accel erator sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the accelerator sensor con nector Check the connection of the accelerator sensor connector Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 4 4 Inspect the accelerator senso...

Page 237: ...round ACS2 V67 Ground Standard values 0 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Procedure completed Clear and check again the DTC Perform After inspection work of INFORMA TION section Replace the engine ECU Perform After inspection work of INFORMA TION section DTC P2138 Accelerator pedal position sensor rationality Inspection...

Page 238: ...ement criteria When the injector drive system circuit 1 current value is smaller than 16 A the fail count is detected with the full count When the engine speed is 750 r min 0 6 seconds Varies according to engine speed 3 Reset condition After normal operation is restored and engine is restarted after having stalled Injector 6 Injector 5 Injector 4 Injector 3 Injector 2 Injector 1 Engine ECU Engine ...

Page 239: ...due to backup control fail safe function Engine output is insufficient Cruise control does not work Idling stop system does not work Vehicle start control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure f...

Page 240: ...l in the engine ECU signal check harness and ground NO YES 1 Inspect the injector connector Was any failure found Connect securely repair or replace if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the injector power supply C E14 ECU CASE GND ECU MOUNTING BOLT E34 SAPH16F010300785 Measurement conditions Tester connections Standard values Starter switch ON Engi...

Page 241: ...linked up connector 12 8 4 9 10 5 6 1 2 11 7 3 A ARROW VIEW JUDGMENT DIRECTION A SAPH16F010300786 Measurement conditions Tester connections Standard values Starter switch ON Injector linked up con nector ECU side 1 injector 11 terminal Ground 2 injector 3 terminal Ground 3 injector 6 terminal Ground 8 V or less Do the measurements meet the standard value Go to step 4 Repair or replace the harness ...

Page 242: ...harness Perform After inspection work of INFOR MATION section 5 Inspect disconnection of injector wire harness SAPH16F010300788 Measurement conditions Tester connections Standard values Starter switch LOCK Injector harness connector terminals 1 IJ1 IJ1 2 IJ2 IJ2 3 IJ3 IJ3 20 C 68 F 0 37 0 57 Do the measurements meet the standard value Go to step 7 Go to step 6 6 Inspect the injector unit SAPH16F01...

Page 243: ...he ON position 5 Select Engine and check if P2146 has been detected in Fault Information NO YES Go to step 7 Replace the injector Perform After inspection work of INFOR MATION section 7 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300790 Has DTC P2146 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After in...

Page 244: ...ns Engine ECU signal check har ness IJ1 E14 Ground I1 S E34 Ground Standard values At least 3 4 of battery voltage The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Go to step 7 3 Inspect the injector wire harness power supply engine ECU injec tor linked up connector Disconnect the injector linked up connector and measure th...

Page 245: ...IJ3 Standard values 20 C 68 F 0 37 0 57 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 7 Go to step 6 6 Inspect the injector unit Measure the resistance between the 1 3 injector terminals and the injector bodies Tester connections Between injector terminal and body Standard values 10 M or more The measure ments meet the sta...

Page 246: ... 2 Judgement criteria When the injector drive system circuit 1 voltage is smaller than 0 9 V the fail count is detected with the full count When the engine speed is 750 r min 0 6 seconds Varies according to engine speed 3 Reset condition After normal operation is restored and engine is restarted after having stalled Injector 6 Injector 5 Injector 4 Injector 3 Injector 2 Injector 1 Engine ECU Engin...

Page 247: ...control fail safe function Engine output is insufficient Cruise control does not work Idling stop system does not work Vehicle start control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Disconn...

Page 248: ...voltage is larger than 9 V the fail count is detected with the full count When the engine speed is 750 r min 0 6 seconds Varies according to engine speed 3 Reset condition After normal operation is restored and engine is restarted after having stalled 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Injector 6 Injector 5 Injector 4 Injector 3 Injector 2 In...

Page 249: ...ne output is insufficient Cruise control does not work Idling stop system does not work Vehicle start control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Harness disconnection or short circuit...

Page 250: ...nnect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect for short circuit of the injector harness engine ECU injector linked up connector 12 8 4 9 10 5 6 1 2 11 7 3 A ARROW VIEW JUDGMENT DIRECTION A SAPH16F010300793 Measurement conditions Tester connections Standard values Starter switch LOCK Injector linked up con nector ECU side 1 injector 11 ...

Page 251: ...ons Tester connections Standard values Starter switch LOCK Injector linked up con nector engine side 1 injector 11 terminal Ground 12 terminal Ground 2 injector 3 terminal Ground 4 terminal Ground 3 injector 5 terminal Ground 6 terminal Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perform After inspection work of INFOR MATION section 4 Inspect disco...

Page 252: ...S 5 Inspect the injector unit SAPH16F010300796 Measurement conditions Tester connections Standard values Starter switch LOCK Between injector terminal and body 10 M or more Do the measurements meet the standard value Replace the injector harness Perform After inspection work of INFOR MATION section Replace the injector Perform After inspection work of INFOR MATION section 6 Check the DTC detected ...

Page 253: ...p connector ECU side 1 injector 11 Ground 12 Ground 2 injector 3 Ground 4 Ground 3 injector 5 Ground 6 Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Repair or replace the harness Perform After inspection work of INFORMA TION section 3 Inspect for short circuit of the injector harness between inject...

Page 254: ... The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Replace the injector har ness Perform After inspection work of INFORMA TION section Replace the injector Perform After inspection work of INFORMA TION section 6 Check the DTC detected Engine ECU Hino DX Check if the DTC P2147 or P2148 has been detected in Engine DTC P2147 or P2148 has be...

Page 255: ...2 Judgement criteria When the injector drive system circuit 2 current value is smaller than 16 A the fail count is detected with the full count When the engine speed is 750 r min 0 6 seconds Varies according to engine speed 3 Reset condition After normal operation is restored and engine is restarted after having stalled Injector 6 Injector 5 Injector 4 Injector 3 Injector 2 Injector 1 Engine ECU K...

Page 256: ...control fail safe function Engine output is insufficient Cruise control does not work Idling stop system does not work Vehicle start control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Disconn...

Page 257: ...i nals of the engine ECU signal check harness and ground NO YES 1 Inspect the injector connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the injector power supply C ECU CASE GND ECU MOUNTING BOLT E18 E38 SAPH16F010300799 Measurement conditions Tester connections Standard values Starter switch ON Engine ECU...

Page 258: ...linked up connector 12 8 4 9 10 5 6 1 2 11 7 3 A ARROW VIEW JUDGMENT DIRECTION A SAPH16F010300800 Measurement conditions Tester connections Standard values Starter switch ON Injector linked up con nector ECU side 4 injector 7 terminal Ground 5 injector 2 terminal Ground 6 injector 10 terminal Ground 8 V or less Do the measurements meet the standard value Go to step 4 Repair or replace the harness ...

Page 259: ...orm After inspection work of INFOR MATION section 5 Inspect disconnection of the injector harness SAPH16F010300802 Measurement conditions Tester connections Standard values Starter switch LOCK Between injector harness connector terminals 4 IJ4 IJ4 5 IJ5 IJ5 6 IJ6 IJ6 20 C 68 F 0 37 0 57 Do the measurements meet the standard value Go to step 7 Go to step 6 6 Inspect the injector unit SAPH16F0103008...

Page 260: ... the ON position 5 Select Engine and check if P2149 has been detected in Fault Information NO YES Go to step 7 Replace the injector Perform After inspection work of INFOR MATION section 7 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300804 Has DTC P2149 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After ...

Page 261: ...rness power supply engine ECU injec tor linked up connector Measure the voltage between each terminal in the injector linked up connector ECU side and ground Tester connections injector linked up connector ECU side 4 injector 7 Ground 5 injector 2 Ground 6 injector 10 Ground Standard values 8 V or less The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard ...

Page 262: ...ions Injector terminals injector bod ies Standard values 10 M or more The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 7 Replace the injector Perform After inspection work of INFORMA TION section 7 Check the DTC detected Engine ECU Hino DX 1 Perform engine warm up engine coolant tempera ture 60 C 140 F or more 2 Check if P214...

Page 263: ... drive system circuit 2 voltage is smaller than 0 9 V the fail count is detected with the full count When the engine speed is 750 r min 0 6 seconds Varies according to engine speed 3 Reset condition After normal operation is restored and engine is restarted after having stalled 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Injector 6 Injector 5 Injector...

Page 264: ...nsufficient Cruise control does not work Idling stop system does not work Vehicle start control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Disconnection or short circuit in sensor harness Irr...

Page 265: ...the fail count is detected with the full count When the engine speed is 750 r min 0 6 seconds Varies according to engine speed 3 Reset condition After normal operation is restored and engine is restarted after having stalled 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function is not available Injector 6 Inje...

Page 266: ... work Idling stop system does not work Vehicle start control does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Disconnection or short circuit in sensor harness Irregular contact disconnection or poo...

Page 267: ...onnect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect for short circuit of the injector harness engine ECU injector linked up connector 12 8 4 9 10 5 6 1 2 11 7 3 A ARROW VIEW JUDGMENT DIRECTION A SAPH16F010300807 Measurement conditions Tester connections Standard values Starter switch LOCK Injector linked up con nector ECU side 4 injector 7 ...

Page 268: ...itions Tester connections Standard values Starter switch LOCK Injector linked up con nector engine side 4 injector 7 terminal Ground 8 terminal Ground 5 injector 1 terminal Ground 2 terminal Ground 6 injector 9 terminal Ground 10 terminal Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perform After inspection work of INFOR MATION section 4 Inspect dis...

Page 269: ...5 Inspect the injector unit SAPH16F010300810 Measurement conditions Tester connections Standard values Starter switch LOCK Between injector terminal and body 10 M or more Do the measurements meet the standard value Replace the injector harness Perform After inspection work of INFOR MATION section Replace the injector Perform After inspection work of INFOR MATION section 6 Check the DTC detected En...

Page 270: ... work of INFORMA TION section Go to step 2 2 Inspect for short circuit of the injector wire harness Engine ECU injector linked up connector Disconnect the injector harness connector and engine ECU con nector measure the resistance between each terminal in the injector linked up connector ECU side and ground Tester connections injector linked up connector ECU side 4 injector 7 Ground 8 Ground 5 inj...

Page 271: ... The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 5 Go to step 6 5 Inspect the injector unit Measure the resistance between the 4 6 injector terminals and the injector bodies Tester connections injector terminals injector bod ies Standard values 10 M or more The measure ments meet the standard value Go to YES The measure ment...

Page 272: ...C 282 2 F or less and this condition continues for at least 3 seconds 3 Reset condition After restoration to normal condition 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function is not available Idling stop system is not available Vehicle start control is not available 5 Symptoms on the vehicle when the DTC ...

Page 273: ...imated failure factors Sensor is disconnected or sensing unit is malfunctioning due to dirt clogging damage etc Abnormal sensor resistance Engine ECU sensor power supply failure or internal circuit failure Harness disconnection or short circuit Looseness or poor contact of the connector ...

Page 274: ...or at least 3 seconds 3 Reset condition After restoration to normal condition 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function is not available Idling stop system is not available Vehicle start control is not available 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup con...

Page 275: ...8 Estimated failure factors Abnormal resistance of the sensor Engine ECU sensor power supply failure or internal circuit failure Harness disconnection or short circuit Looseness or poor contact of connector Sensor internal short circuit ...

Page 276: ...or 2 connector 1 Inspect the engine coolant temperature sensor 2 connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the engine coolant temperature sensor 2 Was any failure found Clean the engine coolant temperature sensor 2 and install it properly If damaged replace the engine coolant tem perature sensor 2 ...

Page 277: ...tep 4 Replace the engine coolant temperature sen sor 2 Perform After inspection work of INFOR MATION section 4 Inspect the engine coolant temperature sensor 2 power supply ETSG ETGD SAPH16F010300815 Measurement conditions Tester connections Standard values Starter switch ON Engine coolant tem perature sensor 2 vehicle side con nector ETSG ETGD 4 5 5 5 V Do the measurements meet the standard value ...

Page 278: ...ce the harness Perform After inspection work of INFOR MATION section 6 Inspect disconnection of the wire harness of engine coolant temperature sensor 2 D E57 E69 SAPH16F010300817 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness THW2 E69 AGD3 E57 20 C 68 F 2 59 2 32 k 80 C 176 F 0 326 0 310 k Do the measurements meet the standard value Go...

Page 279: ... engine coolant temperature sensor 2 2 Make sure there is no dirt or damage to the engine cool ant temperature sensor 2 Failure found Go to YES No failure found Go to NO Clean the engine cool ant tempera ture sensor 2 and install it properly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the engine cool ant tempera ture sensor 2 unit Disc...

Page 280: ...ion 6 Inspect dis connection of the wire har ness of engine coolant tem perature sen sor 2 Connect the signal check harness to the engine ECU vehicle side harness and measure the resis tance between the terminal in the engine ECU signal check har ness Tester connections Engine coolant temperature sen sor 2 vehicle side connector THW2 E69 and AGD3 E57 Standard values 20 C 68 F 2 59 2 32 k 80 C 176 ...

Page 281: ...KTR KTQ L2P LCH KTU KTS KTD KTT KTR KTQ KTU KTS KTT AFGD AFSG AFT AFVB AFT AGD6 AFSI AGD5 AFVB THA THW ETH2 K0W L75 L2P LCH KTD K0W L75 CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY LEZ JU JZ CA2L JQ JV CA2L KE CA3L KF CA3H JX CA2L JS CA2H CAL0 CAH0 RE H H L H L JW CA2L JR CA2H LEC CANL LED CANH LEB GND LEA VCC A99 3GLD A8V FUSE NOX2 FUSE NOX1 6BLD LE8 CANL LE9 CANH VCC GND...

Page 282: ...is restored 4 Indication warning or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery...

Page 283: ... standard value Go to step 2 Replace the DEF If the DEF concentration is below the stan dard drain the DEF solution through the tank drain with the starter switch ON and then refill the tank with at least 5 liters 1 3 gal lons of DEF solution Afterward drive the vehicle and confirm that the problem does not recur under driving conditions Perform After inspection work of INFOR MATION section 2 Insp...

Page 284: ... and poor contact NO YES 3 Inspect the air flow sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the air flow sensor Was any failure found If damaged replace the air flow sensor Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the exhaust gas temperature sensor SCR inlet...

Page 285: ...or SCR inlet NO YES 6 Inspect the exhaust gas temperature sensor SCR inlet Was any failure found Clean the exhaust gas temperature sensor SCR inlet and install it properly Perform After inspection work of INFOR MATION section Go to step 7 7 Inspect the exhaust gas temperature sensor SCR inlet unit FAT FAT SAPH16F010300822 Measurement conditions Tester connections Standard values Starter switch LOC...

Page 286: ...pect the exhaust temperature sensor DOC outlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 9 9 Inspect the exhaust gas temperature sensor DOC outlet Was any failure found Clean the exhaust gas temperature sensor DOC Outlet and install it properly Perform After inspection work of INFOR MATION section Go to step 1...

Page 287: ...to step 11 Replace the exhaust gas temperature sensor DOC outlet Perform After inspection work of INFOR MATION section 11 Inspect the ambient air temperature sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 12 12 Inspect the ambient air temperature sensor Was any failure found Clean the ambient air temperature...

Page 288: ... S5 UJ08E10 for removal and installation of the DEF injector 3 Connect the vehicle to Hino DX 4 Set the starter switch to the ON position 5 Select Check Function and check the DEF injector actuation Inspection procedure 1 Select Check Function 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank temperature is 5 ...

Page 289: ... Select Engine and check if P2214 has been detected in Fault Information NO YES Is operation normal Go to step 15 Replace the DEF injector After replacing the DEF injector execute a DPR forced regeneration Perform After inspection work of INFOR MATION section 15 Inspect the NOx sensor Hino DX Select Engine SAPH16F010300826 Has DTC P2214 been detected Replace the engine ECU After replacing the engi...

Page 290: ... liters 1 3 gallons of DEF solution Afterward drive the vehi cle and con firm that the problem does not recur under driving conditions Perform After inspection work of INFORMA TION section 2 Inspect the exhaust pipe Check the exhaust pipe and make sure it has no cracks or exhaust leaks soot leaks and verify that coupling flanges are properly tightened Failure found Go to YES No failure found Go to...

Page 291: ...ture sensor SCR inlet 2 Make sure there is no dirt or damage to the exhaust gas temperature sensor SCR inlet Failure found Go to YES No failure found Go to NO Clean the exhaust gas temperature sensor SCR inlet and install it prop erly If damaged replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of INFORMA TION section Go to step 7 7 Inspect the exhaust gas temperat...

Page 292: ... work of INFORMA TION section Go to step 10 10 Inspect the exhaust gas temperature sensor DOC outlet unit Measure the resistance between the terminals of the exhaust gas temperature sensor DOC outlet Tester connections Exhaust gas temperature sensor DOC outlet TEX1 GND1 Standard values 20 C 68 F 13 7 29 8 k 50 C 122 F 7 13 13 7 k 80 C 176 F 4 1 7 13 k The measure ments meet the standard value Go t...

Page 293: ...tep 14 Replace the sensor Perform After inspection work of INFORMA TION section 14 Inspection of the DEF injec tor Hino DX Remove the DEF injector from the muffler and select Check func tions in Hino EX menu ECU and inspect the operation of DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all t...

Page 294: ...2214 has been detected Go to YES No DTC has beendetected Go to NO Replace the engine ECU After replac ing the engine ECU execute a DPR forced regeneration Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P2214 NOx sensor SCR downstream Performance and Monitoring capability Inspection procedure Step Action Descriptio...

Page 295: ...Failure determination time 3 seconds 3 Reset condition After normal operation is restored and starter switch OFF 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Symptoms on the vehicle due...

Page 296: ...ENGINE CONTROL SYSTEM J08E 4 1073 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Engine ECU failure ...

Page 297: ...the boost pressure sensor pipes and hoses and make sure they are free of dirt clogging or damage NO YES 1 Inspect the boost pressure sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the boost pressure sensor Was any failure found Replace the boost pressure sensor if the boost pressure sensor is dir...

Page 298: ...rter switch to the ON position 8 Select Engine and check if P2227 has been detected in Fault Information NO YES 3 Check the DTC detected Engine ECU 2 Hino DX Select Engine When communicat ion with the engine ECU is interrupted while the engine ECU is connected to the Hino DX the connection symbol at the left bottom of the Hino DX screen figure on the left becom es disconnected SAPH16F010300828 Has...

Page 299: ... and hoses and make sure they are free of dirt clogging or damage Failure found Go to YES No failure found Go to NO Replace the boostpressure sensor if the boostpressure sensor is dirty clogged or damaged Perform After inspection work of INFORMA TION section Go to step 3 3 Check the DTC detected Engine ECU 2 Hino DX 1 Erase the trouble history 2 Set the starter switch to the LOCK position 3 Make s...

Page 300: ...ailure timer 3 seconds 3 Reset condition After restoration to normal condition 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection w...

Page 301: ...ENGINE CONTROL SYSTEM J08E 4 1078 8 Estimated failure factors Malfunction of engine ECU ...

Page 302: ...fter restoration to normal condition 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in t...

Page 303: ... ON position 5 Select Engine and check if DTC has been detected in Fault Infor mation NO YES 1 Check the DTC detected Engine ECU 1 Select Engine SAPH16F010300831 Has a DTC other than P2228 or P2229 been detected Go to the diagnostic procedure of a related DTC Go to step 2 2 Check the DTC detected Engine ECU 2 Select Engine When communicat ion with the engine ECU is interrupted while the engine ECU...

Page 304: ...tected Go to NO Go to diagno sis procedure of a related DTC Go to step 2 2 Check the DTC detected Engine ECU 2 1 Erase the trouble history 2 Set the starter switch to the LOCK position 3 Make sure the engine ECU main relay is OFF in Hino DX menu This cuts off the communication between Hino DX and the engine ECU 4 Set the starter switch to the ON position 5 Select Engine and check if DTC has been d...

Page 305: ... not accumulated in the fuel filter 4 Indication warning or system control regulation when the DTC is set MIL OFF Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTC...

Page 306: ...ter water level sensor SIGNAL terminal and GND terminal 1 Inspect the fuel filter Was any failure found Drain water out of the fuel filter Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the fuel filter water level sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 3 Inspect the fu...

Page 307: ...orm After inspection work of INFOR MATION section 4 Inspect the fuel filter water level sensor power supply F FF L4F F FG L4D SAPH16F010300835 Measurement conditions Tester connections Standard values Starter switch ON Fuel filter water level sensor vehi cle side connector F FF F FG 10 16 V Do the measurements meet the standard value Go to step 5 Inspect the fuel filter water level sensor power ci...

Page 308: ...TION section 6 Inspect for disconnection in wire harness of the fuel filter water level sensor A V42 F FS L4E SAPH16F010300837 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness Fuel filter water level sensor vehi cle side connector WIF V42 F FS Less than 1 Do the measurements meet the standard value Go to step 7 Repair or replace the harn...

Page 309: ...ttery between the 12 V terminal in the fuel filter water level sen sor and the GND terminal 2 Measure the voltage between the fuel filter water level sensor SIGNAL termi nal and GND terminal Tester connections Fuel filter water level sensor SIGNAL GND Standard values 0 V no water 0 6 0 7 V Water level within allowable range The measure ments meet the standard value Go to YES The measure ments do n...

Page 310: ...Measure the resistance between the engine ECU signal check harness terminal and fuel filter water level sensor vehicle side connector terminal Tester connections Engine ECU signal check har ness fuel filter water level sen sor vehicle side connector WIF V42 F FS Standard values Less than 1 Within the standard value Go to YES Outside the standard value Go to NO Go to step 7 Repair or replace the ha...

Page 311: ...c 4 4 psi or 35 kPa sec 5 1 psi Engine speed fluctuation is less than 100 r min 2 Judgement criteria Difference between estimated boost pressure actual boost pressure is either 55 kPa sec 8 0 psi sec or 30 kPa sec 4 4 psi sec 3 Reset condition After normal operation is restored and the starter switch is on the LOCK position 4 Indication warning or system control regulation when the DTC is set MIL ...

Page 312: ...hesitation 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Hesitation or sticking due to corrosion of VNT link system rods Faulty connector contact to REA Harness disconnection or short circuit EGR valve malfunction Intake system failure Boost pressure ...

Page 313: ...elect VNT check 3 Click Check start 4 Click VNT opening UP Inspect the response delay at each step of the Target VNT posi tion and Actual VNT position from 0 to 90 5 Click VNT opening DOWN Inspect the response delay at each step of the Target VNT posi tion and Actual VNT position from 90 to 0 HINT The VNT opening position changes of 10 per step between 0 90 NO YES 1 Check the response delay of the...

Page 314: ...ag following characteristics of the target EGR valve opening and actual EGR valve opening HINT In EGR openings from 0 100 1 step corresponds to a 10 change NO YES 1 Check there is no dirt damage or clogging in the air cleaner ele ment 2 Make sure the element is a Hino genuine part NO YES 2 Check the response delay of the EGR valve Hino DX 4 5 3 1 2 SAPH16F010300841 Standard values The response del...

Page 315: ...damage to the boost pressure sensor NO YES 4 Check the air intake system Was any failure found Clean or replace the faulty part Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the boost pressure sensor Was any failure found Clean the boost pressure sensor and install it properly If dirt clogging or damage was found replace the sensor Perform After inspection work of IN...

Page 316: ...gain 6 Select Engine and check if P226C has been detected in Fault Information HINT Turn the starter switch OFF and ON verifies the wiping operation of the VNT actuator DC motor NO YES 6 Check the operation of the VNT actuator DC motor Hino DX Select Engine SAPH16F010300842 Has DTC P226C been detected Replace the turbocharger Perform After inspection work of INFOR MATION section Procedure complete...

Page 317: ...functions 2 Select VNT check 3 Click Check start 4 Click VNT opening UP Inspect the response delay at each step of the Target VNT position and Actual VNT position from 0 to 90 5 Click VNT opening DOWN Inspect the response delay at each step of the Target VNT position and Actual VNT position from 0 to 90 HINT The VNT opening position changes of 10 per step between 0 90 Standard values The response ...

Page 318: ...cified EGR opening time lag response lag is less than 5 seconds The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Replace the EGR valve Perform After inspection work of INFORMA TION section 3 Inspect air cleaner ele ment 1 Check there is no dirt dam age or clogging in the air cleaner element 2 Make sure the element is a Hino...

Page 319: ...actu ator DC motor Hino DX Connect the VNT controller and VNT actuator connector and erase the trouble history Turn the starter switch from LOCK position to the ON posi tion check if P226C has been detected in Engine HINT Turning the starter switch OFF and ON verifies the wiping operation of the VNT actuator DC motor DTC P226C has been detected Go to YES No DTC has beendetected Go to NO Replace th...

Page 320: ...ys While the engine is stopped During wiping operation 2 Judgement criteria 3 Reset condition After normal operation is restored and starter switch is turned OFF 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function is not available Auxiliary brake function is not available 5 Symptoms on the vehicle when the D...

Page 321: ...ehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Stuck nozzle Stuck external link ...

Page 322: ... 2 Select Engine and check if P22D3 has been detected in Fault Information NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300844 Has a DTC other than P22D3 been detected Go to the diagnostic procedure of a related DTC After the repair go to step 2 Go to step 3 2 Check the DTC detected 2 Engine ECU Hino DX Select Engine SAPH16F010300845 Has DTC P22D3 been detected Go t...

Page 323: ...ition from 0 to 90 5 Select VNT opening DOWN Inspect the response delay at each step of the Target VNT posi tion and Actual VNT position from 90 to 0 HINT The VNT opening position changes of around 10 per step between 0 90 NO YES 3 Check the response delay of the VNT controller Hino DX 4 5 3 1 2 SAPH16F010300846 Standard values From the Target VNT position to the Actual VNT position the response d...

Page 324: ...nu then inspect the response delay at the Target VNT position and Actual VNT position CAUTION Perform the inspection while the engine is stopped to avoid damages Inspection procedure 1 Select Check functions 2 Select VNT check 3 Click Check start 4 Select VNT opening UP Inspect the response delay at each step of the Target VNT position and Actual VNT position from 0 to 90 5 Select VNT opening DOWN...

Page 325: ...LMZ LM6 LM0 LM7 LM6 Z3 ENG To CAN circuit DPR BA 1 EGR controller BA 1 To CAN circuit DPR Common rail pressure sensor Intake air temperature sensor intake manifold Boost pressure sensor Air flow sensor Engine speed main sensor crankshaft position sensor Engine ECU LCE PCR3 GND1 KRP K6E KRX K6D SIG1 VCC1 GND2 SIG2 VCC2 AVC1 PCR2 AGD1 PCR1 AGD2 KRY PCR4 LL3 E2 AVC2 KRQ K2C K8P K8M LLK LLH LLJ K8N LB...

Page 326: ...essure is 75 kPa 10 8 psi Above conditions continue for at least 8 seconds 2 Judgement criteria When the sum of the differences between the theoretical EGR rate and actual EGR rate is equal to or greater than the threshold value Above criterion is determined from the boost pressure intake manifold temperature air intake quantity fuel injec tion rate and engine speed 3 Reset condition After normal ...

Page 327: ...ENGINE CONTROL SYSTEM J08E 4 1104 EGR valve malfunction Clogged air intake system VNT controller malfunction ...

Page 328: ... check 3 Click Check start 4 Click EGR opening UP Check each step from 0 100 of the time lag following characteristics of the target EGR valve opening and actual EGR valve opening 5 Click EGR opening DOWN Check each step from 100 0 of the time lag following characteristics of the target EGR valve opening and actual EGR valve opening HINT In EGR openings from 0 100 1 step corresponds to a 10 change...

Page 329: ...ach step of the Target VNT posi tion and Actual VNT position from 90 to 0 HINT The VNT opening position changes of 10 per step between 0 90 NO YES 1 Check there is no dirt damage or clogging in the air cleaner ele ment 2 Make sure the element is a Hino genuine part NO YES 2 Check the response delay of the VNT controller Hino DX 4 5 3 1 2 SAPH16F010300849 Standard values The response delay should b...

Page 330: ...le for dirt clogging or damage NO YES 4 Inspect the air flow sensor Was any failure found If dirt clogging or damage was found replace the sensor Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the air flow sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 6 6 Check the air intake s...

Page 331: ...boost pressure sensor Was any failure found Clean the boost pressure sensor and install it properly If dirt clogging or damage was found replace the sensor Perform After inspection work of INFOR MATION section Go to step 8 8 Inspect the intake air temperature sensor intake manifold connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION secti...

Page 332: ...Remove foreign substances and clean the EGR valve Replace the EGR valve if it is damaged Perform After inspection work of INFOR MATION section Go to step 11 11 Check the injector Hino DX Engine Ne r min NE Rotational fluctuation 1 500 r min measurement by Hino DX Select Engine SAPH16F010300850 Measurement conditions Engine speed 1 500 r min No load T M shift lever Neutral position A C off and Air ...

Page 333: ...ne and check if P240F has been detected in Fault Information NO YES Go to step 12 Replace the injector Perform After inspection work of INFOR MATION section 12 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300852 Has DTC P240F been detected Return to step 1 and perform again the inspection Procedure completed Perform After inspection work of INFOR MATION section ...

Page 334: ... meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 2 Replace the valve Perform After inspection work of INFORMA TION section 2 Check the response delay of the VNT controller Hino DX Select Check functions from the menu then inspect the response delay at the Target VNT position and Actual VNT position Inspection procedure 1 Select Check function...

Page 335: ... contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 6 6 Check the air intake system Check the air intake system between air cleaner and diesel throttle for dirt clogging or dam age The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Cl...

Page 336: ...he intake air temperature sensor intake manifold Failure found Go to YES No failure found Go to NO Clean the intake air tem perature sen sor intake manifold and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 10 10 Inspect the EGR valve 1 Check the EGR valve for damage due to foreign sub stances 2 Check if there is soot obstructin...

Page 337: ...ion vehicle Measure ments met the standard value Both injection amount and rotational vari ation Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 12 Replace the injector Perform After inspection work of INFORMA TION section 12 Check the DTC detected Engine ECU Hino DX Perform engine warm up engine coolant temperature 60 C 140 F or more check if P240F has been detecte...

Page 338: ...ed since start of engine Difference between engine coolant temperature and intake temperature is within 8 C 14 4 F Difference between BCU exhaust gas temperature sensor value and exhaust gas temperature sensor value DOC outlet is within 30 C 54 F Engine coolant temperature and intake temperature are at least 10 C 14 F Value of BCU exhaust gas temperature sensor 30 C 86 F No other DTC is detected 2...

Page 339: ...unction Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Exhaust gas temperature sensor DOC inlet Disconnected sensor or sensing unit failure due to dirt clogging damage etc Abnormal sensor resistance Failure of e...

Page 340: ...lative exhaust gas flow amount of non operating burner 50 kg After the above Battery voltage is in the range of 10 V to 16 V Engine speed 500 r min for at least 5 seconds Engine speed 1750 r min Fuel injection amount 15 mm3 st Exhaust gas flow rate 500 kg h Difference between engine coolant temperature and intake temperature is more than 8 C 14 4 F In addition the following conditions continue for...

Page 341: ...on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Exhaust gas temperature sensor DOC inlet Disconnected sensor o...

Page 342: ...nsor DOC inlet 1 Inspect the exhaust gas temperature sensor DOC inlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the exhaust gas temperature sensor DOC inlet Was any failure found Clean the exhaust gas temperature sensor DOC inlet and install it properly If damaged replace the exhaust gas temper atu...

Page 343: ... the standard value Go to step 4 Replace the exhaust gas temperature sensor DOC inlet Perform After inspection work of INFOR MATION section 4 Inspect the sensor power supply LCY LCZ SAPH16F010300856 Measurement conditions Tester connections Standard values Starter switch ON Exhaust gas tem perature sensor DOC inlet vehicle side connector LCZ LCY 4 5 5 5 V Do the measurements meet the standard valu...

Page 344: ...er inspection work of INFOR MATION section 6 Inspect disconnection of the exhaust gas temperature sensor DOC inlet harness B V46 V49 SAPH16F010300858 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness ADG9 V46 ET2 V49 20 C 68 F 13 7 29 8 k 50 C 122 F 7 13 13 7 k 80 C 176 F 4 1 7 13 k Do the measurements meet the standard value Go to step 7...

Page 345: ...le to Hino DX 4 Set the starter switch to the ON position 5 Select Engine and check if P242B has been detected in Fault Information NO YES 7 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300859 Has DTC P242B been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 346: ... Make sure there is no dirt or damage to the exhaust gas temperature sensor DOC inlet Failure found Go to YES No failure found Go to NO Clean the exhaust gas temperature sensor DOC inlet and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the exhaust gas temperature sensor DOC inlet unit Disconnect the exhaust gas tem ...

Page 347: ...N section 6 Inspect dis connection of the exhaust gas tempera ture sensor DOC inlet harness Connect the exhaust gas temper ature sensor DOC inlet connec tor and measure the resistance of the engine ECU signal check harness terminals Tester connections ADG9 V46 ET2 V49 Standard values 20 C 68 F 13 7 29 8 k 50 C 122 F 7 13 13 7 k 80 C 176 F 4 1 7 13 k The measure ments meet the standard value Go to ...

Page 348: ...y recognized 2 DTC set condition 1 Check conditions Battery voltage is in the range of 10 V to 16 V The engine has stopped or runs at 500 r min or higher for continuous 5 seconds 2 Judgement criteria Voltage of the exhaust gas temperature sensor DOC inlet remains less than 0 0057 V 1 240 C 2 264 F for 3 seconds 3 Reset condition Immediately after normal operation is restored 4 Indication warning o...

Page 349: ... in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Exhaust gas temperature sensor DOC inlet Loose disconnected sensor or failure in sensing area contamination clogging or breakage Abnormal resistance of sensor Failure in engine ECU sensor power supply Disconnection or short circuit in sensor harness Irregular co...

Page 350: ...ir temperature is 20 C 4 F or higher Battery voltage is in the range of 10 V to 16 V The engine has stopped or runs at 500 r min or higher for continuous 5 seconds No other DTCs are present 2 Judgement criteria Voltage of the exhaust gas temperature sensor DOC inlet remains at 4 958 V or higher 46 C 50 8 F or lower for 3 seconds 3 Reset condition Immediately after normal operation is restored 4 In...

Page 351: ... range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Exhaust gas temperature sensor DOC inlet Loose disconnected sensor or failure in sensing area contamination clogging or breakage Abnormal resistance of sensor Short circuit in the sensor Failure in engine ECU sensor power supply Disconnection or short circuit in sensor harnes...

Page 352: ...mperature sensor DOC inlet 1 Inspect the exhaust gas temperature sensor DOC inlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the exhaust gas temperature sensor DOC inlet Was any failure found Clean the exhaust gas temperature sensor DOC inlet and install it properly If damaged replace the exhaust ga...

Page 353: ...ts meet the standard value Go to step 4 Replace the exhaust gas temperature sensor DOC inlet Perform After inspection work of INFOR MATION section 4 Inspect the sensor power supply LCY LCZ SAPH16F010300863 Measurement conditions Tester connections Standard values Starter switch ON Exhaust gas tem perature sensor DOC inlet vehicle side connector LCZ LCY 4 5 5 5 V Do the measurements meet the standa...

Page 354: ...form After inspection work of INFOR MATION section 6 Inspect disconnection of the exhaust gas temperature sensor DOC inlet harness B V46 V49 SAPH16F010300865 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness ADG9 V46 ET2 V49 50 C 122 F 9 75 k 100 C 212 F 3 77 150 C 302 F 1 80 Do the measurements meet the standard value Go to step 7 Repair...

Page 355: ... 4 Set the starter switch to the ON position 5 Select Engine and check if the DTC 242C or P242D has been detected in Fault Information NO YES 7 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300866 Has DTC P242C or P242D been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION sec...

Page 356: ...nd Go to NO Clean the exhaust gas temperature sensor DOC inlet and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the exhaust gas temperature sensor DOC inlet unit Measure the resistance between the terminals of the exhaust gas temperature sensor DOC inlet Tester connections Exhaust gas temperature sensor DOC inlet TE...

Page 357: ...ne ECU signal check harness Tester connections Engine ECU signal check har ness ADG9 V46 ET2 V49 Standard values 50 C 122 F 9 75 k 100 C 212 F 3 77 150 C 302 F 1 80 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 7 Repair or replace the harness Perform After inspection work of INFORMA TION section 7 Check the DTC detected En...

Page 358: ...ferential pressure in DPR part is detected 2 DTC set condition 1 DTC detection condition The engine must not be stopped After automatic regeneration Burner in inactive status Calculated exhaust gas flow rate of 205 L s or higher Exhaust brake is inactive 2 Judgement criteria Engine ECU PTO accelerator sensor K95 ET4 ET2 EXPS ADG9 AVC5 LCG KR4 GND3 TEX3 KUH LCT KUQ VOUT GND KSK KSL VCC KSJ LCY LCZ ...

Page 359: ...e rear end surface Abnormal control of the temperature at regeneration Burner system failure Excessively high burner outlet temperature Filter damage due to abnormally high temperature at regeneration due to excessive soot emission Injector Characteristic abnormality of injection volume SCV Faulty control of common rail pressure EGR valve Faulty control of EGR opening angle Diesel throttle valve F...

Page 360: ...shold value obtained from the intake air quantity fuel injection quantity and the prescribed exhaust gas flow rate derived from the exhaust temperature and this is detected 6 times Example A differential pressure of 2 kPa 0 3 psi or less is detected 6 times when the average exhaust gas flow rate is 800 L s 3 Reset condition Immediately after normal operation is restored and DPR related memory is r...

Page 361: ...rature Filter damage due to abnormally high temperature at regeneration due to excessive soot emission Injector Characteristic abnormality of injection volume SCV Faulty control of common rail pressure EGR valve Faulty control of EGR opening angle Diesel throttle valve Faulty control of diesel throttle valve opening angle Confirmation points for judgment Fault in the differential pressure sensor s...

Page 362: ...X Report to read the his tory of the exhaust gas temperature sensor DOC inlet HINT Refer to the chapter HINO DIAGNOSTIC EXPLORER in the sec tion Hino DX manual for the detail of Hino DX report in the con tents of Past Work Information NO YES 1 Check the DTC detected Engine ECU Select Engine SAPH16F010300869 Has DTC P141F been detected Check the burner system BCU Go to step 2 2 Check the exhaust ga...

Page 363: ... hose SCR Catalysts NH3 Slip DOC DPR SAPH16F010300871 Was any failure found Repair clean or replace the differential pres sure sensor pipe Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the differential pressure sensor hose Differential pressure sensor pipe and hose SCR Catalysts NH3 Slip DOC DPR SAPH16F010300872 Was any failure found Repair cleaning or replace the di...

Page 364: ...nsor NO YES 5 Inspect the differential pressure sensor connector Was any failure found Connect securely Repair if needed Perform After inspection work of INFOR MATION section Go to step 6 6 Inspect the differential pressure sensor SAPH16F010300873 Was any failure found Clean the differential pressure sensor and install it properly If damaged replace the differential pressure sensor Perform After i...

Page 365: ... electrical tester NO YES 7 Inspect the differential pressure sensor unit GND VCC SAPH16F010300874 GND VOUT SAPH16F010300875 Measurement conditions Tester connections Standard values Starter switch LOCK DPR differential pressure sensor VCC GND VOUT GND 2 15 k Do the measurements meet the standard value Go to step 8 Replace the differential pressure sensor Perform After inspection work of INFOR MAT...

Page 366: ...urner inlet Looseness and poor contact NO YES 8 Inspect the DPR filter Damage SAPH16F010300876 Soot leakage SAPH16F010300877 Was any failure found Replace the DPR filter and the burner and clean the igniter Perform After inspection work of INFOR MATION section Go to step 9 9 Inspect the exhaust gas temperature sensor burner inlet connector Was any failure found Connect securely Repair if needed Pe...

Page 367: ...sor burner inlet 10 Inspect the outside of the exhaust gas temperature sensor burner inlet Was any failure found Clean the exhaust gas temperature sensor burner inlet and install it properly If damaged replace the exhaust gas temper ature sensor burner inlet Perform After inspection work of INFOR MATION section Go to step 11 11 Inspect the exhaust gas temperature sensor burner inlet unit ET ET ET ...

Page 368: ...burner inlet Perform After inspection work of INFOR MATION section 12 Inspect the exhaust gas temperature sensor burner outlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 13 13 Inspect the exhaust gas temperature sensor burner outlet Was any failure found Clean the exhaust gas temperature sensor burner outlet an...

Page 369: ... start 4 Click EGR opening UP Inspect the response delay at each step of the Target EGR posi tion and Actual EGR position from 0 to 100 5 Click EGR opening DOWN Inspect the response delay at each step of the Target EGR posi tion and Actual EGR position from 100 to 0 HINT The EGR opening position changes of 10 per step between 0 100 14 Inspect the exhaust gas temperature sensor burner outlet unit D...

Page 370: ...t the response delay at each step of the Target VNT posi tion and Actual VNT position from 90 to 0 HINT The VNT opening position changes of 10 per step between 0 90 NO YES Standard values From the Target EGR position to the Actual EGR position the response delay should be within 5 seconds Are the measurements within standard value Go to step 16 Replace the EGR valve Perform After inspection work o...

Page 371: ...ntity 3 Select Engine speed from the Data Monitor menu and measure the rotational fluctuation 17 Inspect the diesel throttle valve Was any failure found Replace the diesel throttle valve Perform After inspection work of INFOR MATION section Go to step 18 18 Inspect the SCV Was any failure found Repair or replace the faulty part Perform After inspection work of INFOR MATION section Go to step 19 19...

Page 372: ...ndard values Type of MT Allison 2200 Allison 2500 Allison 3500 Q mm3 st 5 0q 6 0q Ne r min 26 Do the measurements meet the standard values Do the injection volume and the rotational fluctuation meet their standard values Go to step 20 Replace the injector Perform After inspection work of INFOR MATION section 20 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300885 Has DTC P244A ...

Page 373: ...ation pattern 1 After engine has reached operating temperature more than 82 C 179 6 F 2 After air compressor completed building pressure 3 A C Head lights off 4 All devices off PTO Refrigeration compressor etc 5 Check that actual common rail pressure following target 1 Test method 750r min Measure each engine speed for 20 seconds Time Engine speed Engine speed pattern 1000 r min 1500 r min 2500 r ...

Page 374: ...asured SAPH16F010300888 3 If the following symptoms occur FAIL If not OK Time Common rail pressure Engine speed pattern Pressure is reduced by 5 MPa or more continually for 5 seconds or more Actual common rail pressure Target common rail pressure SAPH16F010300889 Time Common rail pressure Engine speed pattern Pressure is increased by 5 MPa or more continually for 5 seconds or more Actual common ra...

Page 375: ... pressure rapidly Replace the common rail f The maximum common rail pressure exceeds 222 MPa during pressure drop Check the return pipe Common rail pressure Accelerator pattern 222 MPa Time Actual common rail pressure Target common rail pressure SAPH16F010300891 Common rail pressure Accelerator pattern 222 MPa Time Actual common rail pressure Target common rail pressure SAPH16F010300892 Common rai...

Page 376: ...ne speed pattern The pressure is disturbed at a given speed and the pressure decreases at higher speed Remains for 5 seconds or longer 10 MPa or more Actual common rail pressure Target common rail pressure SAPH16F010300895 Time Common rail pressure Engine speed pattern Remains for 5 seconds or longer 10 MPa or more Actual common rail pressure Target common rail pressure SAPH16F010300896 Common rai...

Page 377: ...e than 82 C 179 6 F 2 After air compressor has completed building pressure 3 A C Head lights are off 4 All other devices turned off PTO Refrigeration compressor etc 5 Engine speed 750 r min Average current value 30sec Fluctuation in current value Time sec Target current value Current value mA SAPH16F010300898 Criteria FINAL VALUE OF PUMP CURRENT TARGET Average current value 1740 80 mA Fluctuation ...

Page 378: ...mpera ture history Go to YES No such his tory detected Go to NO Go to step 8 Go to step 3 3 Inspect the dif ferential pres sure sensor pipe Inspect the differential pressure sensor pipe for clogging cracks or other damages Failure found Go to YES No failure found Go to NO Repair clean or replace the differential pressure sen sor pipe Perform After inspection work of INFORMA TION section Go to step...

Page 379: ... the stan dard value Go to NO Go to step 8 Replace the sensor Perform After inspection work of INFORMA TION section 8 Inspect the DPR filter 1 Remove the DPR filter and check if there is no soot damages or other abnormal ities at its end 2 Check for proof of a forceful removal of the DPR filter Failure found Go to YES No failure found Go to NO Replace the DPR filter and the burner and clean the ig...

Page 380: ... stan dard value Go to NO Go to step 12 Replace the sensor Perform After inspection work of INFORMA TION section 12 Inspect the exhaust gas temperature sensor burner outlet connec tor Check the connection of the exhaust gas temperature sensor connector burner outlet Loose ness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspect...

Page 381: ...e Target EGR position and Actual EGR position Inspection procedure 1 Select Check functions 2 Select EGR check 3 Click Check start 4 Click EGR opening UP Inspect the response delay at each step of the Target EGR position and Actual EGR position from 0 to 90 5 Click EGR opening DOWN Inspect the response delay at each step of the Target EGR position and Actual EGR position from 90 to 0 Standard valu...

Page 382: ...meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 17 Replace the turbocharger Perform After inspection work of INFORMA TION section 17 Inspect the diesel throttle valve Check if there are no abnormal opening angles or that the valve is not stuck Failure found Go to YES No failure found Go to NO Replace the diesel throttle valve Perform After in...

Page 383: ...on r min 26 or less for with all type of transmis sion vehicle Measure ments met the standard value Both injection amount and rotational vari ation Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 20 Replace the injector Perform After inspection work of INFORMA TION section 20 Check the DTC detected Engine ECU Hino DX Perform engine warm up Engine coolant temperature...

Page 384: ...as pressure sensor dif ferential pressure sensor and the DPR temperature sensor Description of malfunction 2 DTC set condition 1 DTC detection condition The engine must not be stopped After automatic regeneration Burner in inactive status Calculated exhaust gas flow rate of 205 L s or higher Exhaust brake is inactive PTO accelerator sensor K95 ET4 ET2 EXPS ADG9 AVC5 LCG KR4 GND3 TEX3 KUH LCT KUQ V...

Page 385: ...stem did not operate DTC is stored Incomplete regeneration DPR temperature does not rise and regeneration is incomplete Exhaust gas temperature sensor burner outlet Check if sensing is wrong because of abnormal temperature characteristics Soot remains because of excessive quantity of soot accumulation Injector fuel injection quantity characteristics failure SCV faulty common rail pressure control ...

Page 386: ...culation is based on abnormal intake air quantity Exhaust gas temperature sensor Check if sensing is wrong because gas flow rate calculation is based on abnormal temperature characteristics Diesel throttle Diesel throttle opening control defective Exhaust brake Stuck on the closed side ...

Page 387: ...oot deposited from Hino DX report and oper ate using the method that matches the detection condition If the amount of deposited soot is less than 5 0 g L check Sheet 1 If the amount of deposited soot is more than 5 0 g L check Sheet 2 HINT Refer to the chapter HINO DIAGNOSTIC EXPLORER in the sec tion Hino DX manual for the detail of Hino DX report in the con tents of Past Work Information NO YES 1...

Page 388: ...king at the rear edge of the DPR filter no damage and no other abnormality NO YES 3 Check the DPR filter Damage SAPH16F010300902 Soot leakage SAPH16F010300903 Was any failure found Replace the DPR filter and the burner nozzle and clean the igniter Go to step 7 after replacement Go to step 4 ...

Page 389: ...pressure sensor exhaust gas pressure sensor unit SAPH16F010300904 Measurement conditions Tester connections Standard values Starter switch LOCK Differential pres sure sensor con nector VCC GND VOUT GND 2 15 k GND VCC SAPH16F010300905 GND VOUT SAPH16F010300906 Are the measurements within standard value Go to step 5 Replace the differential pressure sensor exhaust gas pressure sensor Perform After i...

Page 390: ...re found Repair cleaning or replace differential pres sure sensor pipe Perform After inspection work of INFOR MATION section Go to step 6 6 Inspect the differential pressure sensor hose Differential pressure sensor pipe and hose SCR Catalysts NH3 Slip DOC DPR SAPH16F010300908 Was any failure found Repair cleaning or replace differential pres sure sensor hose After replacement perform DPR forced re...

Page 391: ...Hino DX menu 6 Select Suction air volume check from Check functions on the menu and check that the characteristic air flow sensor perfor mance error does not exceed 10 compare with new and old sensors NO YES 7 Perform an engine basic inspection Hino DX Select Engine SAPH16F010300909 Was any failure found Repair or replace the faulty part If the air flow sensor is defective go to step 8 Go to step ...

Page 392: ...emperature sensor burner inlet 9 Inspect the exhaust gas temperature sensor burner inlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 10 10 Inspect the exhaust gas temperature sensor burner inlet Was any failure found Clean the exhaust gas temperature sensor burner inlet and install it properly If damaged replace...

Page 393: ...lace the exhaust gas temperature sensor burner inlet Perform After inspection work of INFOR MATION section 12 Inspect the exhaust gas temperature sensor burner outlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 13 13 Inspect the exhaust gas temperature sensor burner outlet Was any failure found Clean the exhaust...

Page 394: ...as temperature sensor burner outlet unit DIT DIT SAPH16F010300912 Measurement conditions Tester connections Standard values Starter switch LOCK Exhaust gas tem perature sensor burner outlet DIT DIT 0 3 1 8 Do the measurements meet the standard value Perform DPR forced regeneration Procedure completed Perform After inspection work of INFOR MATION section Replace the exhaust gas temperature sensor b...

Page 395: ...at the amount of soot deposited from Hino DX report and oper ate using the method that matches the detection condition If the amount of deposited soot is less than 5 0 g L check Sheet 1 If the amount of deposited soot is more than 5 0 g L check Sheet 2 HINT Refer to the chapter HINO DIAGNOSTIC EXPLORER in the sec tion Hino DX manual for the detail of Hino DX report in the con tents of Past Work In...

Page 396: ...Event TR hours Event Flame temp 574 1866 23 18 EECU_REQUEST_START_AUTO_REGEN 244 575 1866 23 48 FAILED_IGNITION MISFIRE 213 Yes Event TR hours Event Flame temp 934 1254 47 38 EECU_REQUEST_START_AUTO_REGEN 246 935 1254 47 59 IGNITION_SUCCESS 223 936 1254 50 01 CANNOT_REACH_TEMP 132 937 1254 50 01 EECU_REQUEST_STOP_REGEN 132 Yes Event TR hours Event Flame temp 948 1258 33 04 EECU_REQUEST_START_AUTO_...

Page 397: ...Flame temp 959 1262 38 05 EECU_REQUEST_START_AUTO_REGEN 260 960 1262 43 21 IGNITION_SUCCESS 241 961 1262 43 24 EECU_REQUEST_STOP_REGEN 337 963 1262 46 54 EECU_REQUEST_START_MANUAL_REGEN 630 964 1262 47 18 IGNITION_SUCCESS 510 965 1262 56 29 EECU_REQUEST_STOP_REGEN 911 Event log example SAPH16F010300915 Did you find a response log Go to step 6 Go to step 8 HINT The DPR manual regeneration request s...

Page 398: ...34 1254 47 38 EECU_REQUEST_START_MANUAL_REGEN 246 935 1254 47 59 IGNITION_SUCCESS 223 936 1254 50 01 CANNOT_REACH_TEMP 132 937 1254 50 01 EECU_REQUEST_STOP_REGEN 132 Yes Event TR hours Event Flame temp 948 1258 33 04 EECU_REQUEST_START_MANUAL_REGEN 266 949 1258 33 26 IGNITION_SUCCESS 232 950 1258 33 49 LOST_FLAME 197 Event log example SAPH16F010300917 Did you find a response log If FAILED IGNITION...

Page 399: ... the DPR filter and the burner nozzle and clean the igniter After DPR manual regeneration the diagnosis procedure will be complete Perform After inspection work of INFOR MATION section Go to step 9 9 Inspect DPR indicator light SAPH16F010300919 Was any failure found Repair or replace the faulty part Replace the DPR filter and the burner nozzle and clean the igniter After DPR manual regeneration th...

Page 400: ...ce the DPR filter and the burner nozzle and clean the igniter After DPR manual regeneration the diagnosis procedure will be complete Perform After inspection work of INFOR MATION section Go to step 11 11 Inspect accelerator switch Accelerator switch SAPH16F010300921 Was any failure found Repair or replace the faulty part Replace the DPR filter and the burner nozzle and clean the igniter After DPR ...

Page 401: ...air or replace the faulty part Replace the DPR filter and the burner nozzle and clean the igniter After DPR manual regeneration the diagnosis procedure will be complete Perform After inspection work of INFOR MATION section Go to step 13 13 Inspect the external accelerator signal Hino DX Was any failure found Check the external accelerator sensor Repair if necessary Replace the DPR filter and the b...

Page 402: ...sor un operating Engine coolant temperature more than 80 C 176 F Engine Ne rpm NE Rotational fluctuation 1 500 rpm measurement by Hino DX SAPH16F010300924 Standard values Type of MT Allison 2200 Allison 2500 Allison 3500 Q mm3 st 5 0q 6 0q Ne r min 26 Do the measurements meet the standard values Do the injection volume and the rotational fluctuation meet their standard values You forgot to press t...

Page 403: ... ditions Check that the amount of soot deposited from Hino DX report and operate using the method that matches the detec tion condition If the amount of deposited soot is less than 5 0 g L check Sheet 1 If the amount of deposited soot is more than 5 0 g L check Sheet 2 HINT Refer to the chapter HINO DIAGNOSTIC EXPLORER in the section Hino DX manual for the detail of Hino DX report in the contents ...

Page 404: ...n work of INFORMA TION section Go to step 6 6 Inspect the dif ferential pres sure sensor hose Inspect the differential pressure sensor hose for clogging cracks and other damages Failure found Go to YES No failure fond Go to NO Repair clean ing or replace differential pressure sen sor hose After replace ment perform DPR forced regeneration Perform After inspection work of INFORMA TION section Perfo...

Page 405: ... of INFORMA TION section 9 Inspect the exhaust gas temperature sensor burner inlet connec tor Check the connection of the exhaust gas temperature sensor burner inlet connector Loose ness and poor contact Failure found Go to YES No failure fond Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 10 10 Inspect the exhaust gas temperature sensor...

Page 406: ...ture sensor burner outlet 1 Check the installation of the exhaust gas temperature sensor burner outlet 2 Make sure there is no dirt or damage to the exhaust gas temperature sensor burner outlet Failure found Go to YES No failure fond Go to NO Clean the exhaust gas temperature sensor burner outlet and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION s...

Page 407: ... two types of DTC detection conditions The inspection method depends on these con ditions Check that the amount of soot deposited from Hino DX report and operate using the method that matches the detec tion condition If the amount of deposited soot is less than 5 0 g L check Sheet 1 If the amount of deposited soot is more than 5 0 g L check Sheet 2 HINT Refer to the chapter HINO DIAGNOSTIC EXPLORE...

Page 408: ... pro cedure If CANNOT ACHIEVE TEMP is dis played go to DTC P1400 inspection pro cedure Go to step 5 5 Check burner system 2 Hino DX In the log you received check if EECU REQUEST START MAN UAL REGEN is present after EECU REQUEST START AUTO REGEN Correspond ing log Go to YES No corre sponding log Go to NO Go to step 6 Go to step 8 6 Check burner system 3 Hino DX In the obtained log check if EECU REQ...

Page 409: ...on will cancel the manual regen eration Replace the DPR filter and the burner nozzle and clean the igniter After perform ing the DPR manual regen eration the inspection pro cedure will be complete Perform After inspection work of INFORMA TION section 8 Inspect DPR switch 1 Check the connection of the DPR switch connector Looseness and poor con tact 2 Check the switch unit 3 Inspect the harness for...

Page 410: ...After inspection work of INFORMA TION section Go to step 10 10 Inspect the neutral switch 1 Inspect the neutral connec tor mating poor contact 2 Inspect the switch unit 3 Inspect the harness for dis connections and short cir cuits Failure found Go to YES No failure found Go to NO Repair or replace the faulty part Replace the DPR filter and the burner nozzle and clean the igniter After DPR manual r...

Page 411: ...ection work of INFORMA TION section Go to step 12 12 Inspect PTO signal 1 Inspect the PTO switch con nector mating poor con tact 2 Check the PTO input signal 3 Inspect the switch unit 4 Inspect the harness for dis connections and short cir cuits Failure found Go to YES No failure found Go to NO Repair or replace the faulty part Replace the DPR filter and the burner nozzle and clean the igniter Aft...

Page 412: ...Select Engine speed from the Data Monitor menu and measure the rotational fluc tuation Measurement conditions Engine speed 1 500 r min No load Neutral A C off and Air compressor un operating Engine coolant temperature more than 80 C 176 F Standard values Injection quantity mm3 st 5 0 q or more for with MT vehicle 6 0 q or more for with Allison 2200 2500 3500 vehicle Rotation fluc tuation r min 26 ...

Page 413: ... injection rate 40 mm3 st cyl Battery voltage is in the range of 10 V to 16 V Engine speed fluctuation 156 r min Fuel injection rate fluctuation 87 mm3 st cyl Atmospheric pressure 75 kPa 10 8 psi Vehicle speed 21 km h 13 mph Intake rate 75 g sec Intake temperature sensor with built in air flow sensor is at least 10 C 14 F The above conditions continue for at least 40 seconds 2 Judgement criteria L...

Page 414: ... 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction Insufficient output or engine stall because of DPR filter clogging due to abnormal soot buildup 6 Pre inspection work Check that the battery voltage is in...

Page 415: ...as temperature sensor 1 Inspect the EGR cooler outlet gas temperature sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the EGR cooler outlet gas temperature sensor Was any failure found Clean the EGR cooler outlet gas temperature sensor and install it properly If damaged replace the EGR cooler outl...

Page 416: ...ion due to deformation or other damage 3 Check if coolant is leaking from the EGR cooler Do the measurements meet the standard value Go to step 4 Replace the EGR cooler outlet gas tempera ture sensor Perform After inspection work of INFOR MATION section 4 Inspect the coolant Was any failure found Replenish the coolant or repair or replace the faulty part Perform After inspection work of INFOR MATI...

Page 417: ...t 4 Select EGR opening UP Inspect the response delay at each step of the Target EGR posi tion and Actual EGR position from 0 to 100 5 Select EGR opening DOWN Inspect the response delay at each step of the Target EGR posi tion and Actual EGR position from 100 to 0 HINT The EGR opening position changes of around 10 per step between 0 100 Remove the soot in the gas passageway inlet outlet or repair o...

Page 418: ... NO YES Standard values The response delay should be less than 5 seconds Do the measurements meet the standard value Go to step 9 Replace the EGR valve Perform After inspection work of INFOR MATION section 9 Inspect the diesel throttle valve Was any failure found Replace the diesel throttle valve Perform After inspection work of INFOR MATION section Go to step 10 10 Inspect the SCV Hino DX Was any...

Page 419: ...APH16F010300929 Measurement conditions Engine speed 1 500 r min No load T M shift lever Neutral A C off and Air compressor un operating Engine coolant temperature More than 80 C 176 F NE Rotational fluctuation Engine NE r min 1500r min measurement by Hino DX SAPH16F010300930 Standard values Type of MT Allison 2200 Allison 2500 Allison 3500 Q mm3 st 5 0q 6 0q Ne r min 26 Do the measurements meet th...

Page 420: ...he ON position 4 Select Engine and check if P2457 has been detected in Fault Information NO YES 12 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300932 Has DTC P2457 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 421: ...er engine has reached operating temperature more than 82 C 179 6 F 2 After air compressor completed building pressure 3 A C Head lights off 4 All devices off PTO Refrigeration compressor etc 5 Check that actual common rail pressure following target 1 Test method 750r min Measure each engine speed for 20 seconds Time Engine speed Engine speed pattern 1000 r min 1500 r min 2500 r min 2000 r min SAPH...

Page 422: ...935 3 If the following symptoms occur FAIL If not OK Time Common rail pressure Engine speed pattern Pressure is reduced by 5 MPa or more continually for 5 seconds or more Actual common rail pressure Target common rail pressure SAPH16F010300936 Time Common rail pressure Engine speed pattern Pressure is increased by 5 MPa or more continually for 5 seconds or more Actual common rail pressure Target c...

Page 423: ... pressure rapidly Replace the common rail f The maximum common rail pressure exceeds 222 MPa during pressure drop Check the return pipe Common rail pressure Accelerator pattern 222 MPa Time Actual common rail pressure Target common rail pressure SAPH16F010300938 Common rail pressure Accelerator pattern 222 MPa Time Actual common rail pressure Target common rail pressure SAPH16F010300939 Common rai...

Page 424: ...ne speed pattern The pressure is disturbed at a given speed and the pressure decreases at higher speed Remains for 5 seconds or longer 10 MPa or more Actual common rail pressure Target common rail pressure SAPH16F010300942 Time Common rail pressure Engine speed pattern Remains for 5 seconds or longer 10 MPa or more Actual common rail pressure Target common rail pressure SAPH16F010300943 Common rai...

Page 425: ...e than 82 C 179 6 F 2 After air compressor has completed building pressure 3 A C Head lights are off 4 All other devices turned off PTO Refrigeration compressor etc 5 Engine speed 750 r min Criteria FINAL VALUE OF PUMP CURRENT TARGET Average current value 1740 80 mA Fluctuation in current value 80 mA Average current value 30sec Fluctuation in current value Time sec Target current value Current val...

Page 426: ...und Go to NO Clean the EGR cooler outlet gas tem perature sen sor and install it properly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the EGR cooler outlet gas tem perature sen sor unit measure the resistance between the terminals of the EGR cooler outlet gas temperature sensor Tester connections EGR cooler outlet gas tempera ture sens...

Page 427: ...he EGR cooler Failure found Go to YES No failure found Go to NO Remove the soot in the gas passageway inlet outlet or repair or replace the faulty part If the only cause of the malfunction was soot go to step 6 Go to step 7 7 Inspect the EGR valve 1 Check the EGR valve for damage due to incursion of foreign substances 2 Check if the inlet outlet of the exhaust gas passage way is obstructed by soot...

Page 428: ...the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 9 Replace the EGR valve Perform After inspection work of INFORMA TION section 9 Inspect the diesel throttle valve Check the working condition of the diesel throttle valve Connec tion or valve opening degree abnormalities Failure found Go to YES No failure found Go to NO Replace the diesel throttle va...

Page 429: ...ation fluctuation r min 26 or less for with all type of transmis sion vehicle Measure ments met the standard value Both injection amount and rotational vari ation Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 12 Replace the injector Perform After inspection work of INFORMA TION section 12 Check the DTC detected Engine ECU Hino DX Perform engine warm up engine cool...

Page 430: ...e was a difference between the actual amount of soot deposit calculation and the ideal amount of soot deposit calculation 3 Reset condition Immediately after normal operation is restored and DPR related memory is reset 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup contro...

Page 431: ...position 5 Select Engine and check if DTC has been detected in Fault Infor mation NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300946 Has a DTC other than P2459 been detected Go to diagnosis procedure of a related DTC Go to step 2 2 Check the DTC detected Engine ECU Hino DX Select Engine When communicat ion with the engine ECU is interrupted while the engine ECU is co...

Page 432: ...related DTC Go to step 2 2 Check the DTC detected Engine ECU Hino DX 1 Erase the trouble history 2 Set the starter switch to the LOCK position 3 Make sure the engine ECU main relay is OFF in Hino DX menu This cuts off the communication between Hino DX and the engine ECU 4 Set the starter switch to the ON position 5 Select Engine and check if P2459 has been detected in Fault Information DTC P2459 h...

Page 433: ... control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure ...

Page 434: ...anual regeneration was not performed Since the regeneration condition idle condition may not be met check the following Inspect the neutral switch accelerator switch system and vehicle speed sensor system Check for disconnection in the DPR switch PTO signal ON or unresponsive return of external accelerator ...

Page 435: ...r than P2463 has been detected in Fault Information NO YES 1 Select Burner and check if DTC has been detected in Fault Infor mation NO YES 1 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300948 Has a DTC other than P2463 been detected Go to diagnosis procedure of a related DTC Go to step 2 2 Check the DTC detected Burner Has DTC P2463 been detected Go to diagnosis procedure of ...

Page 436: ... 934 1254 47 38 EECU_REQUEST_START_AUTO_REGEN 246 935 1254 47 59 IGNITION_SUCCESS 223 936 1254 50 01 CANNOT_REACH_TEMP 132 937 1254 50 01 EECU_REQUEST_STOP_REGEN 132 Yes Event TR hours Event Flame temp 948 1258 33 04 EECU_REQUEST_START_AUTO_REGEN 266 949 1258 33 26 IGNITION_SUCCESS 232 950 1258 33 49 LOST_FLAME 197 Event log example SAPH16F010300949 Is the pertinent log displayed If FAILED IGNITIO...

Page 437: ...ed Go to DTC P200C inspection procedure Go to step 6 6 Burner system check 4 Hino DX No Event TR hours Event Flame temp 857 1228 24 36 EECU_REQUEST_START_MANUAL_REGEN 202 858 1228 24 58 IGNITION_SUCCESS 196 859 1228 25 17 EECU_REQUEST_STOP_REGEN 496 Yes Event TR hours Event Flame temp 574 1866 23 18 EECU_REQUEST_START_MANUAL_REGEN 244 575 1866 23 48 FAILED_IGNITION MISFIRE 213 Yes Event TR hours E...

Page 438: ...is that manual regeneration was canceled by depressing the accelerator pedal moving the shift lever operating the PTO and pressing the DPR button 2 times during DPR manual regeneration Replace the DPR filter and burner nozzle and clean the igniter Perform a DPR manual regeneration to complete the check procedure Perform After inspection work of INFOR MATION section 7 Inspect DPR switch SAPH16F0103...

Page 439: ...ch harness NO YES 8 Inspect the DPR indicator light SAPH16F010300954 Was any failure found Repair or replace the faulty part Replace the DPR filter and burner nozzle and clean the igniter Perform a DPR manual regeneration to complete the check procedure Perform After inspection work of INFOR MATION section Go to step 9 9 Inspect the neutral switch SAPH16F010300955 Was any failure found Repair or r...

Page 440: ...ck the PTO signal input 3 Check the switch unit 4 Check there is no disconnection or short circuit of the PTO switch harness 10 Inspect the accelerator switch Accelerator switch SAPH16F010300956 Was any failure found Repair or replace the faulty part Replace the DPR filter and burner nozzle and clean the igniter Perform a DPR manual regeneration to complete the check procedure Perform After inspec...

Page 441: ...egeneration to complete the check procedure Perform After inspection work of INFOR MATION section Go to step 12 12 Check the external accelerator signal Hino DX Was any failure found Check the installation of the external accelerator sensor Repair if necessary Replace the DPR filter and burner nozzle and clean the igniter Perform a DPR manual regeneration to complete the check procedure Perform Af...

Page 442: ...s tem check 1 Hino DX 1 Collect the burner events log from the Hino DX 2 Check whether EECU REQUEST START AUTO REGEN is the latest 3 Check FAILED IGNITION MISFIRE LOST FLAME or CANNOT ACHIEVE TEMP are displayed after the latest EECU REQUEST START AUTO REGEN Correspond ing log Go to YES No corre sponding log Go to NO If FAILED IGNITION MISFIRE is displayed go to DTC P140D inspection pro cedure If L...

Page 443: ...DTC P1400 inspection pro cedure The cause is that manual regeneration was canceled by depressing the accelerator pedal moving the shift lever operating the PTO and pressing the DPR button 2 times during DPR manual regeneration Replace the DPR and per form a DPR manual regen eration to com plete the check proce dure Perform After inspection work of INFORMA TION section 7 Inspect DPR switch 1 Check ...

Page 444: ...pro cedure Perform After inspection work of INFORMA TION section Go to step 9 9 Inspect the neutral switch 1 Check the connection of the neutral switch connector Looseness or poor con tact 2 Inspect the switch unit 3 Check there is no discon nection or short circuit of the neutral switch harness Failure found Go to YES No failure found Go to NO Repair or replace the faulty part Replace the DPR fil...

Page 445: ...erform After inspection work of INFORMA TION section Go to step 11 11 Inspect the PTO switch 1 Check the connection of the PTO switch connector Looseness or short circuit 2 Inspect the switch unit 3 Check the PTO signal input 4 Check there is no discon nection or short circuit of the PTO switch harness Failure found Go to YES No failure found Go to NO Repair or replace the faulty part Replace the ...

Page 446: ...he installation of the external accelerator sensor Repair if necessary Replace the DPR filter and burner nozzle and clean the igniter Perform a DPR manual regeneration to complete the check pro cedure Perform After inspection work of INFORMA TION section Caused by fail ure to press DPR switch Replace the DPR filter and burner nozzle and clean the igniter Perform a DPR manual regeneration to comple...

Page 447: ... than 10 seconds has elapsed since start of engine Difference between engine coolant temperature and intake temperature is within 8 C 14 4 F Difference between BCU exhaust gas temperature sensor value and exhaust gas temperature sensor value DOC inlet is within 70 C 126 F Engine coolant temperature and intake temperature are at least 10 C 14 F Value of BCU exhaust gas temperature sensor is less th...

Page 448: ...tion when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Exhaust...

Page 449: ...d Cumulative exhaust gas flow amount 3 kg Cumulative exhaust gas flow amount of non operating burner 50 kg After the above Battery voltage is 10 V 16 V Engine speed 500 r min for at least 5 sec Difference between engine coolant temperature and intake temperature 8 C 14 4 F Exhaust gas flow rate 500 kg h Engine speed 1 750 r min Fuel injection amount 15 mm3 st PTO accelerator sensor K95 ET4 ET2 EXP...

Page 450: ...is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is st...

Page 451: ...or DOC outlet 1 Inspect the exhaust gas temperature sensor DOC outlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the exhaust gas temperature sensor DOC outlet Was any failure found Clean the exhaust gas temperature sensor DOC outlet and install it properly If damaged replace the exhaust gas temper a...

Page 452: ... Go to step 4 Replace the exhaust gas temperature sensor DOC outlet Perform After inspection work of INFOR MATION section 4 Inspect the sensor power supply KSF KSE SAPH16F010300961 Measurement conditions Tester connections Standard values Starter switch ON Exhaust gas tem perature sensor DOC outlet vehi cle side connector KSF KSE 4 5 5 5 V Do the measurements meet the standard value Go to step 7 G...

Page 453: ...er inspection work of INFOR MATION section 6 Inspect disconnection of the exhaust gas temperature sensor DOC outlet harness B V46 V57 SAPH16F010300963 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness ADG9 V46 ET4 V57 20 C 68 F 13 7 29 8 k 50 C 122 F 7 13 13 7 k 80 C 176 F 4 1 7 13 k Do the measurements meet the standard value Go to step ...

Page 454: ...e to Hino DX 4 Set the starter switch to the ON position 5 Select Engine and check if P246F has been detected in Fault Information NO YES 7 Check the DTC detected Engine ECU 2 Hino DX Select Engine SAPH16F010300964 Has DTC P246F been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 455: ...C outlet and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the exhaust gas temperature sensor DOC outlet unit Measure the resistance of the exhaust gas temperature sensor DOC outlet terminals Tester connections Exhaust gas temperature sensor DOC outlet TEX1 GND1 Standard values 20 C 68 F 13 7 29 8 k 50 C 122 F 7 13 1...

Page 456: ...he engine ECU signal check harness terminal Tester connections Engine ECU signal check har ness ADG9 V46 ET4 V57 Standard values 20 C 68 F 13 7 29 8 k 50 C 122 F 7 13 13 7 k 80 C 176 F 4 1 7 13 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 7 Repair or replace the harness Perform After inspection work of INFORMA TION sect...

Page 457: ...ttery voltage is in the range of 10 V to 16 V The engine has stopped or runs at 500 r min or higher for continuous 5 seconds or longer 2 Judgement criteria Voltage of the exhaust gas temperature sensor DOC outlet remains less than 0 0057 V 1 240 C 2 264 F for 3 seconds 3 Reset condition After restoration to normal condition PTO accelerator sensor K95 ET4 ET2 EXPS ADG9 AVC5 LCG KR4 GND3 TEX3 KUH LC...

Page 458: ...eck that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Exhaust gas temperature sensor DOC outlet Loose disconnected sensor or failure in sensing area contamination clogging or breakage Abnormal resistance of sensor Failure in engine ECU sensor power supply Disconnection or short circui...

Page 459: ...s in the range of 10 V to 16 V The engine has stopped or runs at 500 r min or higher for continuous 5 seconds or longer No other DTCs are present 2 Judgement criteria Voltage of the exhaust gas temperature sensor DOC outlet remains at 4 958 V or higher 46 C 50 8 F or lower for 3 seconds 3 Reset condition After restoration to normal condition PTO accelerator sensor K95 ET4 ET2 EXPS ADG9 AVC5 LCG KR...

Page 460: ...eck that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Exhaust gas temperature sensor DOC outlet Loose disconnected sensor or failure in sensing area contamination clogging or breakage Abnormal resistance of sensor Failure in engine ECU sensor power supply Disconnection or short circui...

Page 461: ...sor DOC outlet 1 Inspect the exhaust gas temperature sensor DOC outlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the exhaust gas temperature sensor DOC outlet Was any failure found Clean the exhaust gas temperature sensor DOC outlet and connect the sensor securely If damaged replace the exhaust gas...

Page 462: ...o to step 4 Replace the exhaust gas temperature sensor DOC outlet Perform After inspection work of INFOR MATION section 4 Inspect the exhaust gas temperature sensor DOC outlet power supply KSF KSE SAPH16F010300968 Measurement conditions Tester connections Standard values Starter switch ON Exhaust gas tem perature sensor DOC outlet vehi cle side connector KSF KSE 4 5 5 5 V Do the measurements meet ...

Page 463: ...er inspection work of INFOR MATION section 6 Check disconnection in wire harness of exhaust gas temperature sensor DOC outlet B V46 V57 SAPH16F010300970 Measurement conditions Tester connections Standard values Starter switch LOCK Engine ECU signal check harness ADG9 V46 ET4 V57 50 C 122 F 7 4 19 6 k 100 C 212 F 3 0 6 2 k 150 C 302 F 1 5 2 6 k Do the measurements meet the standard value Go to step...

Page 464: ... 4 Set the starter switch to the ON position 5 Select Engine and check if the DTC P2470 or P2471 has been detected in Fault Information NO YES 7 Check the DTC detected Engine ECU Hino DX Select Engine SAPH16F010300971 Has DTC P2470 or P2471 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION se...

Page 465: ...ion of the exhaust gas temperature sensor DOC outlet 2 Make sure there is no dirt or damage to the exhaust gas temperature sensor DOC outlet Failure found Go to YES No failure found Go to NO Clean the exhaust gas temperature sensor DOC outlet and install it prop erly If damaged replace the sensor Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the exhaust gas temperatu...

Page 466: ...ction in wire harness of exhaust gas temperature sensor DOC outlet 1 Connect the exhaust gas temperature sensor DOC outlet connector 2 Measure the resistance between the terminals of the engine ECU signal check harness Tester connections Engine ECU signal check har ness ADG9 V46 ET4 V57 Standard values 50 C 122 F 7 4 19 6 k 100 C 212 F 3 0 6 2 k 150 C 302 F 1 5 2 6 k The measure ments meet the sta...

Page 467: ...TC set condition 1 DTC detection condition While the engine is in operation Always While the engine is stopped During wiping operation 2 Judgement criteria 3 Reset condition After normal operation is restored and the starter switch is on the LOCK position 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function i...

Page 468: ... Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Faulty contact in VNT actuator REA connector Harness disconnection or short circuit Actuator internal sensor failure Controller internal failure ...

Page 469: ...t the starter switch to the ON position 2 Select Engine and check if P2563 has been detected in Fault Information NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300973 Has a DTC other than P2563 for example U010C been detected Go to diagnosis procedure of a related DTC Go to step 2 after repair Go to step 3 2 Check the DTC detected 2 Engine ECU Hino DX Select Engine S...

Page 470: ...the VNT actuator vehicle side connector NO YES 3 Check the connector connection Hino DX VNT controller VNT controller SAPH16F010300975 Has DTC P2563 been detected Go to step 4 Procedure completed Poor contact of the connector Perform After inspection work of INFOR MATION section 4 Inspect the VNT actuator harness 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 VNT ACTUATOR VNT CONTROLLER SAP...

Page 471: ...he starter switch to the LOCK position 6 Set the starter switch to the ON position again 7 Select Engine and check if P2563 has been detected in Fault Information NO YES 5 Replace the VNT controller Hino DX Select Engine SAPH16F010300977 Has DTC P2563 been detected Replace the turbocharger Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of IN...

Page 472: ...nector con nection Hino DX 1 Set the starter switch to the LOCK position 2 Disconnect the connector connecting the VNT actuator and VNT controller and then securely re connect it 3 Set the starter switch to the ON position 4 Check if P2563 has been detected in Engine DTC P2563 has been detected Go to YES No DTC has beendetected Go to NO Go to step 4 Procedure completed Poor contact of the connec t...

Page 473: ... Set the starter switch to the ON position again 7 Check if P2563 has been detected in Engine DTC P2563 has been detected Go to YES No DTC has beendetected Go to NO Replace the turbocharger Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P2563 Nozzle position sensor failure range High level VNT actuator position se...

Page 474: ...ection condition While the engine is in operation Always While the engine is stopped During wiping operation 2 Judgement criteria 3 Reset condition After normal operation is restored and the starter switch is on the LOCK position 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function is not available Auxiliary ...

Page 475: ...at the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Faulty contact in VNT actuator REA connector Harness disconnection or short circuit Actuator internal sensor failure Controller internal failure ...

Page 476: ...n operation Always While the engine is stopped During wiping operation 2 Judgement criteria 3 Reset condition After normal operation is restored and the starter switch is on the LOCK position 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function is not available Auxiliary brake function is not available 5 Symp...

Page 477: ... is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Faulty contact in VNT actuator REA connector Harness disconnection or short circuit Actuator internal sensor failure Controller internal failure ...

Page 478: ...1 Set the starter switch to the ON position 2 Select Engine and check if the DTC P2564 or P2565 has been detected in Fault Information NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300980 Has a DTC other than DTC for example U010C been detected Go to diagnosis procedure of a related DTC Go to step 2 after repair Go to step 3 2 Check the DTC detected 2 Engine ECU Hino...

Page 479: ... in the VNT actuator vehicle side connector NO YES 3 Check the connector connection Hino DX VNT controller VNT controller SAPH16F010300982 Has DTC P2564 or P2565 been detected Go to step 4 Procedure completed Poor contact of the connector Perform After inspection work of INFOR MATION section 4 Inspect the VNT actuator harness 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 VNT ACTUATOR VNT C...

Page 480: ...itch to the LOCK position 6 Set the starter switch to the ON position again 7 Select Engine and check if the DTC P2564 or P2565 has been detected in Fault Information NO YES 5 Replace the VNT controller Hino DX Select Engine SAPH16F010300984 Has DTC P2564 or P2565 been detected Replace the turbocharger Perform After inspection work of INFOR MATION section Procedure completed Perform After inspecti...

Page 481: ...ated DTC Go to step 2 after repair Go to step 3 2 Check the DTC detected Engine ECU 2 Hino DX Check if the DTC P2564 or P2565 has been detected in Engine DTC P2564 or P2565 has beendetected Go to YES No DTC has beendetected Go to NO Go to step 3 Procedure completed Perform After inspection work of INFORMA TION section 3 Check the connector con nection Hino DX 1 Set the starter switch to the LOCK p...

Page 482: ... Repair or replace the harness Perform After inspection work of INFORMA TION section 5 Replace the VNT controller Hino DX Check if the DTC P2564 or P2565 has been detected DTC P2564 or P2565 has beendetected Go to YES No DTC has beendetected Go to NO Replace the turbocharger Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION sect...

Page 483: ... condition 1 DTC detection condition While the engine is in operation Always While the engine is stopped During wiping operation 2 Judgement criteria 3 Reset condition After normal operation is restored and the starter switch is on the LOCK position 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function is not ...

Page 484: ...e to malfunction Engine output is restricted 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors VNT link is stuck or cannot operate due to rust etc ...

Page 485: ... switch to the ON position 2 Select Engine and check if P259E has been detected in Fault Information NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300986 Has a DTC other than P259E been detected Go to the diagnostic procedure of a related DTC After repair go to step 2 Go to step 3 2 Check the DTC detected 2 Engine ECU Hino DX Select Engine SAPH16F010300987 Has DTC P2...

Page 486: ... check if P259E has been detected in Fault Information HINT Turn the starter switch OFF and ON verifies the wiping operation of the VNT actuator DC motor NO YES 3 Check the turbocharger external appearance Link SAPH16F010300988 Was any failure found Remove foreign substance and go to step 4 Go to step 4 4 Check the operation of the VNT controller Hino DX Select Engine SAPH16F010300989 Measurement ...

Page 487: ...tion from 0 to 90 5 Select VNT opening DOWN Inspect the response delay at each step of the Target VNT posi tion and Actual VNT position from 90 to 0 HINT The VNT opening position changes of around 10 per step between 0 90 NO YES 5 Check the response delay of the VNT controller 2 Hino DX 4 5 3 1 2 SAPH16F010300990 Standard values From the Target VNT position to the Actual VNT position the response ...

Page 488: ...9E has been detected Go to YES No DTC has beendetected Go to NO Go to step 3 Procedure completed Perform After inspection work of INFORMA TION section 3 Check the tur bocharger external appearance Check the turbocharger external appearance and make sure no foreign substances are trapped around the link Failure found Go to YES No failure found Go to NO Remove for eign sub stance and go to step 4 Go...

Page 489: ... Inspect the response delay at each step of the Target VNT position and Actual VNT position from 90 to 0 Standard values From the Target VNT position to the Actual VNT position the response delay should be within 3 seconds The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Procedure completed Perform After inspection work of INFORMA TION ...

Page 490: ... detection condition While the engine is in operation Always While the engine is stopped During wiping operation 2 Judgement criteria 3 Reset condition After normal operation is restored and the starter switch is on the LOCK position 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted Cruise control function is not available Auxili...

Page 491: ...vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Disconnection of external link ...

Page 492: ...he starter switch to the ON position 2 Select Engine and check if P259F has been detected in Fault Information NO YES 1 Check the DTC detected 1 Engine ECU Hino DX Select Engine SAPH16F010300992 Has a DTC other than P259F been detected Go to the diagnostic procedure of a related DTC After repair go to step 2 Go to step 3 2 Check the DTC detected 2 Engine ECU Hino DX Select Engine SAPH16F010300993 ...

Page 493: ...on again 5 Select Engine and check if P259F has been detected HINT Turn the starter switch OFF and ON verifies the wiping operation of the VNT actuator DC motor NO YES 3 Check operation of VNT controller Hino DX Select Engine SAPH16F010300994 Measurement conditions Starter switch LOCK ON Has DTC P259F been detected Replace the turbocharger Perform After inspection work of INFOR MATION section Go t...

Page 494: ...tion from 0 to 90 5 Select VNT opening DOWN Inspect the response delay at each step of the Target VNT posi tion and Actual VNT position from 90 to 0 HINT The VNT opening position changes of around 10 per step between 0 90 NO YES 4 Check the response delay of the VNT controller 2 Hino DX 4 5 3 1 2 SAPH16F010300995 Standard values From the Target VNT position to the Actual VNT position the response ...

Page 495: ...ed DTC Go to step 2 after repair Go to step 3 2 Check the DTC detected 2 Engine ECU Hino DX Check if P259F has been detected in Engine DTC P259F has been detected Go to YES No DTC has beendetected Go to NO Go to step 3 Procedure completed Perform After inspection work of INFORMA TION section 3 Check the operation of the VNT con troller Hino DX 1 Erase the malfunction his tory set the starter switc...

Page 496: ...WN Inspect the response delay at each step of the Target VNT position and Actual VNT position from 90 to 0 Standard values From the Target VNT position to the Actual VNT position the response delay should be within 3 seconds The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Procedure completed Perform After inspection work of INFORMA TIO...

Page 497: ...iteria Fuel rail pressure threshold map 60 sec continue 3 Reset condition After normal operation is restored and the starter switch is on the LOCK position 4 Indication warning or system control regulation when the DTC is set MIL OFF Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Common rail pressure sensor Engine ECU LL...

Page 498: ... due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors Supply pump failure Malfunction of engine ECU ...

Page 499: ...sure in Data Monitor 5 Start the engine while checking the common rail pressure 1 Inspect the start of the engine Does the engine start Go to step 4 Go to step 2 2 Inspect the supply pump SAPH16F010300998 Was any failure found Replace the supply pump and go to step 4 after replacement Go to step 3 3 Function check of supply pump Hino DX Idling Starter Engine starting Hour Common rail pressure 222M...

Page 500: ...e ECU software part number ECU part number by Hino DX Select About System in the View menu Confirm the latest part number with Hino national service man ager NO YES Standard values The actual common rail pressure rises and stabilizes at a con stant value Was any failure found Replace the supply pump go to step 4 after replacement Contact the Hino national service manager 4 SCV free acceleration te...

Page 501: ...nctured or bent 2 Make sure the fuel pipe joint bolts are not loose NO YES 6 Inspect the fuel filter SAPH16F010301001 Measurement conditions Standard values While engine is running At least 25 4 mm 1 in above collar and below the element upper level Fuel level does not con tinue to drop during wide open throttle Was any failure found Replace the fuel filter element and go to step 7 Go to step 12 7...

Page 502: ...S 1 Make sure the gauze filter built into the supply pump is not clogged 8 Inspect the fuel tank breather Was any failure found Repair or replace the faulty part and go to step 9 Go to step 9 9 Inspect the fuel tank feed pipe Was any failure found Repair or replace the faulty part and go to step 10 Go to step 10 10 Inspect the fuel tank Was any failure found Remove the foreign object and clean the...

Page 503: ...btained in step 4 and check if they improved Clean the gauze filter and go to step 12 Go to step 12 12 Inspect the fuel high pressure pipe Was any failure found Repair or replace the faulty part and go to step 13 Go to step 13 13 Inspect the bubble separator Was any failure found Repair or replace the faulty part and go to step 14 If failure was found in steps 7 12 Go to step 14 If failure was not...

Page 504: ...hicle side connector Procedure completed Perform After inspection work of INFOR MATION section Go to step 15 15 Inspect the SCV connector Was any failure found Repair or replace the faulty part and go to step 16 Go to step 16 16 Inspect the common rail pressure sensor connector Was any failure found Repair or replace the faulty part and go to step 17 Go to step 17 17 Inspect the common rail pressu...

Page 505: ...CV free acceler ation test 2 Compare the test results with those obtained in step 4 and check if they improved NO YES Go to step 18 Repair the common rail pressure sensor and then go to step 18 18 Inspect the crankshaft position sensor engine speed main sensor Hino DX Select Engine SAPH16F010301004 Was any failure found Check the faulty sensor and repair or replace if as needed After inspection go...

Page 506: ...proved NO YES 1 Check if the fuel return pipe and hose are clogged NO YES 1 Perform an SCV test and a malfunction reproduction test For a detailed procedure refer to the separate SCV free acceler ation test 2 Compare the test results with those obtained in step 4 and check if they improved 20 SCV free acceleration test Hino DX Select Engine SAPH16F010301006 Did the test results improve Procedure c...

Page 507: ...ed in step 4 and check if they improved NO YES Did the test results improve Procedure completed Perform After inspection work of INFOR MATION section Go to step 23 23 Check again the fuel pipe Was any failure found Repair or replace the faulty part and go to step 24 Go to step 24 24 SCV free acceleration test Hino DX Select Engine SAPH16F010301008 Did the test results improve Procedure completed P...

Page 508: ...ompare the test results with those obtained in step 4 and check if they improved NO YES 25 Check again the sensor system Was any failure found Repair or replace the faulty part and go to step 26 Go to step 26 26 SCV free acceleration test Hino DX Select Engine SAPH16F010301009 Did the test results improve Procedure completed Perform After inspection work of INFOR MATION section Contact the Hino na...

Page 509: ...er engine has reached operating temperature more than 82 C 179 6 F 2 After air compressor completed building pressure 3 A C Head lights off 4 All devices off PTO Refrigeration compressor etc 5 Check that actual common rail pressure following target 1 Test method 750r min Measure each engine speed for 20 seconds Time Engine speed Engine speed pattern 1000 r min 1500 r min 2500 r min 2000 r min SAPH...

Page 510: ...012 3 If the following symptoms occur FAIL If not OK Time Common rail pressure Engine speed pattern Pressure is reduced by 5 MPa or more continually for 5 seconds or more Actual common rail pressure Target common rail pressure SAPH16F010301013 Time Common rail pressure Engine speed pattern Pressure is increased by 5 MPa or more continually for 5 seconds or more Actual common rail pressure Target c...

Page 511: ... pressure rapidly Replace the common rail f The maximum common rail pressure exceeds 222 MPa during pressure drop Check the return pipe Common rail pressure Accelerator pattern 222 MPa Time Actual common rail pressure Target common rail pressure SAPH16F010301015 Common rail pressure Accelerator pattern 222 MPa Time Actual common rail pressure Target common rail pressure SAPH16F010301016 Common rai...

Page 512: ...ne speed pattern The pressure is disturbed at a given speed and the pressure decreases at higher speed Remains for 5 seconds or longer 10 MPa or more Actual common rail pressure Target common rail pressure SAPH16F010301019 Time Common rail pressure Engine speed pattern Remains for 5 seconds or longer 10 MPa or more Actual common rail pressure Target common rail pressure SAPH16F010301020 Common rai...

Page 513: ...e than 82 C 179 6 F 2 After air compressor has completed building pressure 3 A C Head lights are off 4 All other devices turned off PTO Refrigeration compressor etc 5 Engine speed 750 r min Criteria FINAL VALUE OF PUMP CURRENT TARGET Average current value 1740 80 mA Fluctuation in current value 80 mA Average current value 30sec Fluctuation in current value Time sec Target current value Current val...

Page 514: ...increased it stabilized at a constant value Go to YES Unlike the above Go to NO Replace the fuel pump and go to step 4 after replace ment Inform to TMS Perform After inspection work of INFORMA TION section 4 SCV free acceleration test Hino DX 1 Select Freeze Frame of DTC P0088 in Fault Infor mation in Hino DX menu and confirm the freeze frame data 2 Conduct an SCV test and confirm the existing dat...

Page 515: ...Go to YES No failure found Go to NO Repair or replace the faulty part and go to step 9 Go to step 9 9 Inspect the fuel tank feed pipe Make sure the fuel tank feed pipe is not clogged Failure found Go to YES No failure found Go to NO Repair or replace the faulty part and go to step 10 Go to step 10 10 Inspect the fuel tank Drain fuel out of the fuel tank and check if there are foreign objects insid...

Page 516: ...the com mon rail pressure sensor connec tor Looseness and poor contact Failure found Go to YES No failure found Go to NO Repair or replace the faulty part and go to step 17 Go to step 17 17 Inspect the common rail pressure sen sor power sup ply Disconnect the common rail pres sure sensor connector and mea sure the voltage between the terminals VCC and GND of the common rail pressure sensor vehicle...

Page 517: ...ved Go to YES The results did not improve Go to NO Procedure completed Perform After inspection work of INFORMA TION section Go to step 21 21 Inspect the fuel return pipe and hose Check if the fuel return pipe and hose are clogged Failure found Go to YES No failure found Go to NO Repair or replace the faulty part and go to step 22 Go to step 22 22 SCV free acceleration test Hino DX 1 Perform an SC...

Page 518: ... steps 15 to 18 Failure found Go to YES No failure found Go to NO Repair or replace the faulty part and go to step 26 Go to step 26 26 SCV free acceleration test Hino DX 1 Perform an SCV test and a malfunction reproduction test For a detailed procedure refer to the separate SCV free acceleration test 2 Compare the test results with those obtained in step 4 and check if they improved The results im...

Page 519: ... malfunction Faulty injector correction value is detected 2 DTC set condition 1 DTC detection condition Correction data was not written in the engine ECU Wrong correction data was written in the engine ECU 2 Judgement criteria Either of the two above detection conditions continues for at least 3 seconds 3 Reset condition Just after restoration to normal condition 4 Indication warning or system con...

Page 520: ...s in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Data do not match correction data registered with the server Correction data insertion error Only when inserting the data by hand Engine ECU failure ...

Page 521: ...ection value is detected 2 DTC set condition 1 DTC detection condition Injector correction data inside the engine ECU abnormal 2 Judgement criteria Any of the above detection conditions continues for at least 3 seconds 3 Reset condition Immediately after normal operation is restored 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle...

Page 522: ...SYSTEM J08E 4 1299 7 After inspection work Clear all past DTCs Check that no DTC is detected after test drive 8 Estimated failure factors Data do not match correction data registered with the server Engine ECU failure ...

Page 523: ... and check again DTC code Check that P268A or P2696 has not been displayed in Fault Information NO YES 1 Check the injector replace record Does the injector have a replacement record Go to step 3 Go to step 2 2 Inspect the injector calibration data QR CODE Hino DX Select Engine SAPH16F010301025 Has DTC P268A or P2696 been detected Go to step 3 Procedure completed Perform After inspection work of I...

Page 524: ... memory and check again DTC code Check that P268A or P2696 has not been displayed in Fault Information NO YES 3 Inspect the injector calibration data QR CODE Hino DX SAPH16F010301026 Has DTC P268A or P2696 been detected Replace the engine ECU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 525: ...ation injector calibration data QR CODE of the service server 2 Erase the DTC memory and check again DTC code Check that DTC P268A or P2696 is not displayed in Fault Information the DTC has beendetected Go to YES No DTC has beendetected Go to NO Go to step 3 Procedure completed Perform After inspection work of INFORMA TION section 3 Inspect the injector cali bration data QR CODE Hino DX Check if t...

Page 526: ...mperature 2 is no greater than 15 C 59 F DEF pump is not operating There is no record of vehicle speed 2 km h There is no record of transmission being in any gear other than neutral There is no record of malfunction determination after starter switch has been turned ON DEF sensor H L LEK LEJ CANL CANH KP KN CA3H CA3L NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L 12 CA2L CA3H KH KG CA3L CA3H K...

Page 527: ...egulation when the DTC is set Diag lamp ON DEF quality malfunction lamp Engine output is restricted Vehicle speed is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Vehicle does not speed up Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the...

Page 528: ... Standard values Concentration 32 5 2 5 Do the measurements meet the standard value Go to step 2 Replace the DEF If the DEF concentration is below the stan dard drain the DEF solution through the tank drain with the starter switch ON and then refill the tank with at least 5 liters 1 3 gal lons of DEF solution Afterward drive the vehicle and confirm that the problem does not recur under driving con...

Page 529: ...ck if DTC P2BA9 has been detected in Fault Information NO YES Remove the foreign substances and clean the DEF tank interior CAUTION Use fresh water or a diluted DEF solution to clean the DEF tank interior Perform After inspection work of INFOR MATION section Go to step 4 4 Check the DEF quality sensor Was any failure found Clean the DEF quality sensor Go to step 4 Go to step 5 5 Check the DTC dete...

Page 530: ...F concentration is below the standard drain the DEF solution through the tank drain with the starter switch ON and then refill the tank with at least 5 liters 1 3 gallons of DEF solution Afterward drive the vehi cle and con firm that the problem does not recur under driving conditions Perform After inspection work of INFORMA TION section 2 Perform a basic engine check Perform a basic engine check ...

Page 531: ... the DEF quality sensor Failure found Go to YES No failure found Go to NO Clean the DEF quality sensor Go to step 4 Go to step 5 5 Check the DTC detected Engine ECU Hino DX 1 Temporarily install the DEF quality sensor in the DEF tank and mount the tank on the vehicle This makes it possible to connect the DEF quality sensor connector 2 Fill the tank with the stan dard concentration of DEF solution ...

Page 532: ... OFF Engine output is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction NOx sensor 2 Common rail CAN J C3 Common rail CAN J C1 NOx sensor 1 JZ JU JV JQ 7 6 3 2 KL 7 KM 6 JX 8 JS 5 LEC LED CANL CANH H L JW 4 JR 1 LE8 LE9 CANL CANH DEF Sensor KN 8 KP 5 LEJ ...

Page 533: ... After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors CAN communication harness failure disconnection short circuit or terminating resistance Poor connector contact or faulty connector fit Failure of unit connected to the engine ECU Engine ECU failure ...

Page 534: ... the DTC detected Engine ECU Select Engine SAPH16F010301030 Has DTC U0073 been detected Replace the engine ECU NOTICE If multiple CAN communication related DTCs U are detected it is considered failure of the main CAN communication line Refer to ENGINE CAN COMMINICATION LINE CAN COMMUNICATION LINE MALFANCTION PART DETERMINATION TABLE of CAN chapter and inspect the diagnosed item of the detected DTC...

Page 535: ...er switch to the ON position 4 Check if U0073 has been detected in Engine DTC U0073 has been detected Go to YES No DTC has beendetected Go to NO Replace the engine ECU NOTICE If multiple CAN commu nication related DTCs U are detected it is considered failure of the main CAN communica tion line Refer to ENGINE CAN COM MINICATION LINE CAN COMMUNI CATION LINE MALFANC TION PART DETERMINA TION TABLE of...

Page 536: ...F Engine output is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient Symptoms on the vehicle due to malfunction NOx sensor 2 Common rail CAN J C3 Common rail CAN J C1 NOx sensor 1 JZ JU JV JQ 7 6 3 2 KL 7 KM 6 JX 8 JS 5 LEC LED CANL CANH H L JW 4 JR 1 LE8 LE9 CANL CANH DEF Sensor KN 8 KP 5 LEJ LEK...

Page 537: ...ck that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors CAN circuit failure engine CAN EGR controller failure Harness disconnection or short circuit ...

Page 538: ...ENGINE CONTROL SYSTEM J08E 4 1315 INSPECTION PROCEDURE U010A Refer to the ENGINE CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 539: ... and the starter switch is turned OFF 4 Indication warning or system control regulation when the DTC is set MIL ON Diag lamp OFF Engine output is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient NOx sensor 2 Common rail CAN J C3 Common rail CAN J C1 NOx sensor 1 JZ JU JV JQ 7 6 3 2 KL 7 KM 6 JX 8...

Page 540: ...re inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors CAN circuit failure engine CAN VNT controller failure Harness disconnection or short circuit ...

Page 541: ...ENGINE CONTROL SYSTEM J08E 4 1318 INSPECTION PROCEDURE U010C Refer to the ENGINE CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 542: ...hicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction Several diagnoses are produced because of failure of main CAN communication harness NOx sensor 2 Common rail CAN J C3 Common rail CAN J C2 Common rail CAN J C1 NOx sensor 1 JZ JU JV JQ 7 6 3 2 KL 7 KM 6 JX 8 JS 5 LEC LED CANL CANH H L JW 4 JR 1 LE8 LE9 CANL CANH DEF...

Page 543: ...e normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors CAN communication harness failure disconnection short circuit or terminating resistance Poor connector contact or faulty connector fit DCU failure Engine ECU failure ...

Page 544: ...ENGINE CONTROL SYSTEM J08E 4 1321 INSPECTION PROCEDURE U010E Refer to the ENGINE CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 545: ...e DTC is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction Multiple DTC are detected because of failure of main CAN communication harness NOx sensor 2 Common rail CAN J C3 Common rail CAN J C1 NOx sensor 1 JZ JU JV JQ 7 6 3 2 KL 7 KM 6 JX 8 JS 5 LEC LED CANL CANH H L JW ...

Page 546: ...ge is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors CAN circuit failure engine CAN NOx sensor 1 control part failure Harness disconnection or short circuit Controller power supply system failure ...

Page 547: ...ENGINE CONTROL SYSTEM J08E 4 1324 INSPECTION PROCEDURE U029D Refer to the ENGINE CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 548: ...C is set MIL ON Diag lamp OFF 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction Multiple DTC are detected because of failure of main CAN communication harness NOx sensor 2 Common rail CAN J C3 Common rail CAN J C1 NOx sensor 1 JZ JU JV JQ 7 6 3 2 KL 7 KM 6 JX 8 JS 5 LEC LED CANL CANH H L JW 4 JR...

Page 549: ...ge is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors CAN circuit failure engine CAN NOx sensor 2 control part failure Harness disconnection or short circuit Controller power supply system failure ...

Page 550: ...ENGINE CONTROL SYSTEM J08E 4 1327 INSPECTION PROCEDURE U029E Refer to the ENGINE CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 551: ...e DTC is set MIL ON NOx sensor 2 Common rail CAN J C2 NOx sensor 1 JZ JU JV JQ 7 6 3 2 KL 7 KM 6 JX 8 JS 5 LEC LED CANL CANH H L JW 4 JR 1 LE8 LE9 CANL CANH DEF Sensor KN 8 KP 5 LEJ LEK CANL CANH H L KE 3 KF 2 BCU KG 4 KH 1 LJL LJK CAL0 CAH0 CAN TMN EGR Controller VNT Controller L4R EGRH L4S EGRL Twist Twist Twist Twist Twist KV8 VNTH KV9 VNTL LEY CAH0 LEZ CAL0 KRG CA2H F2F CANL F2E CANH J8 L4R J5...

Page 552: ...ion Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors CAN circuit failure engine CAN DEF sensor failure DEF sensor power supply GND harness disconnection or short circuit ...

Page 553: ...ENGINE CONTROL SYSTEM J08E 4 1330 INSPECTION PROCEDURE U02A2 Refer to the ENGINE CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 554: ...data set No not received data set No LF6 CAL1 LF5 DCU CAH1 Twist LJN CAL1 LJM BCU CAH1 RJ CA2L RE CA2H RK CA2L RF CA2H AW AV AW AV RD CA2H RH CA2L L8Z ECAL L8Y Vehicle Control ECU ECAH Twist Twist L84 CDGL L83 CDGH Twist CAN CAN KS4 KS3 Twist Diagnosis Connector 16P JF CANL CANL JH CANL JG Twist Twist L2 METH JB CANH CANH JD CANH JC F4 DLC3 F5 DLC3 METH L1 METH L3 MC5 MC5 ER0 ER1 Telematics Unit N...

Page 555: ...ehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors DCU malfunction ...

Page 556: ... U0301 been detected Replace the DCU NOTICE If multiple CAN communication related DTCs U are detected it is considered failure of the main CAN communication line Refer to ENGINE CAN COMMINICATION LINE CAN COMMUNICATION LINE MALFANCTION PART DETERMINATION TABLE and DIAG NOSIS CAN COMMINICATION LINE CAN COMMUNICATION LINE MALFANCTION PART DETERMINATION TABLE of CAN chapter and inspect the diagnosed ...

Page 557: ...n detected Go to YES No DTC has beendetected Go to NO Replace the DCU NOTICE If multiple CAN commu nication related DTCs U are detected it is considered failure of the main CAN communica tion line Refer to ENGINE CAN COM MINICATION LINE CAN COMMUNI CATION LINE MALFANC TION PART DETERMINA TION TABLE and DIAG NOSIS CAN COMMINICA TION LINE CAN COM MUNICATION LINE MAL FANCTION PART DETER MINATION TABL...

Page 558: ... longer LF6 CAL1 LF5 DCU CAH1 Twist Twist Twist LJN CAL1 LJM BCU CAH1 AW AV AW AV CU CU CV CV L8Z ECAL L8Y Vehicle Control ECU ECAH Twist Twist L84 CDGL L83 CDGH Twist CAN CAN KS4 KS3 Twist Diagnosis Connector 16P JF CANL CANL JH CANL JG Twist Twist L2 METH JB CANH CANH JD CANH JC F4 DLC3 F5 DLC3 METH L1 METH L3 MC5 MC5 ER0 ER1 CA1L LOM CA1L JJ CA1H LOM CA1H JN CA1H JL CA1H JP S3 S1 S4 S3 S2 S1 S5...

Page 559: ... the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Idling stop system does not work Cruise control does not work Auxiliary brake does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 ...

Page 560: ...ENGINE CONTROL SYSTEM J08E 4 1337 INSPECTION PROCEDURE U1001 Refer to the DIAGNOSIS CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 561: ... at least 3 seconds LF6 CAL1 LF5 DCU CAH1 Twist Twist Twist LJN CAL1 LJM BCU CAH1 AW AV AW AV CU CU CV CV L8Z ECAL L8Y Vehicle Control ECU ECAH Twist Twist L84 CDGL L83 CDGH Twist CAN CAN KS4 KS3 Twist Diagnosis Connector 16P JF CANL CANL JH CANL JG Twist Twist L2 METH JB CANH CANH JD CANH JC F4 DLC3 F5 DLC3 METH L1 METH L3 MC5 MC5 ER0 ER1 CA1L LOM CA1L JJ CA1H LOM CA1H JN CA1H JL CA1H JP S3 S1 S4...

Page 562: ...e vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Idling stop system does not work Cruise control does not work Auxiliary brake does not work Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Est...

Page 563: ...ENGINE CONTROL SYSTEM J08E 4 1340 INSPECTION PROCEDURE U110A Refer to the DIAGNOSIS CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 564: ... LF6 CAL1 LF5 DCU CAH1 Twist Twist Twist LJN CAL1 LJM BCU CAH1 AW AV AW AV CU CU CV CV L8Z ECAL L8Y Vehicle Control ECU ECAH Twist Twist L84 CDGL L83 CDGH Twist CAN CAN KS4 KS3 Twist Diagnosis Connector 16P JF CANL CANL JH CANL JG Twist Twist L2 METH JB CANH CANH JD CANH JC F4 DLC3 F5 DLC3 METH L1 METH L3 MC5 MC5 ER0 ER1 CA1L LOM CA1L JJ CA1H LOM CA1H JN CA1H JL CA1H JP S3 S1 S4 S3 S2 S1 S5 S7 S6 ...

Page 565: ...ptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check that the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check that no DTC is stored after test drive 8 Estimated failure factors CAN circuit failure engine CAN BCU failure Harness disconn...

Page 566: ...ENGINE CONTROL SYSTEM J08E 4 1343 INSPECTION PROCEDURE U111E Refer to the ENGINE CAN COMMUNICATION LINE in the chapter CAN COMMUNICATION ...

Page 567: ...103 DTC P203C 5 110 DTC P203D 5 114 DTC P2044 5 118 DTC P2045 5 122 DTC P2047 5 126 DTC P2048 5 129 DTC P2049 5 135 DTC P204B 5 142 DTC P204C 5 146 DTC P204D 5 153 DTC P205B 5 160 DTC P205C 5 173 DTC P205D 5 177 DTC P206A 5 181 DTC P208A 5 185 DTC P208B 5 190 DTC P208C 5 193 DTC P208D 5 197 DTC P20A0 5 201 DTC P20A1 5 208 DTC P20A2 5 212 DTC P20A3 5 219 DTC P20B1 5 225 DTC P20B2 5 231 DTC P20B3 5 ...

Page 568: ...re start of checking works Make sure to set the starter switch to the LOCK position before disconnecting a connector Replace the part or the component that have a failure or trouble Do not fix and reuse it Delete the past malfunction code after recording Then conduct a diagnosis again to check for present failures Delete the past failure memory after completion of a diagnostic analysis ...

Page 569: ... image of a connector as viewed from the connecting face A test probe must access the back face of a connector However some types of connector do not allow a test probe to contact with the back face such as a waterproof connector In such case a test probe may be allowed to access the front face of a connector but a special care must be used to avoid a risk of damage in terminals As to a connector ...

Page 570: ...ive signal DEF injector T T DEF pump temperature sensor 1 DEF pump motor drive signal Reverting valve drive signal DEF tank heater valve drive signal DEF tank heater valve L T DEF tank temperature sensor DEF tank level sensor DEF tank T T Ambient air temperature sensor DEF pump temperature sensor 2 P DCU temperature sensor 1 DCU built in DCU temperature sensor 2 DCU built in DEF line pressure sens...

Page 571: ...AW AV AW AV S5 S7 S5 S7 LCM H L CA1H LCN LF5 LF6 CA1L CAL1 SD SF SD SF CP CP CQ CQ KH KG CA3L CA3H KM CA3H KL CA3L 1D 99 99 A49 1 A48 Z29 6 00 B Y 3 00 B 5 00 B 2 00 BR G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W 0 50 P 0 50 V 0 50 G 0 50 R 0 50 B 0 50 W 0 50 G 0 50 R 0 50 R 0 50 W 0 50 B 0 50 W CANL H L RF RK 0 50 G 0 50 R 0 50 B 0 50 W 0 75 P 0 75 W B 0 75 B W 0 75 W B...

Page 572: ...gas After treatment system Exhaust gas temperature sensor DOC outlet Differential pressure sensor Exhaust gas temperature sensor SCR inlet Ambient air temperature sensor External resistor unit Exhaust gas temperature sensor DOC inlet Exhaust gas temperature sensor Burner outlet Exhaust gas temperature sensor Burner inlet SAPH16F020400004 ...

Page 573: ...nt shutoff valve NOx sensor 1 NOx sensor 2 NOx sensor controller 2 NOx sensor controller 1 Exhaust gas temperature sensor SCR inlet SAPH16F020400005 BCU Exhaust gas temperature sensor Burner inlet Ignition cable DEF tank Flame Temperature Sensor Burner unit DEF sensor Combustion air valve Coolant shutoff valve Igniter Igniter DCU SAPH16F020400006 ...

Page 574: ...F6 CAH0 LEY CAL0 LEZ GND1 LET GND4 LEW B2 LEP GND2 LEU GND5 LEX B3 LEQ GND3 LEV B1 LEN B4 LER TE1B LF2 TE1A LF1 TE2B LF4 TE2A LF3 ISGW LES WMW LFA DML LF9 PSRS LFR PSR LFP PSR LFQ PMPS LFL PMP LFK DMH LF8 EXT LFG EXT LFH ATS LNN ATSS LNM PMP LFJ PMV LFN WMV LFB PMV LFM 53P connecter 86P connecter SAPH16F020400007 ...

Page 575: ...o see if the malfunction is of the past or present In the case of the past malfunction this light will turn off if a status is judged to be normal in 3 times of driving DTC must be cleared on the Hino DX after MIL comes off Definition of 1 time of driving a Begins with engine start and ends with engine shut off b Begins with engine start and ends after four hours of continu ous engine on operation...

Page 576: ...performed by authorized HINO dealer STARTER SWITCH ENGINE MALFUNCTION INDICATOR LIGHT START ON OFF ON LOCK RUNNING STOP TIME SAPH16F020400010 SAPH16F020400011 SST Computer interface Hino Bowie The main body and cables for RS232C and USB 09993 E9070 Cable between vehicle and Hino Bowie S0904 21220 DENSO DST i set without LCD Without Bluetooth 95171 01020 With Bluetooth 95171 01040 DENSO DST i set w...

Page 577: ...U 5 11 2 CONNECT THE PC DIAGNOSIS TOOL 1 Set the starter switch to the LOCK position 2 Connect the PC DIAGNOSIS TOOL to the diagnosis connector on the left side of steering column PC diagnosis connector SAPH16F020400012 ...

Page 578: ...tery DCU connector Wire harness 5 52 Light P204F P0563 Sensor supply voltage out of range Out of range high Battery DCU connector Wire harness 5 56 Light P204F P060C DeNOx ECU error DCU 5 60 Light P204F P062F Controller store data error DCU 5 63 Light P204F P0667 DeNOx ECU temperature sensor 1 2 rationality DCU 5 66 Light P204F P0668 DeNOx ECU temperature sensor Out of range low DCU 5 69 Light P20...

Page 579: ...ght P204F P204C DEF pressure sensor out of range Out of range low DEF pump DCU Wire harness 5 146 Light P204F P204D DEF pressure sensor out of range Out of range high DEF pump DCU Wire harness 5 153 Light P204F P205B DEF tank temperature sensor rational ity DEF tank temperature sensor DCU connector Wire harness 5 160 Light P204F P205C DEF tank temperature sensor out of range Out of range low DEF t...

Page 580: ...t shutoff valve Wire harness DCU connector 5 225 Light P204F P20B2 DEF tank heater valve stuck Coolant shutoff valve DCU connector 5 231 Light P204F P20B3 DEF tank heater valve circuit Circuit low Coolant shutoff valve Wire harness DCU connector 5 243 Light P204F P20B4 DEF tank heater valve circuit Circuit high Coolant shutoff valve Wire harness DCU connector 5 249 Light P204F P20E8 Suction line p...

Page 581: ...42 Light P204F P2481 Exhaust gas temperature sensor SCR inlet out of range Out of range low Exhaust gas temperature sensor Wire harness DCU connector 5 353 Light P204F P2482 Exhaust gas temperature sensor SCR inlet out of range Out of range high Exhaust gas temperature sensor Wire harness DCU connector 5 360 Light P204F P2483 Exhaust gas temperature sensor SCR inlet rationality Exhaust gas tempera...

Page 582: ...unication NOx sensor SCR downstream NOx sensor Wire harness 5 418 Light P204F U02A2 DeNOx ECU CAN communication DEF tank sensor DEF sensor Wire harness 5 421 Light P204F U0597 Invalid Data Received From AC to DC Converter DeNOx ECU DCU 5 424 DIAGNOSTIC TROUBLE CODE DTC TABLE MALFUNC TION INDI CATOR LIGHT DTC NO DIAGNOSIS ITEM INSPECTION ITEM REFER PAGE ECU DCU ...

Page 583: ... from Engine ECU 8 C 46 4 F Common rail_ CAN_J C3 Common rail_ CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL DEF sensor DEF tank temperature sensor H L KP CA3H KN CA3L LEK LEJ CANH CANL H L Engine ECU DCU S5 S7 S5 S7 AW AV AW AV LCM H L CA1H LCN LF5 L...

Page 584: ...gulation when the DTC is set MIL ON Stop of each temperature sensor failure diagnosis 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 if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estima...

Page 585: ...ect the ambient air temperature sensor connector Ambient sensor DEF tank SAPH16F020400014 Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the connector of the external resistor Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 3 Inspect the D...

Page 586: ...pect the ambient air temperature sensor Was any failure found Clean the ambient air temperature sensor and install it properly If damaged replace the ambient air temperature Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the ambient air temperature sensor unit HH1 HH1 SAPH16F020400015 Measurement conditions Tester connections Standard values Starter switch LOCK Ambien...

Page 587: ...ES 6 Inspect the external resistor unit ER ER SAPH16F020400016 Measurement conditions Tester connections Standard values Starter switch LOCK External resistor ER ER 2 k Do the measurements meet the standard value Go to step 7 Replace the external resistor Perform After inspection work of INFOR MATION section 7 Inspect the sensor power supply HH1 LGK HH1 LJK HH1 HH1 SAPH16F020400017 Measurement con...

Page 588: ...e electrical tester to measure the resistance between the terminals of the DCU 86P vehicle side connector 8 Inspect for short circuit in the ambient air temperature sensor harness ATS ATSS SAPH16F020400018 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector ATSS Ground ATS Ground Do the measurements meet the standard value Go to step 9 Repai...

Page 589: ...ATS 25 C 77 F 3 7 k Do the measurements meet the standard value Go to step 10 Repair or replace the harness Perform After inspection work of INFOR MATION section 10 Inspect the engine coolant temperature sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 11 11 Inspect the engine coolant temperature sensor Was an...

Page 590: ...erature sensor unit WTM WTM SAPH16F020400020 Measurement conditions Tester connections Standard values Starter switch LOCK Engine coolant temperature sensor WTM WTM 20 C 68 F 2 59 2 32 k 80 C 176 F 0 326 0 310 k Do the measurements meet the standard value Go to step 13 Replace the engine coolant temperature sen sor Perform After inspection work of INFOR MATION section 13 Inspect the exhaust gas te...

Page 591: ... exhaust gas temperature sensor SCR inlet Was any failure found Clean the exhaust gas temperature sensor and install it properly If damaged replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of INFOR MATION section Go to step 15 15 Inspect the exhaust gas temperature sensor SCR inlet unit FAT FAT SAPH16F020400021 Measurement conditions Tester connections Standard va...

Page 592: ...d check if P0071 has been detected in Fault Infor mation NO YES 16 Inspect the DEF pump temperature sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 17 17 Check the DTC detected DCU Select DCU SAPH16F020400022 Has DTC P0071 been detected Replace the DCU Perform After inspection work of INFOR MATION section Pro...

Page 593: ...d Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the DCU 86P con nector Check the connection of the DCU 86P connector Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 4 4 In...

Page 594: ...rk of INFORMA TION section 7 Inspect the sensor power supply Measure the voltage between the terminals of the ambient air tem perature sensor vehicle side con nector Tester connections Ambient air temperature sensor vehicle side connector HH1 HH1 Standard values 4 5 5 5 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 10 Go...

Page 595: ...needed Perform After inspection work of INFORMA TION section Go to step 11 11 Inspect the engine cool ant tempera ture sensor 1 Check the installation of the engine coolant temperature sensor 2 Make sure there is no dirt or damage to the engine cool ant temperature sensor Failure found Go to YES No failure found Go to NO Clean the engine cool ant tempera ture sensor and install it properly If dama...

Page 596: ...pection work of INFORMA TION section Go to step 15 15 Inspect the exhaust gas temperature sensor SCR inlet unit Measure the resistance between the terminals of the exhaust gas temperature sensor SCR inlet Tester connections Exhaust gas temperature sensor SCR inlet FAT FAT Standard values 20 C 68 F 220 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard v...

Page 597: ...n DCU DTC P0071 has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P0071 Ambient air temperature sensor rationality Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 598: ...TC detection condition Starter switch ON 2 Judgement criteria Ambient air temperature sensor voltage Less than 3 4 V 3 Reset condition After having restored to the normal condition 4 Indication warning or system control regulation when the DTC is set MIL ON Each temperature sensors failure diagnosis is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup cont...

Page 599: ...EM DCU 5 33 8 Estimated failure factors Disconnection or short circuit in the sensor harness Disconnection or poor fit of connector Malfunction of the ambient air temperature sensor Failure of the external resistor ...

Page 600: ... no dirt or damage to the sensing unit of the ambient air temperature sensor 1 Inspect the ambient air temperature sensor connector Ambient sensor DEF tank SAPH16F020400024 Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the connector of the external resistor Was any failure found Connect securely repair if needed...

Page 601: ...ed replace the ambient air temperature Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the ambient air temperature sensor unit HH1 HH1 SAPH16F020400025 Measurement conditions Tester connections Standard values Starter switch LOCK Ambient air temperature sensor HH1 HH1 25 C 77 F 1 7 k Do the measurements meet the standard value Go to step 5 Replace the ambient air tempe...

Page 602: ...ster to measure the resistance between the terminals of the DCU 86P vehicle side connector and the ground Go to step 6 Replace the external resistor Perform After inspection work of INFOR MATION section 6 Inspect the sensor power supply HH1 LGK HH1 LJK HH1 HH1 SAPH16F020400027 Measurement conditions Tester connections Standard values Starter switch ON Ambient air temperature sensor vehicle side co...

Page 603: ...tarter switch LOCK DCU 86P vehicle side connector ground ATSS Ground ATS Ground Do the measurements meet the standard value Go to step 8 Repair or replace the harness Perform After inspection work of INFOR MATION section 8 Inspect for disconnection in the ambient air temperature sensor harness ATS ATSS SAPH16F020400029 Measurement conditions Tester connections Standard values Starter switch LOCK D...

Page 604: ...f P0072 has been detected in Fault Infor mation NO YES Go to step 9 Repair or replace the harness Perform After inspection work of INFOR MATION section 9 Check the DTC detected DCU Select DCU SAPH16F020400030 Has DTC P0072 been detected Replace the DCU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 605: ...r inspection work of INFORMA TION section Go to step 3 3 Inspect the ambient air temperature sensor 1 Check the installation of the ambient air temperature sensor 2 Make sure there is no dirt or damage to the ambient air temperature sensor Failure found Go to YES No failure found Go to NO Clean the ambient air temperature sensor and install it prop erly If damaged replace the ambient air temperatu...

Page 606: ...the signal check harness Tester connections DCU 86P vehicle side connector ATSS Ground ATS Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 8 Repair or replace the harness Perform After inspection work of INFORMA TION section 8 Inspect for dis connection in the ambient air temperature sensor har ness Me...

Page 607: ... YES No DTC has beendetected Go to NO Replace the DCU Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P0072 Ambient air temperature sensor out of range Out of range low Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 608: ...r voltage More than 4 783 V 3 Reset condition After having restored to the normal condition 4 Indication warning or system control regulation when the DTC is set MIL ON SCR system failure lamp LIT If the failure is not corrected within 500 miles Engine power limited If the failure is not corrected within 2 000 miles Vehicle speed limited 5 Symptoms on the vehicle when the DTC is set Symptoms on th...

Page 609: ...l past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Disconnection or short circuit in the sensor harness Disconnection or poor fit of connector Malfunction of the ambient air temperature sensor Failure of the external resistor ...

Page 610: ... no dirt or damage to the sensing unit of the ambient air temperature sensor 1 Inspect the ambient air temperature sensor connector Ambient sensor DEF tank SAPH16F020400032 Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the connector of the external resistor Was any failure found Connect securely repair if needed...

Page 611: ...eplace the ambient air temperature sensor Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the ambient air temperature sensor unit HH1 HH1 SAPH16F020400033 Measurement conditions Tester connections Standard values Starter switch LOCK Ambient air temperature sensor HH1 HH1 25 C 77 F 1 7 k Do the measurements meet the standard value Go to step 5 Replace the ambient air te...

Page 612: ... the resistance between the terminals of the DCU 86P vehicle side connector and the ground Go to step 6 Replace the external resistor Perform After inspection work of INFOR MATION section 6 Inspect the sensor power supply HH1 LGK HH1 LJK HH1 HH1 SAPH16F020400035 Measurement conditions Tester connections Standard values Starter switch ON Ambient air temperature sensor vehicle side connector HH1 HH1...

Page 613: ...s Starter switch LOCK DCU 86P vehicle side connector ATSS Ground ATS Ground Do the measurements meet the standard value Go to step 8 Repair or replace the harness Perform After inspection work of INFOR MATION section 8 Inspect for disconnection in the ambient air temperature sensor harness ATS ATSS SAPH16F020400037 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 8...

Page 614: ...f P0073 has been detected in Fault Infor mation NO YES Go to step 9 Repair or replace the harness Perform After inspection work of INFOR MATION section 9 Check the DTC detected DCU Select DCU SAPH16F020400038 Has DTC P0073 been detected Replace the DCU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 615: ...FORMA TION section Go to step 3 3 Inspect the ambient air temperature sensor 1 Check the installation of the ambient air temperature sensor 2 Connect the signal check harness to measure the resistance between the ter minals of the DCU 86P vehi cle side connector Failure found Go to YES No failure found Go to NO Clean the ambient air temperature sensor and install it prop erly If damaged replace th...

Page 616: ...se the signal check harness Tester connections DCU 86P vehicle side connector ATSS Ground ATS Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 8 Repair or replace the harness Perform After inspection work of INFORMA TION section 8 Inspect for dis connection in the ambient air temperature sensor har ness...

Page 617: ... YES No DTC has beendetected Go to NO Replace the DCU Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P0073 Ambient air temperature sensor out of range Out of range high Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 618: ... DTC is set MIL ON SCR system malfunction lamp on DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After i...

Page 619: ...cle side connector NO YES 1 Inspect the DCU 53P connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the voltage of the DCU power supply GND1 B3 SAPH16F020400040 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 53P vehicle side connector B3 GND1 9 16 V Do the measurements meet...

Page 620: ... has been detected in Fault Information NO YES 3 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400041 Has DTC P0562 been detected Replace the DCU After replacing the DCU perform a forced regeneration Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 621: ...use the electrical tester to measure the voltage between the terminals of the DCU 53P vehicle side connector Tester connections DCU 53P vehicle side connector B3 GND1 Standard values 9 16 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Repair or replace the DCU power supply circuit Fuse DCU Perform After inspection work ...

Page 622: ... DTC is set MIL ON SCR system malfunction lamp on DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After i...

Page 623: ...ehi cle side connector NO YES 1 Inspect the DCU 53P connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the voltage of DCU power supply GND1 B3 SAPH16F020400043 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 53P vehicle side connector B3 GND1 9 16 V Do the measurements meet...

Page 624: ...as been detected in Fault Infor mation NO YES 3 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400044 Has DTC P0563 been detected Replace the DCU After replacing the DCU perform a forced regeneration Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 625: ... use the electrical tester to measure the voltage between the terminals of the DCU 53P vehicle side connector Tester connections DCU 53P vehicle side connector B3 GND1 Standard values 9 16 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Repair or replace the DCU power supply circuit Fuse DCU Perform After inspection work...

Page 626: ...ter having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehicle due to malfunction 6 Pre inspe...

Page 627: ...nlet drops below 200 C 392 F 7 Set the starter switch to the ON position 8 Select DCU and check if P060C has been detected in Fault Information NO YES 1 Check the DTC detected DCU Hino DX Select DCU When communicat ion with the DCU is interrupted while the DCU is connec ted to the Hino DX the connection symbol at the left bottom of the Hino DX screen figure on the left becom es disconnected SAPH16...

Page 628: ...if the DCU main relay is OFF in the Hino DX menu This cuts off the communication between Hino DX and the DCU NOTICE The main relay turns OFF 1 minute after the exhaust gas temperature SCR inlet drops below 200 C 392 F 7 Set the starter switch to the ON position 8 Check if P060C has been detected in DCU DTC P060C has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU After rep...

Page 629: ...DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DT...

Page 630: ...nlet drops below 200 C 392 F 7 Set the starter switch to the ON position 8 Select DCU and check if P062F has been detected in Fault Infor mation NO YES 1 Check the DTC detected DCU Hino DX Select DCU When communicat ion with the DCU is interrupted while the DCU is connec ted to the Hino DX the connection symbol at the left bottom of the Hino DX screen figure on the left becom es disconnected SAPH1...

Page 631: ...Check if the DCU main relay is OFF in the Hino DX menu This cuts off the communication between Hino DX and the DCU NOTICE The main relay turns OFF 1 minute after the exhaust gas temperature SCR inlet drops below 200 C 392 F 7 Set the starter switch to the ON position 8 Check if P062F has been detected in DCU DTC P062F has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU Aft...

Page 632: ...The absolute value of temperature sensor 1 temperature sensor 2 15 C 59 F for more than 10 sec 3 Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DCU failure inspection is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purifi...

Page 633: ...nd check if P0667 has been detected in Fault Infor mation NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400047 Has DTC P0667 been detected Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFOR MATION section Erase the malfunction history Procedure completed Perform After inspection work of INFOR MATION section ...

Page 634: ...ck the DTC detected DCU Hino DX Check if P0667 has been detected in DCU DTC P0667 has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFORMA TION section Erase the mal function his tory Procedure completed Perform After inspection work of INFORMA TION section ...

Page 635: ...e of the Sensor 2 is less than 0 85 V for 0 4 sec or more 3 Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DCU malfunction diagnosis has been stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 P...

Page 636: ...nd check if P0668 has been detected in Fault Infor mation NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400048 Has DTC P0668 been detected Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFOR MATION section Erase the malfunction history Procedure completed Perform After inspection work of INFOR MATION section ...

Page 637: ...eck the DTC detected DCU Hino DX Check if P0668 has been detected in DCU DTC P0668 has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFORMA TION section Erase the mal function his tory Procedure completed Perform After inspection work of INFORMA TION section ...

Page 638: ...an 2 0 V for 0 4 sec or more Voltage of the Sensor 2 is more than 2 0 V for 0 4 sec or more 3 Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DCU malfunction diagnosis has been stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on ...

Page 639: ...nd check if P0669 has been detected in Fault Infor mation NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400049 Has DTC P0669 been detected Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFOR MATION section Erase the malfunction history Procedure completed Perform After inspection work of INFOR MATION section ...

Page 640: ...No 1 Check the DTC detected DCU Hino DX Check if P0669 has been detected in DCU DTC P0669 has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFORMA TION section Erase the mal function his tory Procedure completed Perform After inspection work of INFORMA TION section ...

Page 641: ...tery switch is turned OFF or a battery terminal is disconnected during the DCU shutdown process Diagnostic Code P068A may be detected Description of malfunction ROM data reading error detected 2 DTC set condition 1 DTC detection condition Engine running 2 Judgement criteria If the ROM data writing status was incomplete before the preceding DCU shut down 3 Reset condition DCU detects normal termina...

Page 642: ...vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Battery Abnormal voltage 16 V or more 6 V or less Battery was replaced before DCU shutdown was completed Battery voltage was cut before DCU shutdown was completed DCU malfunction ...

Page 643: ...8A for exam ple P0562 has been detected in Fault Information NOTICE If the battery switch is turned OFF or a battery terminal is dis connected during the DCU shutdown process Diagnostic Code P068A may be detected NO YES 1 Check the DTC detected DCU Select DCU SAPH16F020400051 Has a DTC other than P068A been detected Go to the diagnosis procedure of a related DTC Go to step 2 ...

Page 644: ...IGSW LES CAH0 LEY CAH1 LF5 GND1 LET GND4 LEW B2 LEP GND2 LEU GND5 LEX B3 LEQ GND3 LEV B1 LEN B4 LER CAL1 LF6 CAL0 LEZ Battery DCU 53 Pin connector GND1 LET GND4 LEW B2 LEP GND2 LEU GND5 LEX B3 LEQ GND3 LEV B1 LEN B4 LER SAPH16F020400052 Measurement conditions Tester connections Standard values Starter switch ON DCU 53P connector Engine sub harness side B1 BAT B2 BAT B3 BAT B4 BAT 9 V 16 V All Do t...

Page 645: ... B1 LEN B4 LER CAL1 LF6 CAL0 LEZ B GS B GT 6 96 IG GX 5 F5 21 FM 1 J7 2 J8 3 J9 4 JA 16 MG 13 MD 14 ME 12 MC 15 MF 9 M9 10 MA 11 MB 14 FE 22 FN 5 JB 6 JC B GR 5 95 3 93 4 94 DCU 53 Pin connector Cab main harness to chassis front harness connector chassis side GND1 LET GND4 LEW B2 LEP GND2 LEU GND5 LEX B3 LEQ GND3 LEV B1 LEN B4 LER SAPH16F020400054 Measurement conditions Tester connections Standard...

Page 646: ...ed turn the starter switch ON again 8 Select DCU and check if P068A has been detected in Fault Infor mation NO YES 4 Check the DTC detected DCU Hino DX Select DCU When communicat ion with the DCU is interrupted while the DCU is connec ted to the Hino DX the connection symbol at the left bottom of the Hino DX screen figure on the left becom es disconnected SAPH16F020400055 Has P068A been detected R...

Page 647: ...nnector Engine sub harness side B1 BAT B2 BAT B3 BAT B4 BAT Standard values 9 V 16 V The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Repair or replace the battery power supplying cir cuit harness fuse etc Perform After inspection work of INFORMA TION section 3 Inspect the DCU harness Using the electrical tester mea sure th...

Page 648: ...ted to Hino DX 7 After checking that the com munication between the Hino DX and the DCU has been disconnected turn the starter switch ON again 8 Check if P068A has been detected in DCU DTC P068A has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section ...

Page 649: ... sec or longer Temperature sensor 2 duty Below 15 for 5 sec or longer Temperature sensor 2 duty Over 85 for 5 sec or longer 3 Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle...

Page 650: ...DEF SCR SYSTEM DCU 5 84 8 Estimated failure factors Disconnection or short circuit in sensor harness Irregular contact disconnection or poor fit of connector Malfunction of DEF pump temperature sensor ...

Page 651: ...ide con nector and each terminal of the DCU 86P vehicle side connector NO YES 1 Inspect the DEF pump temperature sensor harness PMP PMP PMPS PMP PMPS PMP SAPH16F020400057 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump vehicle side connector DCU 86P vehicle side connector PMP PMP PMP PMP PMPS PMPS 1 or less Do the measurements meet the standard value Go to st...

Page 652: ...t DCU and check if P142A has been detected in Fault Infor mation NO YES 2 Check the DTC detected DCU 1 Hino DX Select DCU SAPH16F020400058 Has DTC P142A been detected Go to step 3 Procedure completed Install a new DCU Perform After inspection work of INFOR MATION section 3 Check the DTC detected DCU 2 Select DCU SAPH16F020400059 Has DTC P142A been detected Replace the DCU Perform After inspection ...

Page 653: ...the harness Perform After inspection work of INFORMA TION section 2 Check the DTC detected DCU 1 Hno DX 1 Connect a new DCU 2 Connect the vehicle to the Hino DX 3 Set the starter switch to the ON position 4 Check if P142A has been detected in DCU DTC P142A has been detected Go to YES No DTC has beendetected Go to NO Go to step 3 Procedure completed Install a new DCU Perform After inspection work o...

Page 654: ...cool ant temperature is within 8 C 46 4 F The coolant shutoff valve is released DEF defrosts Coolant temperature is over 40 C 104 F The above condition continues for 10 minutes or longer 2 Judgement criteria Difference between the DEF pump temperature and the outside temperature over 22 C 71 6 F Rise in the DEF pump temperature less than 1 5 C 34 7 F ECU Engine coolant temperature sensor 1 AW AV A...

Page 655: ...he DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction Control will not work properly if the DEF freezes 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Coolant shutoff valve Stuck closed Cool...

Page 656: ...ect the ambient air temperature sensor connector Ambient sensor DEF tank SAPH16F020400061 Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the connector of the external resistor Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 3 Inspect the D...

Page 657: ...the ambient air temperature sensor Was any failure found Clean the ambient air temperature sensor and install it properly If damaged replace the ambient air temperature sensor Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the ambient air temperature sensor unit HH1 HH1 SAPH16F020400062 Measurement conditions Tester connections Standard values Starter switch LOCK Ambi...

Page 658: ...icle side connector 6 Inspect the external resistor unit ER ER SAPH16F020400063 Measurement conditions Tester connections Standard values Starter switch LOCK External resistor ER ER 2 k Do the measurements meet the standard value Go to step 7 Replace the external resistor Perform After inspection work of INFOR MATION section 7 Inspect disconnection of the ambient air temperature sensor harness ATS...

Page 659: ...r inspection work of INFOR MATION section 8 Inspect the exhaust gas temperature sensor SCR inlet connector Exhaust gas temperature sensor SCR inlet SAPH16F020400065 Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 9 9 Inspect the exhaust gas temperature sensor SCR inlet Was any failure found Clean the exhaust gas temperature s...

Page 660: ...nnector Looseness and poor contact 10 Inspect the exhaust gas temperature sensor SCR inlet unit FAT FAT SAPH16F020400066 Measurement conditions Tester connections Standard values Starter switch LOCK Exhaust gas temperature sensor SCR inlet FAT FAT 20 C 68 F 220 Do the measurements meet the standard value Go to step 11 Replace the exhaust gas temperature sensor SCR inlet Perform After inspection wo...

Page 661: ...Perform After inspection work of INFOR MATION section Go to step 12 12 Inspect the engine coolant temperature sensor Was any failure found Clean the engine coolant temperature sensor and install it properly If damaged replace the engine coolant temperature sensor Perform After inspection work of INFOR MATION section Go to step 13 13 Inspect the engine coolant temperature sensor unit WTM WTM SAPH16...

Page 662: ...ine with your hand CAUTION Be careful not to burn yourself when the coolant is hot NO YES 1 Make sure there are no leaks in the engine cooling system lines and hoses 2 Check the engine cooling system lines and hoses and check if there are no disconnections clogging punctures or cracks Go to step 14 Replace the engine coolant temperature sen sor Perform After inspection work of INFOR MATION section...

Page 663: ...comes out from the other side NO YES Repair or replace the faulty part Perform After inspection work of INFOR MATION section Go to step 16 16 Inspect the DEF pump Was any failure found Replace the DEF pump Perform After inspection work of INFOR MATION section Replace the coolant shutoff valve Perform After inspection work of INFOR MATION section ...

Page 664: ...nd Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the DCU 86P con nector Check the connection of the DCU 86P connector Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 4 4 I...

Page 665: ... har ness Measure the resistance of the wire harness and sensor between the DCU 86P vehicle side con nector and the ambient air tem perature sensor 1 Connect the ambient air temperature sensor connec tor 2 Disconnect the DCU 86P connector 3 Connect the signal check harness and measure the resistance between the ter minals of the DCU 86P vehi cle side connector Tester connections DCU 86P vehicle si...

Page 666: ... exhaust gas temperature sensor SCR inlet Tester connections Exhaust gas temperature sensor SCR inlet FAT FAT Standard values 20 C 68 F 220 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 11 Replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of INFORMA TION section 11 Inspect the engine cool a...

Page 667: ...heck the operation of the coolant shutoff valve Hino DX Select Coolant shutoff valve from the Activation Test menu and operate the coolant shutoff valve When the valve is open Check if the pressure inside the down stream coolant line is rising by feeling the line with your hand When the valve is closed Check if the pressure inside the down stream coolant line is dropping by feeling the line with y...

Page 668: ...mes out from the other side Failure found Go to YES No failure found Go to NO Replace the DEF pump Perform After inspection work of INFORMA TION section Replace the coolant shut off valve Perform After inspection work of INFORMA TION section DTC P142B DEF pump temperature sensor 1 rationality Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 669: ...50 kPa 123 psi and 950 kPa 138 psi 2 Judgement criteria At system start up Pressure line check start DEF pump speed keep and DEF injector full open If DEF pressure is 750 kPa 108 psi after 4 sec from DEF injector open failure counter is count up When Failure counts 22 DTC is detected 3 Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation ...

Page 670: ...ine output is insufficient Vehicle does not speed up when malfunction does not improve within 50 min Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Clogging of the DEF injector Clogging of the DEF pipe ...

Page 671: ... removal and installation of the DEF injector 3 Set the starter switch to the ON position 4 Select DCU 5 Select Check functions on Hino DX menu and check the opera tion of the DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank temperature is 5 C 23 F or...

Page 672: ...020400072 Is operation normal New injector installed in the muffler proce dure completed After installing the injector idle the engine for about 10 min and on the menu Data Monitor check if the DEF is sta ble between 800 kPa 116 psi and 1 051 kPa 152 psi Perform After inspection work of INFOR MATION section Replace the DEF pipe pressure line After replacing the pipe idle the engine for about 10 mi...

Page 673: ... Judgement Check Yes No Yes No 1 Inspect the DEF pipe DEF pump injector Check the DEF pipe pressure line and check if there are no dis connections clogging corrosion or cracks Failure found Go to YES No failure found Go to NO Replace the DEF pipe pressure line Perform After inspection work of INFORMA TION section Go to step 2 ...

Page 674: ... the ON position 4 Select DCU 5 Select Check functions on Hino DX menu and check the operation of the DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank tempera ture is 5 C 23 F or lower perform warm up to raise it to 10 C 50 F or higher HINT Refer to t...

Page 675: ... 10 min and on the menu Data Monitor check if the DEF is stable between 800 kPa 116 psi and 1 051 kPa 152 psi Perform After inspection work of INFORMA TION section Replace the DEF pipe pressure line After replac ing the pipe idle the engine for about 10 min and on the menu Data Monitor check if the DEF is stable between 800 kPa 116 psi and 1 051 kPa 152 psi Perform After inspection work of INFORMA...

Page 676: ...having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF level indicator is stopped Common rail_CAN_J C3 Common rail_CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL DEF sensor DEF tank lev...

Page 677: ...ntrol fail safe function Symptoms on the vehicle due to malfunction DEF level indicator is OFF 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors DEF tank level sensor failure ...

Page 678: ...ine and check if a CAN communication system mal function U02A2 has been detected in Fault Information NO YES 1 Check the DTC detected Engine Hino DX Select Engine SAPH16F020400074 Has DTC U02A2 been detected Go to the diagnostic procedure of a related DTC Replace the DEF tank level sensor Perform After inspection work of INFOR MATION section ...

Page 679: ...ment Check Yes No Yes No 1 Check the DTC detected Engine Hino DX Check if a CAN communication system malfunction U02A2 has been detected in Engine DTC U02A2 has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the DEF tank level sensor Perform After inspection work of INFORMA TION section ...

Page 680: ...tion After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF level indicator is stopped Common rail_CAN_J C3 Common rail_CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL DEF sensor D...

Page 681: ...ntrol fail safe function Symptoms on the vehicle due to malfunction DEF level indicator is OFF 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors DEF tank level sensor failure ...

Page 682: ...ngine and check if a CAN communication system mal function U02A2 has been detected in Fault Information NO YES 1 Check the DTC detected Engine Hino DX Select Engine SAPH16F020400076 Has DTC U02A2 been detected Go to diagnosis procedure of a related DTC Replace the DEF tank level sensor Perform After inspection work of INFOR MATION section ...

Page 683: ...ment Check Yes No Yes No 1 Check the DTC detected Engine Hino DX Check if a CAN communication system malfunction U02A2 has been detected in Engine DTC U02A2 has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the DEF tank level sensor Perform After inspection work of INFORMA TION section ...

Page 684: ...eset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF level indicator is stopped Common rail_CAN_J C3 Common rail_CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL DE...

Page 685: ...l fail safe function DEF level indicator is OFF Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors DEF tank temperature sensor 2 failure ...

Page 686: ...ngine and check if a CAN communication system mal function U02A2 has been detected in Fault Information NO YES 1 Check the DTC detected Engine Hino DX Select Engine SAPH16F020400078 Has DTC U02A2 detected Go to diagnosis procedure of a related DTC Replace the DEF tank temperature sensor Perform After inspection work of INFOR MATION section ...

Page 687: ...on Judgement Check Yes No Yes No 1 Check the DTC detected Engine Hino DX Check if a CAN communication system malfunction U02A2 has been detected in Engine DTC U02A2 has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the DEF sensor Perform After inspection work of INFORMA TION section ...

Page 688: ...Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF level indicator is stopped Common rail_CAN_J C3 Common rail_CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL D...

Page 689: ...l fail safe function DEF level indicator is OFF Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors DEF tank temperature sensor 2 failure ...

Page 690: ...ne and check if a CAN communication system mal function U02A2 has been detected in Fault Information NO YES 1 Check the DTC detected Engine Hino DX Select Engine SAPH16F020400080 Has DTC U02A2 been detected Go to diagnosis procedure of a related DTC Replace the DEF tank temperature sensor Perform After inspection work of INFOR MATION section ...

Page 691: ...ion Judgement Check Yes No Yes No 1 Check the DTC detected Engine Hino DX Check if a CAN communication system malfunction U02A2 has been detected in Engine DTC U02A2 has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the DEF sensor Perform After inspection work of INFORMA TION section ...

Page 692: ...s set MIL ON SCR system malfunction lamp ON DEF injection is stopped NOx purification function is stopped If malfunction does not improve within 500 miles engine output is restricted If malfunction does not improve within 2 000 miles vehicle speed is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification fu...

Page 693: ...tch to the ON position 4 Select DCU 5 Select Check functions on Hino DX menu and check the opera tion of the DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank temperature is 5 C 23 F or lower perform warm up to raise it to 10 C 50 F or higher HINT Refe...

Page 694: ...UJ08E10 for removal and installation of the DEF injector 3 Set the starter switch to the ON position 4 Select DCU 5 Select Check functions on Hino DX menu and check the operation of the DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank tempera ture is ...

Page 695: ...aving restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work...

Page 696: ...DEF injector NO YES 1 Inspect for short circuit in the DEF injector harness Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DEF injector unit DMH DML SAPH16F020400084 Measurement conditions Tester connections Standard values Starter switch LOCK DEF injector DML DMH 20 C 68 F 11 4 12 6 Do the measurements meet ...

Page 697: ...cal tester to measure the resistance between the terminals of the DCU 86P vehicle side connector 3 Inspect for short circuit in the DEF injector harness DMH DML SAPH16F020400085 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector DML Ground DMH Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perf...

Page 698: ...ions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector DML DMH 20 C 68 F 11 4 12 6 Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Select DCU SAPH16F020400087 Has DTC P2048 been detected Replace the DCU Perform DPR forced regeneration after r...

Page 699: ...tor connect the signal check har ness and measure the resistance between the terminals of the DCU 86P vehicle side connector and the ground Tester connections DCU 86P vehicle side connector DML Ground DMH Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the harness Perform After insp...

Page 700: ...tected Go to YES No DTC has beendetected Go to NO Replace the DCU Per form DPR forced regen eration after replacement Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P2048 DEF injector disconnection Disconnection low side Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 701: ...is set MIL ON SCR system malfunction lamp ON DEF injection is stopped NOx purification function is stopped If malfunction does not improve within 500 miles engine output is restricted If malfunction does not improve within 2 000 miles vehicle speed is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification f...

Page 702: ...DEF SCR SYSTEM DCU 5 136 8 Estimated failure factors Disconnection or short circuit in sensor harness Abnormal resistance of DEF injector Malfunction in DEF injector ...

Page 703: ...s of the DEF injector NO YES 1 Inspect the DEF injector connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DEF injector unit DMH DML SAPH16F020400089 Measurement conditions Tester connections Standard values Starter switch LOCK DEF injector DML DMH 20 C 68 F 11 4 12 6 Do the measurements meet the standa...

Page 704: ...cal tester to measure the resistance between the terminals of the DCU 86P vehicle side connector 3 Inspect for short circuit in the DEF injector harness DMH DML SAPH16F020400090 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector DML Ground DMH Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perf...

Page 705: ...s Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector DML DMH 20 C 68 F 11 4 12 6 Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 DTC the DTC detected DCU Hino DX Select DCU SAPH16F020400092 Has DTC P2049 been detected Replace the DCU Perform DPR forced regeneration afte...

Page 706: ...ec tor connect the signal check har ness and measure the resistance between the terminals of the DCU 86P vehicle side connector and the ground Tester connections DCU 86P vehicle side connector DML Ground DMH Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the harness Perform After i...

Page 707: ...d in DCU DTC P2049 has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P2049 DEF injector disconnection Disconnection high side Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 708: ... 3 psi or 50 kPa 7 3 psi for 10 sec 3 Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorate...

Page 709: ...DEF SCR SYSTEM DCU 5 143 8 Estimated failure factors DEF pump pressure sensor malfunction ...

Page 710: ...set the starter switch to the ON position 4 Select DCU and check if P204B has been detected in Fault Infor mation NO YES 1 Check the DTC detected DCU Select DCU SAPH16F020400094 Has DTC P204B been detected Procedure completed Perform After inspection work of INFOR MATION section Replace the DEF pump Perform After inspection work of INFOR MATION section ...

Page 711: ...e starter switch to the LOCK position 2 Connect the vehicle to Hino DX 3 After three minutes set the starter switch to the ON position 4 Check if P204B has been detected in DCU DTC P204B has been detected Go to YES No DTC has beendetected Go to NO Procedure completed Perform After inspection work of INFORMA TION section Replace the DEF pump Perform After inspection work of INFORMA TION section ...

Page 712: ...than 0 4 sec 3 Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehic...

Page 713: ...EF SCR SYSTEM DCU 5 147 8 Estimated failure factors Harness disconnection or short circuit Malfunction of DEF pump pressure sensor Internal circuit disconnection or short circuit Abnormal output voltage ...

Page 714: ...S 1 Inspect the DEF pump connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DEF pump pressure sensor unit PSR PSRS PSR SAPH16F020400096 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump connector 1 PSR PSR 2 PSR PSRS 3 PSR PSRS 1 185 215 k 2 148 172 k 3 333 387 k Do ...

Page 715: ...measure the resistance between the terminals of the DCU 86P vehicle side connector 3 Check for short circuit in wire harness of DEF pump pressure sensor PSR PSRS PSR SAPH16F020400097 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector PSR Ground PSRS Ground PSR Ground Do the measurements meet the standard value Go to step 4 Repair or replace...

Page 716: ...tandard values Starter switch LOCK DCU 86P vehicle side connector 1 PSR PSR 2 PSR PSRS 3 PSR PSRS 1 185 215 k 2 148 172 k 3 333 387 k Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400099 Has DTC P204C been detected Replace the DCU Perform After in...

Page 717: ...5 215 k 2 148 172 k 3 333 387 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Replace the DEF pump Perform After inspection work of INFORMA TION section 3 Check for short circuit in wire harness of DEF pump pressure sen sor 1 Set the starter switch to the LOCK position 2 Disconnect the DCU 86P connector 3 Connect the sig...

Page 718: ...lues 1 185 215 k 2 148 172 k 3 333 387 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 5 Repair or replace the harness Perform After inspection work of INFORMA TION section 5 Check the DTC detected DCU Hino DX Check if P204C has been detected in DCU DTC P204C has been detected Go to YES No DTC has beendetected Go to NO Rep...

Page 719: ...en the DTC is set MIL ON SCR system malfunction lamp ON DEF injection is stopped NOx purification function is stopped If malfunction does not improve within 500 miles engine output is restricted If malfunction does not improve within 2 000 miles vehicle speed is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas pur...

Page 720: ...work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Harness disconnection or short circuit Malfunction of DEF pump pressure sensor Internal circuit disconnection or short circuit Abnormal output voltage ...

Page 721: ...YES 1 Inspect the DEF pump connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DEF pump pressure sensor unit PSR PSRS PSR SAPH16F020400101 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump connector 1 PSR PSR 2 PSR PSRS 3 PSR PSRS 1 185 215 k 2 148 172 k 3 333 387 k D...

Page 722: ...measure the resistance between the terminals of the DCU 86P vehicle side connector 3 Check for short circuit in wire harness of DEF pump pressure sensor PSR PSRS PSR SAPH16F020400102 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector PSR Ground PSRS Ground PSR Ground Do the measurements meet the standard value Go to step 4 Repair or replace...

Page 723: ...tandard values Starter switch LOCK DCU 86P vehicle side connector 1 PSR PSR 2 PSR PSRS 3 PSR PSRS 1 185 215 k 2 148 172 k 3 333 387 k Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400104 Has P204D been detected Replace the DCU Perform After inspec...

Page 724: ... k 2 148 172 k 3 333 387 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Replace the DEF pump Perform After inspection work of INFORMA TION section 3 Check for short circuit in wire harness of DEF pump pressure sen sor 1 Set the starter switch to the LOCK position 2 Disconnect the DCU 86P connector 3 Connect the signal c...

Page 725: ...lues 1 185 215 k 2 148 172 k 3 333 387 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 5 Repair or replace the harness Perform After inspection work of INFORMA TION section 5 Check the DTC detected DCU Hino DX Check if P204D has been detected in DCU DTC P204D has been detected Go to YES No DTC has beendetected Go to NO Rep...

Page 726: ...een DEF tank temperature and Ambient air temperature 50 C 122 F for 2 sec Common rail_ CAN_J C3 Common rail_ CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL DEF sensor DEF tank temperature sensor H L KP CA3H KN CA3L LEK LEJ CANH CANL H L Engine ECU DCU ...

Page 727: ...le when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction Control does not work properly when DEF freezes 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Poor connector contact or faulty...

Page 728: ... sure there is no dirt or damage to the ambient air tempera ture sensor 1 Inspect the DEF tank temperature sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the ambient air temperature sensor connector Ambient sensor DEF tank SAPH16F020400106 Was any failure found Connect securely repair if needed P...

Page 729: ...the ambient air temperature sensor Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the ambient air temperature sensor unit HH1 LJK HH1 LGK HH1 HH1 SAPH16F020400107 Measurement conditions Tester connections Standard values Starter switch LOCK Ambient air tem perature sensor HH1 HH1 1 7 k Do the measurements meet the standard value Go to step 5 Replace the ambient air te...

Page 730: ...ernal resistor connector Loose ness and poor contact NO YES 6 Inspect the ambient air temperature sensor harness ATS ATSS SAPH16F020400108 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector ATSS ATS 3 7 k Do the measurements meet the standard value Go to step 9 Go to step 7 7 Inspect the connector of the external resistor Was any failure fo...

Page 731: ... unit ER ER SAPH16F020400109 Measurement conditions Tester connections Standard values Starter switch LOCK External resistor ER ER 2 k Do the measurements meet the standard value Repair or replace the harness Perform After inspection work of INFOR MATION section Replace the external resistor Perform After inspection work of INFOR MATION section 9 Inspect the exhaust gas temperature sensor SCR inle...

Page 732: ...nsor SCR inlet Was any failure found Clean the exhaust gas temperature sensor SCR inlet and install it properly If damaged replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of INFOR MATION section Go to step 11 11 Inspect the exhaust gas temperature sensor SCR inlet unit FAT FAT SAPH16F020400110 Measurement conditions Tester connections Standard values Starter swit...

Page 733: ...rature sensor NO YES 12 Inspect the engine coolant temperature sensor connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 13 13 Inspect the engine coolant temperature sensor Was any failure found Clean the engine coolant temperature sensor and install it properly If damaged replace the engine coolant temperature sensor ...

Page 734: ...erature sensor unit WTM WTM SAPH16F020400111 Measurement conditions Tester connections Standard values Starter switch LOCK Engine coolant temperature sensor WTM WTM 20 C 68 F 2 59 2 32 k 80 C 176 F 0 326 0 310 k Do the measurements meet the standard value Go to step 15 Replace the engine coolant temperature sen sor Perform After inspection work of INFOR MATION section 15 Check the DTC detected DCU...

Page 735: ...ter inspection work of INFORMA TION section Go to step 3 3 Inspect the ambient air temperature sensor 1 Check the installation of the ambient air temperature sensor 2 Make sure there is no dirt or damage to the ambient air temperature sensor Failure found Go to YES No failure found Go to NO Clean the ambient air temperature sensor and install it prop erly If damaged replace the ambient air tempera...

Page 736: ... standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 9 Go to step 7 7 Inspect the connector of the external resistor Check the connection of the external resistor connector Looseness and poor contact Failure found Go to YES No failure found Go to NO Connect securely repair if needed Perform After inspection work of INFORMA TION section Go to step 8 8 Insp...

Page 737: ...ON section Go to step 11 11 Inspect the exhaust gas temperature sensor SCR inlet unit Measure the resistance between the terminals of the exhaust gas temperature sensor SCR inlet Tester connections Exhaust gas temperature sensor SCR inlet FAT FAT Standard values 220 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 12 Replace ...

Page 738: ...ool ant temperature sensor Tester connections Engine coolant temperature sen sor WTM WTM Standard values 20 C 68 F 2 59 2 32 k 80 C 176 F 0 326 0 310 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 15 Replace the engine cool ant tempera ture sensor Perform After inspection work of INFORMA TION section 15 Check the DTC dete...

Page 739: ...eset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF level indicator is stopped Common rail_CAN_J C3 Common rail_CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL DE...

Page 740: ...l fail safe function DEF level indicator is OFF Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors DEF tank temperature sensor 1 failure ...

Page 741: ...e and check if a CAN communication system mal function U02A2 has been detected in Fault Information NO YES 1 Check the DTC detected Engine Hino DX Select Engine SAPH16F020400114 Has DTC U02A2 been detected Go to diagnosis procedure of a related DTC Replace the DEF tank temperature sensor 1 Perform After inspection work of INFOR MATION section ...

Page 742: ...on Judgement Check Yes No Yes No 1 Check the DTC detected Engine Hino DX Check if a CAN communication system malfunction U02A2 has been detected in Engine DTC U02A2 has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the DEF sensor Perform After inspection work of INFORMA TION section ...

Page 743: ...Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF level indicator is stopped Common rail_CAN_J C3 Common rail_CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL D...

Page 744: ...l fail safe function DEF level indicator is OFF Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors DEF tank temperature sensor 1 failure ...

Page 745: ...e and check if a CAN communication system mal function U02A2 has been detected in Fault Information NO YES 1 Check the DTC detected Engine Hino DX Select Engine SAPH16F020400116 Has DTC U02A2 been detected Go to diagnosis procedure of a related DTC Replace the DEF tank temperature sensor 1 Perform After inspection work of INFOR MATION section ...

Page 746: ...ion Judgement Check Yes No Yes No 1 Check the DTC detected Engine Hino DX Check if a CAN communication system malfunction U02A2 has been detected in Engine DTC U02A2 has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the DEF sensor Perform After inspection work of INFORMA TION section ...

Page 747: ... restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF level indicator is stopped Common rail_CAN_J C3 Common rail_CAN_J C1 NOx sensor 1 NOx sensor 2 JU JZ JQ KF JV CA2H CA2L CA2H CA2L CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL DEF sensor DEF quality sensor...

Page 748: ...ontrol fail safe function DEF level indicator is OFF Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors DEF quality sensor failure ...

Page 749: ...ect Engine and check if a CAN communication system mal function U02A2 has been detected in Fault Information NO YES 1 Check the DTC detected Engine Hino DX Select Engine SAPH16F020400118 Has DTC U02A2 been detected Go to diagnostic procedure of a related DTC Replace the DEF sensor Perform After inspection work of INFOR MATION section ...

Page 750: ...nt Check Yes No Yes No 1 Check the DTC detected Engine Hino DX Check if a CAN communication system malfunction U02A2 has been detected in Engine DTC U02A2 has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the DEF sensor Perform After inspection work of INFORMA TION section ...

Page 751: ...ction is stopped NOx purification function is stopped If malfunction does not improve within 500 miles engine output is restricted If malfunction does not improve within 2 000 miles vehicle speed is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Engine output is insufficien...

Page 752: ...DEF SCR SYSTEM DCU 5 186 8 Estimated failure factors Harness disconnection or short circuit Looseness or poor contact of connector DEF pump motor malfunction ...

Page 753: ...e DCU 86P connector Looseness and poor contact NO YES 1 Inspect the DEF pump connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DCU 86P connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 ...

Page 754: ... harness PMP PMP PMPS PMP PMPS PMP SAPH16F020400120 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump vehicle side connector DCU 86P vehicle side connector PMP PMP PMP PMP PMPS PMPS 1 or less Do the measurements meet the standard value Replace the DEF pump and go to step 4 Repair or replace the harness Perform After inspection work of INFOR MATION section 4 Che...

Page 755: ...the DEF pump and the DCU 86P vehicle side connector 1 Disconnect the DEF pump connector 2 Disconnect DCU 86P con nector Connect the signal check harness and use the electrical tester to measure the resistance between the DEF pump and each termi nal of the DCU 86P vehicle side connector Tester connections DEF pump vehicle side connector DCU 86P vehicle side connec tor PMP PMP PMP PMP PMPS PMPS Stan...

Page 756: ...ored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehicle due to malfunction 6 Pre inspection work Chec...

Page 757: ...ure from the Data Monitor and check if the DEF pressure is maintained around 900 kPa 800 kPa 1050 kPa 131 psi 116 psi 152 psi NO YES 1 Inspection of the DEF pump pressure Hino DX Select DCU SAPH16F020400123 Standard values DEF pressure 900 kPa 800 kPa 1 050 kPa 131 psi 116 psi 152 psi Do the measurements meet the standard value Procedure completed Perform After inspection work of INFOR MATION sect...

Page 758: ...eep the engine idling about 10 minutes 2 Select DEF pump pressure from the Data Monitor and check if the DEF pressure is maintained around 900 kPa 800 kPa 1 050 kPa 131 psi 116 psi 152 psi Standard values DEF pressure 900 kPa 800 kPa 1 050 kPa 131 psi 116 psi 152 psi Measured value stabi lized within the standard value Go to YES Measured value not sta bilized within the standard value Go to NO Pro...

Page 759: ...ing or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTC...

Page 760: ...e DCU 86P connector Looseness and poor contact NO YES 1 Inspect the DEF pump connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DCU 86P connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 ...

Page 761: ...NO YES 3 Check the DEF pump wire harness PMP PMP PMPS PMP PMPS PMP SAPH16F020400125 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump vehicle side connector DCU 86P vehicle side connector PMP PMP PMP PMP PMPS PMPS 1 or less Do the measurements meet the standard value Replace the DEF pump and go to step 4 Repair or replace the harness Perform After inspection wo...

Page 762: ...terminal of the DCU 86P vehicle side con nector 1 Disconnect the DEF pump connector 2 Disconnect the DCU 86P connector connect the sig nal check harness mea sure the resistance between the DEF pump and each ter minal of the DCU 86P vehi cle side connector Tester connections DEF pump vehicle side connector DCU 86P vehicle side connec tor PMP PMP PMP PMP PMPS PMPS Standard values 1 or less The measu...

Page 763: ...r system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Che...

Page 764: ...e DCU 86P connector Looseness and poor contact NO YES 1 Inspect the DEF pump connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DCU 86P connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 3 ...

Page 765: ...S 3 Check the DEF pump wire harness PMP PMP PMPS PMP PMPS PMP SAPH16F020400128 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump vehicle side connector DCU 86P vehicle side connector PMP PMP PMP PMP PMPS PMPS 1 or less Do the measurements meet the standard value Replace the DEF pump and go to step 4 Repair or replace the harness Perform After inspection work of...

Page 766: ...terminal of the DCU 86P vehicle side connector 1 Disconnect the DEF pump connector 2 Disconnect the DCU 86P connector connect the sig nal check harness mea sure the resistance between the DEF pump and each ter minal of the DCU 86P vehi cle side connector Tester connections DEF pump vehicle side connector DCU 86P vehicle side connec tor PMP PMP PMP PMP PMPS PMPS Standard values 1 or less The measur...

Page 767: ... System failure lamp ON Output restriction is applied when malfunction does not improve within 500 miles Vehicle speed restriction is applied when malfunction does not improve within 2 000 miles 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient when malfunction does not improve within 500 miles Vehicle does ...

Page 768: ...DEF SCR SYSTEM DCU 5 202 8 Estimated failure factors Disconnection or short circuit in sensor harness Irregular contact disconnection or poor fit of connector Malfunction of DEF reverting valve ...

Page 769: ...ing valve NO YES 1 Inspect the DEF pump reverting valve connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DEF pump reverting valve unit PMV PMV SAPH16F020400131 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump reverting valve connector PMV PMV 23 C 73 4 F 2 05 12 0...

Page 770: ...nce between the terminals of the DCU 86P vehicle side connector 3 Inspect for short circuit in the DEF pump reverting valve harness PMV PMV SAPH16F020400132 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector PMV Ground PMV Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perform After inspection ...

Page 771: ...cle side connector PMV PMV 23 C 73 4 F 2 05 12 05 Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400134 Has DTC P20A0 been detected Replace the DCU Perform a DPR forced regeneration after replacement Perform After inspection work of INFOR MATION se...

Page 772: ...ctions DEF pump connector PMV PMV Standard values 23 C 73 4 F 2 05 12 05 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Replace the DEF pump Perform After inspection work of INFORMA TION section 3 Inspect short circuit of the DEF pump reverting valve harness Disconnect the DCU 86P connec tor Connect the signal check harne...

Page 773: ...4 F 2 05 12 05 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 5 Repair or replace the harness Perform After inspection work of INFORMA TION section 5 Check the DTC detected DCU Hino DX Check if P20A0 has been detected in DCU DTC P20A0 has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU Perform a DPR...

Page 774: ...ure sensor drop to 50 kPa 7 3 psi is detected within 25 seconds after starter switch is turned OFF 4 Indication warning or system control regulation when the DTC is set MIL ON DEF injector and DEF pipe may rupture when DEF freezes 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspectio...

Page 775: ...erate the DEF pump 2 Select DEF pump pressure from the Data Monitor menu and check the DEF pressure NO YES 1 Check the operation of the DEF pump reverting valve Hino DX Select DCU SAPH16F020400136 Did you hear the operating sound Go to step 2 Replace DEF pump Perform After inspection work of INFOR MATION section 2 Inspect the DEF pump reverting valve Hino DX Select DCU SAPH16F020400137 Standard va...

Page 776: ...DCU 4 Select DCU and check if P20A1 is detected in Fault Information NO YES 3 Inspect the DEF tank Was any failure found Replace the breather hose Perform After inspection work of INFOR MATION section Go to step 4 4 Check the DTC detected DCU Hino DX Select DCU When communicat ion with the DCU is interrupted while the DCU is connec ted to the Hino DX the connection symbol at the left bottom of the...

Page 777: ...Pa 7 3 psi The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 3 Replace DEF pump Perform After inspection work of INFORMA TION section 3 Inspect the DEF tank Check if the breather hose is not disconnected clogged punctured or cracked Failure found Go to YES No failure found Go to NO Replace the breather hose Perform After inspe...

Page 778: ...ng restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehicle due to malfunction 6 Pre inspection wo...

Page 779: ...DEF SCR SYSTEM DCU 5 213 8 Estimated failure factors Disconnection or short circuit in sensor harness Irregular contact disconnection or poor fit of connector Malfunction of DEF reverting valve ...

Page 780: ...e NO YES 1 Inspect the DEF pump reverting valve connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DEF pump reverting valve unit PMV PMV SAPH16F020400140 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump Reverting valve connector PMV PMV 23 C 73 4 F 2 05 12 05 Do the...

Page 781: ...nce between the terminals of the DCU 86P vehicle side connector 3 Inspect for short circuit in the DEF pump reverting valve harness PMV PMV SAPH16F020400141 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector PMV Ground PMV Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perform After inspection ...

Page 782: ...vehicle side connector PMV PMV 23 C 73 4 F 2 05 12 05 Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Select DCU SAPH16F020400143 Has DTC P20A2 been detected Replace the DCU Perform a DPR forced regeneration after replacement Perform After inspection work of INFOR MATION sectio...

Page 783: ...P connec tor and connect the signal check harness to measure the resis tance between the terminals of the DCU 86P vehicle side con nector and the ground Tester connections DCU 86P vehicle side connector PMV Ground PMV Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the harness Perfo...

Page 784: ...detected Go to NO Replace the DCU Perform a DPR forced regeneration after replace ment Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P20A2 Reverting valve for DEF pump circuit Circuit low Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 785: ...g or system control regulation when the DTC is set MIL ON DEF injector and DEF pipe may rupture when DEF freezes 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC...

Page 786: ...e NO YES 1 Inspect the DEF pump reverting valve connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the DEF pump reverting valve unit PMV PMV SAPH16F020400145 Measurement conditions Tester connections Standard values Starter switch LOCK DEF pump Reverting valve connector PMV PMV 23 C 73 4 F 2 05 12 05 Do the...

Page 787: ...measure the resistance between the terminals of the DCU 86P vehicle side connector 3 Inspect for short circuit in the DEF pump reverting valve harness PMV PMV SAPH16F020400146 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector PMV Ground PMV Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perfor...

Page 788: ...vehicle side connector PMV PMV 23 C 73 4 F 2 05 12 05 Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Select DCU SAPH16F020400148 Has DTC P20A3 been detected Replace the DCU Perform a DPR forced regeneration after replacement Perform After inspection work of INFOR MATION sectio...

Page 789: ...86P connec tor Connect the signal check har ness to measure the resistance between the terminals of the DCU 86P vehicle side connector and the ground Tester connections DCU 86P vehicle side connector PMV Ground PMV Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the harness Perform ...

Page 790: ...detected Go to NO Replace the DCU Perform a DPR forced regeneration after replace ment Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P20A3 Reverting valve for DEF pump circuit Circuit high Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 791: ... System failure lamp ON If malfunction does not improve within 500 miles engine output is restricted If malfunction does not improve within 2 000 miles vehicle speed is restricted 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Engine output is insufficient when malfunction does not improve within 500 miles Vehicle does not speed up wh...

Page 792: ...valve NO YES 1 Inspect the coolant cut off valve DEF tank heater valve connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Check the coolant cut off valve DEF tank heater valve unit LDU LDV SAPH16F020400150 Measurement conditions Tester connections Standard values Starter switch LOCK Coolant cut off valve DEF tank h...

Page 793: ...e the resistance between the terminals of the DCU 86P vehicle side connector 3 Check for short circuit in the coolant cut off valve DEF tank heater valve wire harness WMV WMV SAPH16F020400151 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector WMV Ground WMV Ground Do the measurements meet the standard value Go to step 4 Repair or replace th...

Page 794: ...cle side connector WMV WMV 20 C 68 F 9 04 9 52 Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400153 Has DTC P20B1 been detected Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFOR MATION...

Page 795: ...ank heater valve wire harness Disconnect the DCU 86P connec tor Connect the signal check har ness to measure the resistance between the terminals of the DCU 86 vehicle side connector and the ground Tester connections WMV Ground WMV Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the...

Page 796: ...s beendetected Go to NO Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P20B1 DEF tank heater valve circuit Open load Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 797: ... CA3H KH KG CA3L CA3H KE CA3L KM CA3H KL CA3L JR CA2H JW CA2L LE9 LE8 CANH VCC GND GND VCC GND CANL H L H L H L JS CA2H JX CA2L LED LEC CANH CANL DEF sensor DEF tank temperature sensor H L KP CA3H KN CA3L LEK LEJ CANH CANL H L Engine ECU DCU S5 S7 S5 S7 AW AV AW AV LCM H RD CA2H L H L CA1H LCN RE CA2H CA2L RJ LF5 LF6 CA1L CAL1 CP CP CQ CQ SD SD SF SF K6V CANH K6W CANL H L CAH1 LEY LEZ 250K 500K RH...

Page 798: ...ng or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Symptoms on the vehicle due to malfunction 6 Pre inspection work If DTC P20B1 is detected simultaneously start DTC P2...

Page 799: ... in Fault Information NO YES 1 Check if the connection of the DEF tank temperature sensor con nector Looseness or poor contact NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400155 Has a DTC other than P20B2 been detected Go to diagnosis procedure of a related DTC Go to step 2 2 Inspect the DEF tank temperature sensor connector Was any failure found Connect securely repair if nee...

Page 800: ... sensor NO YES 3 Inspect the engine coolant system pipes or hoses Was any failure found Repair or replace the faulty part Perform After inspection work of INFOR MATION section Go to step 4 4 Inspect the engine coolant temperature sensor connector Was any failure found Connect securely Repair if needed Perform After inspection work of INFOR MATION section Go to step 5 5 Inspect the engine coolant t...

Page 801: ...or unit WTM WTM SAPH16F020400156 Measurement conditions Tester connections Standard values Starter switch LOCK Engine coolant temperature sensor WTM WTM 20 C 68 F 2 59 2 32 k 80 C 176 F 0 326 0 310 k Do the measurements meet the standard value Go to step 7 Replace the engine coolant temperature sen sor Perform After inspection work of INFOR MATION section 7 Inspect the coolant cut off valve DEF ta...

Page 802: ...ank temperature rises when the coolant temper ature is 40 C 104 F or higher NO YES 8 Coolant cut off valve DEF tank heater valve actuation test Hino DX Select DCU SAPH16F020400157 Operating noise is heard Go to step 9 Replace the coolant cut off valve DEF tank heater valve Perform After inspection work of INFOR MATION section 9 Inspect the engine coolant temperature Hino DX Select DCU SAPH16F02040...

Page 803: ...NO YES 10 Inspect the coolant cut off valve DEF tank heater valve unit LDU LDV SAPH16F020400159 Measurement conditions Tester connections Standard values Starter switch LOCK Coolant cut off valve DEF tank heater valve con nector LDU LDV 20 C 68 F 9 04 9 52 Do the measurements meet the standard value Go to step 11 Replace the coolant cut off valve DEF tank heater valve Perform After inspection work...

Page 804: ...ose upstream downstream from DEF pump 2 Blow air from one side and make sure it comes out from the other side NO YES 12 Inspect the DEF sensor Was any failure found Replace the DEF sensor Perform After inspection work of INFOR MATION section Go to step 13 13 Inspect the DEF pump Was any failure found Replace the DEF pump Perform After inspection work of INFOR MATION section Go to step 14 ...

Page 805: ...e starter switch to the ON position 5 Select DCU and check if P20B2 has been detected in Fault Infor mation NO YES 14 Replace the DEF tank temperature sensor Select DCU SAPH16F020400160 Has the DTC P20B2 been detected Replace the DCU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 806: ...kage of the engine coolant system pipes or hoses 2 Check for uncoupled clogged broken or cracked parts in the engine cooling system pipes and hoses Failure found Go to YES No failure found Go to NO Repair or replace the faulty part Perform After inspection work of INFORMA TION section Go to step 4 4 Inspect the coolant tem perature sen sor connector Check the connection of the cool ant temperature...

Page 807: ...ion test Hino DX Check the coolant cut off valve DEF tank heater valve operating noise using Activation Test on Hino DX 1 Set the starter switch to the ON position 2 Select DCU from the menu 3 Select Coolant shutoff valve from the Activation Test menu and check the coolant cut off valve DEF tank heater valve operating noise Operation sound was able to be heard Go to YES It was not audible Go to NO...

Page 808: ...spection work of INFORMA TION section 12 Inspect the DEF sensor 1 Remove the coolant hose upstream downstream from DEF sensor 2 Blow air from one side and make sure it comes out from the other side Failure found Go to YES No failure found Go to NO Replace the DEF sensor Perform After inspection work of INFORMA TION section Go to step 13 13 Inspect the DEF pump 1 Remove the coolant hose upstream do...

Page 809: ...tored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction Control will not work properly if the DEF freezes 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspec...

Page 810: ...e terminals of the coolant cut off valve NO YES 1 Inspect the coolant cut off valve connector Was any failure found Connect securely repair if needed Go to step 2 2 Inspect the coolant cut off valve unit LDU LDV SAPH16F020400162 Measurement conditions Tester connections Standard values Starter switch LOCK Coolant cut off valve connector LDU LDV 20 C 68 F 9 04 9 52 Do the measurements meet the stan...

Page 811: ...er to measure resistance between the terminals of the DCU 86P vehi cle side connector 3 Check for short circuit in the coolant cut off valve wire harness WMV WMV SAPH16F020400163 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector WMV Ground WMV Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Per...

Page 812: ...le side connector WMV WMV 20 C 68 F 9 04 9 52 Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400165 Has DTC P20B3 been detected Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFOR MATION ...

Page 813: ...ss Disconnect the DCU 86P connec tor Connect the signal check har ness to measure the resistance between the terminals of the DCU 86 vehicle side connector and the ground Tester connections WMV Ground WMV Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the harness Perform After insp...

Page 814: ... beendetected Go to NO Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P20B3 DEF tank heater valve circuit Circuit low Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 815: ...e normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Symptoms on the vehicle due to malfunction Control will not work properly if the DEF freezes 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work C...

Page 816: ... cut off valve NO YES 1 Inspect the coolant cut off valve connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Check the coolant cut off valve unit LDU LDV SAPH16F020400167 Measurement conditions Tester connections Standard values Starter switch LOCK Coolant cut off valve connector LDU LDV 20 C 68 F 9 04 9 52 Do the ...

Page 817: ... to measure the resistance between the terminals of the DCU 86P vehicle side connector 3 Check for short circuit in the coolant cut off valve wire harness WMV WMV SAPH16F020400168 Measurement conditions Tester connections Standard values Starter switch LOCK DCU 86P vehicle side connector WMV Ground WMV Ground Do the measurements meet the standard value Go to step 4 Repair or replace the harness Pe...

Page 818: ...ehicle side connector WMV WMV 20 C 68 F 9 04 9 52 Do the measurements meet the standard value Go to step 5 Repair or replace the harness Perform After inspection work of INFOR MATION section 5 Check the DTC detected DCU Select DCU SAPH16F020400170 Has DTC P20B4 been detected Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFOR MATION sect...

Page 819: ...s Disconnect the DCU 86P connec tor Connect the signal check har ness to measure the resistance between the terminals of the DCU 86P vehicle side connector and the ground Tester connections WMV Ground WMV Ground Standard values The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the harness Perform After insp...

Page 820: ...ndetected Go to NO Replace the DCU After replacing the DCU perform a DPR forced regeneration Perform After inspection work of INFORMA TION section Procedure completed Perform After inspection work of INFORMA TION section DTC P20B4 DEF tank heater valve circuit Circuit high Inspection Procedure Step Action Description Judgement Check Yes No Yes No ...

Page 821: ...mperature SCR inlet 150 C 302 F DEF defrosting is done 2 Judgement criteria After the DEF pump starts to build up pressure DEF line pressure does not increase more than 8 000 hPa 116 psi for 50 sec three times in a row Breather hose Coolant outlet Harness connector Coolant inlet Coolant inlet DEF back flow To DEF tank Coolant outlet DEF pressure line outlet DEF back flow To DEF tank DEF back flow ...

Page 822: ...ntrol fail safe function Exhaust gas purification function has deteriorated Engine output is insufficient when malfunction does not improve within 500 miles Vehicle does not speed up when malfunction does not improve within 2 000 miles Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Che...

Page 823: ...Inspect the DEF quantity Are there at least 3 scale marks of DEF Go to step 2 Refill the DEF Perform After inspection work of INFOR MATION section 2 Inspect the DEF tank filter cap SAPH16F020400173 Was any failure found Check the contents described below If there is no failure replace the DEF tank filter Cracks of the filter cap Tightening torque of the filter cap Perform After inspection work of ...

Page 824: ...de DEF hose connector DEF pump side DEF hose suction side HINT If DEF leaks deposits of DEF crystals will form around the muffler NO YES 3 Inspect the DEF pipe Connector Connector DEF hose DEF pump Injector Connector DEF hose SAPH16F020400174 Was any failure found Clean connectors and the area around con nectors and make sure connectors are securely connected After repair work is completed go to s...

Page 825: ...t from the DEF addition test in Check func tions menu on Hino DX NO YES 4 Leak test of the DEF pipe Hino DX Click Leak test SAPH16F020400175 Standard values The DEF pressure is stable in the 8 500 to 9 500 hPa 123 3 to 137 8 psi range for 60 seconds Do the measurements meet the standard value Procedure completed Perform After inspection work of INFOR MATION section Go to step 5 ...

Page 826: ...e Preparation for making SST1 Straight Connector SAE J2044 8x6 SAE3 8 Elbow Connector SAE J2044 8x6 SAE3 8 Clear Tube 1m 8x6 Outer Dia 8mm Inner Dia 6mm Hose Band 2 After overhauling 87209 E006 it can be used for Straight Connector and Elbow Connector 2 1 DEF tank DEF sensor SST1 DEF pump Click Leak test SAPH16F020400176 Measurement conditions Standard values Starter switch ON The DEF pressure is ...

Page 827: ...cts in the DEF tank NO YES 6 Inspection of the DEF pressure 2 Inspection of the DEF tank sensor Hino DX 2 1 DEF DEF sensor SST1 DEF pump SAPH16F020400177 Measurement conditions Standard values Starter switch ON The DEF pressure is stable in the 8 500 to 9 500 hPa 123 3 to 137 8 psi range for 60 seconds Do the measurements meet the standard value Go to step 7 Go to step 8 7 Inspect the DEF tank Was...

Page 828: ...essure 3 Inspection of the DEF pump Hino DX 2 1 DEF tank DEF sensor SST1 DEF pump Inlet connector 88 mm 3 39 in 22 mm 0 87 in SAPH16F020400178 Measurement conditions Standard values Starter switch ON The DEF pressure is stable in the 8 500 to 9 500 hPa 123 3 to 137 8 psi range for 60 seconds Do the measurements meet the standard value Procedure completed Perform After inspection work of INFOR MATI...

Page 829: ...ES No failure found Go to NO Check the contents described below If there is no failure replace the DEF tank filter Cracks of the filter cap Tighten ing torque of the filter cap Perform After inspection work of INFORMA TION section Go to step 3 3 Inspect the DEF pipe 1 Check all connectors and DEF hoses and check if they are free of leaks and DEF crystals 2 Gently pull on connectors and make sure t...

Page 830: ... perform Leak Test from DEF addi tion test of Hino DX Standard values DEF pressure is stable in the 8 500 to 9 500 hPa 123 3 to 137 8 psi range for 60 seconds The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Replace the DEF suction line Perform After inspection work of INFORMA TION section Go to step 6 6 Inspection of the DEF pres sure ...

Page 831: ...o DX 1 Set the starter switch to the LOCK position 2 Replace with a new inlet valve of the DEF pump 3 Connect SST1 again between the DEF tank 1 and the DEF pump 2 4 Set the starter switch to the ON position 5 Use Hino DX and perform Leak test Standard values The DEF pressure is stable in the 8 500 to 9 500 hPa 123 3 to 137 8 psi range for 60 seconds The measure ments meet the standard value Go to ...

Page 832: ...essure rise DEF line pressure does not decrease or is stable at more than 10 000 hPa for 2 sec at DEF pump duty cycle 7 When the DEF pressure was not stable for 8 sec from 8 500 hPa to 9 500 hPa 123 3 psi to 137 8 psi during a period of 300 sec While Normal monitoring DEF line pressure is more than 12 500 hPa 181 3 psi for 5 sec Breather hose Coolant outlet Harness connector Coolant inlet Coolant ...

Page 833: ...ymptoms on the vehicle due to backup control fail safe function Exhaust gas purification function has deteriorated Engine output is insufficient when malfunction does not improve within 500 miles Vehicle does not speed up when malfunction does not improve within 2 000 miles Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After ...

Page 834: ...the Leak test after pressure has stabilized monitor the pressure fluctuation for 60 seconds NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400181 Has DTC P20E8 been detected Proceed to DTC P20E8 diagnosis procedure Go to step 2 2 Inspect the leak of the DEF pipe Hino DX Click Leak test SAPH16F020400182 Standard values DEF pressure must not exceed 8 500 hPa 123 3 psi DEF pressure ...

Page 835: ...ube Items to be prepared for SST2 creation Straight Connector SAE J2044 8x6 5 16 Elbow Connector SAE J2044 8x6 3 8 Clear Tube 1m 8x6 Outer Dia 8mm Inner Dia 6mm Hose band 2 pcs Straight Connector and Elbow Connector are reused from disassembly of 87209 E006 Tank side Pump side 2 1 DEF sensor SST2 SAPH16F020400183 Measurement conditions Standard values Starter switch ON The DEF pressure is stable i...

Page 836: ...e DEF is discharged from the connector in the container NO YES 4 Inspect the DEF pressure 2 Inspection of the DEF sensor Hino DX 2 1 DEF sensor Separate container SAPH16F020400184 Measurement condition Standard values Starter switch ON The DEF pressure is stable in the 8 500 to 9 500 hPa 123 3 to 137 8 psi range for 60 seconds Do the measurements meet the standard value Replace the DEF sensor Perf...

Page 837: ...nspect the DEF pressure 2 Inspection of the DEF pump Hino DX Back flow connector 81 mm 3 19 in φ25 mm 0 98 in 2 1 DEF sensor SST2 SAPH16F020400185 Measurement conditions Standard values Starter switch ON The DEF pressure is stable in the 8 500 to 9 500 hPa 123 3 to 137 8 psi range for 60 seconds Do the measurements meet the standard value Procedure completed Perform After inspection work of INFOR ...

Page 838: ...st not exceed 8 500 hPa 123 3 psi DEF pressure temporarily exceeded 8 500 hPa 123 3 psi but dropped below that value thereafter The measure ment corre sponds to a standard value Go to YES The measure ment does not correspond to a standard value Go to NO Proceed to DTC P20E8 diagnosis pro cedure Go to step 3 3 Inspect the DEF pressure 1 Inspection of the DEF hose Hino DX 1 Set the starter switch to...

Page 839: ...ection work of INFORMA TION section Go to step 5 5 Inspect the DEF pressure 2 Inspection of the DEF pump Hino DX 1 Set the starter switch to the LOCK position 2 Replace with a new back flow valve of the DEF pump 3 Connect the SST2 again between the DEF tank 1 and the DEF pump 2 4 Set the starter switch to the ON position 5 Perform the Leak test of Hino DX Standard values DEF pressure is stable in ...

Page 840: ...DEF pump duty Accumulated DEF injector duty is 0 12 2 Judgement criteria At system running Pressure line check start DEF pump speed keep and DEF injector full open If DEF pressure is 750 kPa 109 psi after 4 sec from DEF injector open DTC is detected 3 Reset condition After having restored to the normal conditions 4 Indication warning or system control regulation when the DTC is set MIL ON SCR Syst...

Page 841: ...ine output is insufficient Vehicle does not speed up when malfunction does not improve within 50 min Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Clogging of the DEF injector Clogging of the DEF pipe ...

Page 842: ...E10 or S5 UJ08E10 for removal and installation of the DEF injector 3 Set the starter switch to the ON position 4 Select DCU 5 Select Check functions on Hino DX menu and check the opera tion of the DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank tempe...

Page 843: ...DX Select DCU SAPH16F020400188 Is operation normal New injector installed in the muffler Proce dure completed After installing the injector idle the engine for about 10 min and from the menu Data Monitor check if the DEF is stable between 800 kPa 116 psi and 1 051 kPa 152 psi Perform After inspection work of INFOR MATION section Re install the DEF injector and replace the DEF pipe pressure line Af...

Page 844: ...Judgement Check Yes No Yes No 1 Inspect the DEF pipe pump injector Check the DEF pipe pressure line and check if there are no dis connections clogging corrosion or cracks Failure found Go to YES No failure found Go to NO Replace the DEF pipe pressure line Perform After inspection work of INFORMA TION section Go to step 2 ...

Page 845: ... to the ON position 4 Select DCU 5 Select Check functions on Hino DX menu and check the operation of the DEF injector Inspection procedure 1 Select Check functions 2 Select DEF addition test 3 Perform addition test as instructed on the Hino DX screen Perform all three patterns NOTICE When the DEF tank tempera ture is 5 C 23 F or lower perform warm up to raise it to 10 C 50 F or higher HINT Refer t...

Page 846: ...lling the injector idle the engine for about 10 min and from the menu Data Monitor check if the DEF is stable between 800 kPa 116 psi and 1 051 kPa 152 psi Perform After inspection work of INFORMA TION section Re install the DEF injector and replace the DEF pipe pressure line After replac ing the pipe idle the engine for about 10 min and from the menu Data Monitor check if the DEF is stable betwee...

Page 847: ...RY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W KTR KTQ L2P LCH KTU KTS KTD KTT KTR KTQ KTU KTS KTT AFGD AFSG AFT AFVB AFT AGD6 AFSI AGD5 AFVB THA AVC2 AGD2 THW PIM ATI AGD4 K0W L75 L2P LCH KTD K0W L75 CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY LEZ JU JZ CA2L JQ JV CA2L KE CA3L KF CA3H JX CA2L JS CA2H CAL0 CAH0 RE H H L H L JW CA2L JR CA2H LEC CANL LED CANH LEB GND LE...

Page 848: ...ion warning or system control regulation when the DTC is set MIL ON DEF injection is stopped NOx purification function is stopped 5 Symptoms on the vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal ra...

Page 849: ...3 Set the starter switch to the ON position 4 Select DCU and check if any DTC other than P2201 for example P2202 P2209 U029D has been detected in Fault Information NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400191 Has a DTC other than P2201 been detected Go to diagnosis procedure of a related DTC Go to step 2 ...

Page 850: ...rter switch to the ON position 5 Erase the malfunction history using Hino DX 6 Perform a DPR forced regeneration 7 Select DCU and check if P2201 has been detected in Fault Infor mation NO YES 2 Inspect the NOx sensor 1 SCR upstream NOx sensor 1 NOx sensor 2 SAPH16F020400192 Select DCU SAPH16F020400193 Has DTC P2201 detected Go to step 3 Replace the NOx sensor 1 SCR upstream Perform After inspectio...

Page 851: ... the engine coolant tem perature sensor NO YES 3 Inspect the engine coolant temperature sensor Engine coolant temperature sensor 1 SAPH16F020400194 Was any failure found Clean the engine coolant temperature sensor and install it properly If damaged replace the engine coolant temperature sensor Perform After inspection work of INFOR MATION section Go to step 4 ...

Page 852: ... F check if the temperature output by the engine cool ant temperature sensor is 50 C 122 F NO YES 4 Check the coolant temperature sensor output signal Hino DX SAPH16F020400195 Standard values Engine coolant temperature sensor output value 50 C 122 F Do the measurements meet the standard value Go to step 5 Replace the engine coolant temperature sen sor Perform After inspection work of INFOR MATION ...

Page 853: ...re is no dirt or damage to the air flow sensor NO YES 5 Inspect the air flow sensor Air flow sensor SAPH16F020400196 Was any failure found If dirt clogging or damage in the sensing unit was found replace the air flow sensor Perform After inspection work of INFOR MATION section Go to step 6 ...

Page 854: ...n to the boost pres sure sensor NO YES 6 Inspect the boost pressure sensor Engine left side view Vehicle front Boost pressure sensor SAPH16F020400197 Was any failure found If dirt clogging or damage in the sensing unit was found replace the boost pressure sensor Perform After inspection work of INFOR MATION section Go to step 7 ...

Page 855: ...utput signal Hino DX Select Engine SAPH16F020400198 Standard values Boost pressure sensor output value There is no abnormal change in the sensor output signal The pressure sensor signal changes according to the engine speed Do the measurements meet the standard value Go to step 8 Replace the boost pressure sensor Perform After inspection work of INFOR MATION section 8 Inspect the intake manifold t...

Page 856: ...nifold temperature sensor unit THG E2 SAPH16F020400199 Measurement conditions Tester connections Standard values Starter switch LOCK Intake manifold temperature sensor THG E2 20 C 68 F 7 336 5 794 k 50 C 122 F 2 435 2 41 k Do the measurements meet the standard value Go to step 10 Replace the intake manifold temperature sensor Perform After inspection work of INFOR MATION section 10 Inspect the NOx...

Page 857: ...INFORMA TION section 3 Inspect the engine cool ant tempera ture sensor 1 Check the installation of the engine coolant temperature sensor Looseness and poor contact 2 Make sure there is no dirt or damage to the engine cool ant temperature sensor Failure found Go to YES No failure found Go to NO Clean the engine cool ant tempera ture sensor and install it properly If damaged replace the engine cool ...

Page 858: ...ostpressure sensor Perform After inspection work of INFORMA TION section Go to step 7 7 Check the boostpressure sensor output signal Hino DX From the Hino DX Data Monitor menu select Actual boost pres sure to race the engine from idling after the engine is started up from No Load Maximum and check if there is no abnormality in the boost pressure sensor output signal Standard values There is no abn...

Page 859: ...e sen sor THG E2 Standard values 20 C 68 F 7 336 5 794 k 50 C 122 F 2 435 2 41 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 10 Replace the intake mani fold tempera ture sensor Perform After inspection work of INFORMA TION section 10 Inspect the NOx sensor 1 Hino DX Replace the NOx sensor 1 with a new one and check again...

Page 860: ...am internal circuit Low failure flag is received from CAN data ECU DCU AW AV AW AV S5 S7 S5 S7 LCM H L CA1H LCN LF5 LF6 CA1L CAL1 SD SF SD SF CP CP CQ CQ KH KG CA3L CA3H KM CA3H KL CA3L 1D 99 99 A49 1 A48 Z29 G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY LEZ JU JZ CA2L JQ JV CA2L KE CA3L KF CA3H JX CA2L ...

Page 861: ... the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Failure of NOx sensor 1 SCR upstream Fail...

Page 862: ...CU and check if a CAN communication system malfunc tion U029D has been detected in Fault Information NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400202 Has DTC U029D been detected Go to the diagnostic procedure of a related DTC Replace the NOx sensor 1 SCR upstream Perform After inspection work of INFOR MATION section ...

Page 863: ...Check Yes No Yes No 1 Check the DTC detected DCU Hino DX Check if a CAN communication system malfunction U029D has been detected in Fault Informa tion DTC U029D has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the NOx sensor 1 SCR upstream Perform After inspection work of INFORMA TION section ...

Page 864: ...nal circuit High failure flag is received from CAN data ECU DCU AW AV AW AV S5 S7 S5 S7 LCM H L CA1H LCN LF5 LF6 CA1L CAL1 SD SF SD SF CP CP CQ CQ KH KG CA3L CA3H KM CA3H KL CA3L 1D 99 99 A49 1 A48 Z29 G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY LEZ JU JZ CA2L JQ JV CA2L KE CA3L KF CA3H JX CA2L JS CA2H...

Page 865: ... the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Failure of NOx sensor 1 SCR upstream Fail...

Page 866: ...CU and check if a CAN communication system malfunc tion U029D has been detected in Fault Information NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400204 Has DTC U029D been detected Go to the diagnostic procedure of a related DTC Replace the NOx sensor 1 SCR upstream Perform After inspection work of INFOR MATION section ...

Page 867: ...dgement Check Yes No Yes No 1 Check the DTC detected DCU Hino DX Check if a CAN communication system malfunction U029D has been detected in DCU DTC P029D has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace the NOx sensor 1 SCR upstream Perform After inspection work of INFORMA TION section ...

Page 868: ...A1H LCN LF5 LF6 CA1L CAL1 SD SF SD SF CP CP CQ CQ KH KG CA3L CA3H KM CA3H KL CA3L 1D 99 99 A49 1 A48 Z29 G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W KTR KTQ L2P LCH KTU KTS KTD KTT KTR KTQ KTU KTS KTT AFGD AFSG AFT AFVB AFT AGD6 AFSI AGD5 AFVB THA AVC2 AGD2 THW PIM ATI AGD4 K0W L75 L2P LCH KTD K0W L75 CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY ...

Page 869: ... vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Harness disconnection or sho...

Page 870: ... NOx sensors 1 and 2 in the vehicle in their opposite loca tion 4 Set the starter switch to the ON position 5 Erase the malfunction history using Hino DX 6 Perform the DPR forced regeneration 7 Select DCU and check if P2204 has been detected in Fault Infor mation NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400206 Has a DTC other than P2204 been detected Go to diagnosis procedu...

Page 871: ... ant temperature sensor is 50 C 122 F NO YES 3 Inspect the engine coolant temperature sensor Was any failure found Clean the engine coolant temperature sensor and install it properly If damaged replace the engine coolant temperature sensor Perform After inspection work of INFOR MATION section Go to step 4 4 Check the engine coolant temperature sensor output signal Hino DX Select Engine SAPH16F0204...

Page 872: ...ost pressure sensor NO YES 5 Inspect the air flow sensor Was any failure found If dirt clogging or damage in the sensing unit was found replace the air flow sensor Perform After inspection work of INFOR MATION section Go to step 6 6 Inspect the boost pressure sensor Was any failure found If dirt clogging or damage in the sensing unit was found replace the boost pressure sensor Perform After inspec...

Page 873: ...output signal Hino DX Select Engine SAPH16F020400209 Standard values Boost pressure sensor output value There is no abnormal change in the sensor output signal The pressure sensor signal changes according to the engine speed Do the measurements meet the standard value Go to step 8 Replace the boost pressure sensor Perform After inspection work of INFOR MATION section 8 Inspect the Intake manifold ...

Page 874: ...old temperature sensor unit THG E2 SAPH16F020400210 Measurement conditions Tester connections Standard values Starter switch LOCK Intake manifold temperature sen sor THG E2 20 C 68 F 7 336 5 794 k 50 C 122 F 2 435 2 41 k Do the measurements meet the standard value Go to step 10 Replace the intake manifold temperature sensor Perform After inspection work of INFOR MATION section 10 Inspection of the...

Page 875: ...s been detected 1 Install NOx sensors 1 and 2 in the vehicle in their oppo site location 2 Erase the malfunction his tory using Hino DX 3 Perform the DPR forced regeneration Check if P2204 has been detected in DCU DTC P2204 has been detected Go to YES No DTC has beendetected Go to NO Go to step 3 Replace the NOx sensor 1 Perform After inspection work of INFORMA TION section 3 Inspect the engine co...

Page 876: ...rk of INFORMA TION section Go to step 6 6 Inspect the boostpressure sensor 1 Check the installation of the boost pressure sensor 2 Make sure there is no dirt clogging or damage in the sensing unit of the boost pressure sensor Failure found Go to YES No failure found Go to NO If dirt clog ging or dam age in the sensing unit was found replace the boostpressure sensor Perform After inspection work of...

Page 877: ...ifold temperature sen sor THG E2 Standard values 20 C 68 F 7 336 5 794 k 50 C 122 F 2 435 2 41 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 10 Replace the intake mani fold tempera ture sensor Perform After inspection work of INFORMA TION section 10 Inspection of the NOx sen sor 1 Hino DX Replace the NOx sensor 1 with a ...

Page 878: ... NOx sensor heater acti vation ECU DCU AW AV AW AV S5 S7 S5 S7 LCM H L CA1H LCN LF5 LF6 CA1L CAL1 SD SF SD SF CP CP CQ CQ KH KG CA3L CA3H KM CA3H KL CA3L 1D 99 99 A49 1 A48 Z29 G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W THW AGD5 CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY LEZ JU JZ CA2L JQ JV CA2L KE CA3L KF CA3H JX CA2L JS CA2H CAL0 CAH0 RE H ...

Page 879: ...is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Disconnection or short circuit in sensor harness Malfunction of NOx sensor 1 SCR upstream Mal...

Page 880: ...vehicle side connector NO YES 1 Inspect the NOx sensor 1 SCR upstream connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the NOx sensor 1 harness CAN communication line CANL CANH SAPH16F020400213 Measurement conditions Tester connections Standard values Starter switch ON NOx sensor 1 vehicle side connector ...

Page 881: ...tions Tester connections Standard values Starter switch LOCK NOx sensor 1 vehicle side connector GND GND Continuity Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perform After inspection work of INFOR MATION section 4 Inspect the NOx sensor 1 harness power supply line VCC GND SAPH16F020400215 Measurement conditions Tester connections Standard values Starter...

Page 882: ...or SCR inlet NO YES 5 Inspect the exhaust gas temperature sensor SCR inlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 6 6 Inspect the exhaust gas temperature sensor SCR inlet Was any failure found Clean the exhaust gas temperature sensor SCR inlet and install it properly If damaged replace the exhaust gas tempe...

Page 883: ...YES 7 Inspect the exhaust gas temperature sensor SCR inlet unit FAT FAT SAPH16F020400216 Measurement conditions Tester connections Standard values Starter switch LOCK Exhaust gas temperature sensor SCR inlet FAT FAT 20 C 68 F 220 Do the measurements meet the standard value Go to step 8 Replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of INFOR MATION section 8 Insp...

Page 884: ... any failure found Clean the engine coolant temperature sensor and install it properly If damaged replace the engine coolant temperature sensor Perform After inspection work of INFOR MATION section Go to step 10 10 Inspect the engine coolant temperature sensor unit WTM WTM SAPH16F020400217 Measurement conditions Tester connections Standard values Starter switch LOCK Engine coolant temperature sens...

Page 885: ...he malfunction history and perform a DPR forced regenera tion 6 Select DCU and check if P2209 has been detected in Fault Infor mation NO YES 11 Inspect the NOx sensor 1 Hino DX Select DCU SAPH16F020400218 Has DTC other than P2209 been detected Replace the DCU Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION section ...

Page 886: ...spect the NOx sensor 1 harness GND line Measure the resistance between the terminals of the NOx sensor 1 vehicle side connector Tester connections NOx sensor 1 vehicle side con nector GND GND Standard values Continuity The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the harness Perform After inspection wo...

Page 887: ...exhaust gas temperature sensor SCR inlet Tester connections Exhaust gas temperature sensor SCR inlet FAT FAT Standard values 20 C 68 F 220 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 8 Replace the exhaust gas temperature sensor SCR inlet unit Perform After inspection work of INFORMA TION section 8 Inspect the engine cool...

Page 888: ...ne coolant temperature sen sor WTM WTM Standard values 20 C 68 F 2 59 2 32 k 80 C 176 F 0 326 0 310 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 11 Replace the engine cool ant tempera ture sensor unit Perform After inspection work of INFORMA TION section 11 Inspect the NOx sensor 1 Hino DX 1 Replace a new NOx sensor 1 2...

Page 889: ... KL CA3L 1D 99 99 A49 1 A48 Z29 G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W KTR KTQ L2P LCH KTU KTS KTD KTT KTR KTQ KTU KTS KTT AFGD AFSG AFT AFVB AFT AGD6 AFSI AGD5 AFVB THA AVC2 AGD2 THW PIM ATI AGD4 K0W L75 L2P LCH KTD K0W L75 CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY LEZ JU JZ CA2L JQ JV CA2L KE CA3L KF CA3H JX CA2L JS CA2H CAL0 CAH0 RE H ...

Page 890: ...vehicle when the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Harness disconnection or shor...

Page 891: ...Ox sensors 1 and 2 in the vehicle in their opposite loca tion 4 Set the starter switch to the ON position 5 Erase the malfunction history using Hino DX 6 Perform a DPR forced regeneration 7 Select DCU and check if P2212 has been detected in Fault Infor mation NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400220 Has a DTC other than P2212 been detected Go to diagnosis procedure o...

Page 892: ...F check if the temperature output by the coolant tem perature sensor is 50 C 122 F 3 Inspect the engine coolant temperature sensor Engine coolant temperature sensor 1 SAPH16F020400222 Was any failure found Clean the engine coolant temperature sensor and install it properly If damaged replace the engine coolant temperature sensor Perform After inspection work of INFOR MATION section Go to step 4 4 ...

Page 893: ...Go to step 5 Replace the engine coolant temperature sen sor Perform After inspection work of INFOR MATION section 5 Inspect the air flow sensor Air flow sensor SAPH16F020400224 Was any failure found If dirt clogging or damage in the sensing unit was found replace the air flow sensor Perform After inspection work of INFOR MATION section Go to step 6 ...

Page 894: ...the boost pressure sensor NO YES 6 Inspect the boost pressure sensor Engine left side view Vehicle front Boost pressure sensor SAPH16F020400225 Was any failure found If dirt clogging or damage in the sensing unit was found replace the boost pressure sensor Perform After inspection work of INFOR MATION section Go to step 7 ...

Page 895: ...utput signal Hino DX Select Engine SAPH16F020400226 Standard values Boost pressure sensor output value There is no abnormal change in the sensor output signal The pressure sensor signal changes according to the engine speed Do the measurements meet the standard value Go to step 8 Replace the boost pressure sensor Perform After inspection work of INFOR MATION section 8 Inspect the intake manifold t...

Page 896: ...ld temperature sensor unit THG E2 SAPH16F020400227 Measurement conditions Tester connections Standard values Starter switch LOCK Intake manifold temperature sensor THG E2 20 C 68 F 7 336 5 794 k 50 C 122 F 2 435 2 41 k Do the measurements meet the standard value Go to step 10 Replace the Intake manifold temperature sensor Perform After inspection work of INFOR MATION section 10 Inspection of the N...

Page 897: ...to step 3 Replace the NOx sensor 2 Perform After inspection work of INFORMA TION section 3 Inspect the engine cool ant tempera ture sensor 1 Check the installation of the engine coolant temperature sensor 2 Make sure there is no dirt or damage to the engine cool ant temperature sensor The output value and the measured value match Go to YES The output value and the measured value do not match Go to...

Page 898: ...ne from idling after the engine is started up from No Load Maximum and check if there is no abnormality in the boost pressure sensor output signal Standard values There is no abnormal change in the sensor output signal The pressure sensor signal changes according to the engine speed There is no abnormal change in the sensor output signal Go to YES There is abnormal change in the sensor output sign...

Page 899: ...0 Replace the intake mani fold tempera ture sensor Perform After inspection work of INFORMA TION section 10 Inspect the NOx sensor 2 Hino DX Replace the NOx sensor 2 with a new one and check again if DTC P2212 is detected in the DCU after the switch is ON DTC P2212 has been detected Go to YES No DTC has beendetected Go to NO Replace the DCU Perform After inspection work of INFORMA TION section NOx...

Page 900: ... internal circuit Low failure flag is received from CAN data ECU DCU AW AV AW AV S5 S7 S5 S7 LCM H L CA1H LCN LF5 LF6 CA1L CAL1 SD SF SD SF CP CP CQ CQ KH KG CA3L CA3H KM CA3H KL CA3L 1D 99 99 A49 1 A48 Z29 G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY LEZ JU JZ CA2L JQ JV CA2L KE CA3L KF CA3H JX CA2L JS...

Page 901: ...the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Failure of NOx sensor 2 SCR downstream Fai...

Page 902: ...U and check if a CAN communication system malfunc tion U029E has been detected in Fault Information NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400230 Has DTC U029E been detected Go to the diagnostic procedure of a related DTC Replace the NOx sensor 2 SCR down stream Perform After inspection work of INFOR MATION section ...

Page 903: ...Judgement Check Yes No Yes No 1 Check the DTC detected DCU Hino DX Check if a CAN communication system malfunction U029E has been detected in DCU DTC U029E has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace NOx sensor 2 SCR downstream Perform After inspection work of INFORMA TION section ...

Page 904: ...ownstream High failure flag is received from CAN data ECU DCU AW AV AW AV S5 S7 S5 S7 LCM H L CA1H LCN LF5 LF6 CA1L CAL1 SD SF SD SF CP CP CQ CQ KH KG CA3L CA3H KM CA3H KL CA3L 1D 99 99 A49 1 A48 Z29 G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2A TE2B LEY LEZ JU JZ CA2L JQ JV CA2L KE CA3L KF CA3H JX CA2L JS CA2H C...

Page 905: ...the DTC is set Symptoms on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Failure of NOx sensor 2 SCR downstream Fai...

Page 906: ...U and check if a CAN communication system malfunc tion U029E has been detected in Fault Information NO YES 1 Check the DTC detected DCU Hino DX Select DCU SAPH16F020400232 Has DTC U029E been detected Go to the diagnostic procedure of a related DTC Replace the NOx sensor 2 SCR down stream Perform After inspection work of INFOR MATION section ...

Page 907: ...Judgement Check Yes No Yes No 1 Check the DTC detected DCU Hino DX Check if a CAN communication system malfunction U029E has been detected in DCU DTC U029E has been detected Go to YES No DTC has beendetected Go to NO Go to the diag nostic proce dure of a related DTC Replace NOx sensor 2 SCR downstream Perform After inspection work of INFORMA TION section ...

Page 908: ...ensor 2 SCR outlet heater has started to operate Common rail_ CAN_J C1 Common rail_ CAN_J C2 Common rail_ CAN_J C3 ECU DCU AW AV AW AV S5 S7 S5 S7 LCM H L CA1H LCN LF5 LF6 CA1L CAL1 SD SF SD SF CP CP CQ CQ KH KG CA3L CA3H KM CA3H KL CA3L 1D 99 99 A49 1 A48 Z29 G4P 1 BATTERY1 BATTERY GND FR W H BATT GND CABLE G4 A K6V H L CANH K6W AGD5 THW CANL H L RF RK CA2H CA2L CAH1 LF2 LF1 TE1A TE1B LF4 LF3 TE2...

Page 909: ...s on the vehicle due to backup control fail safe function Exhaust gas purification function is declined Symptoms on the vehicle due to malfunction 6 Pre inspection work Check if the battery voltage is in the normal range 7 After inspection work Clear all past DTCs Check if no DTC is stored after test drive 8 Estimated failure factors Harness disconnection or short circuit NOx sensor 2 SCR downstre...

Page 910: ...side connector NO YES 1 Inspect the NOx sensor 2 SCR downstream connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 2 2 Inspect the NOx sensor 2 harness CAN communication line CANL CANH SAPH16F020400234 Measurement conditions Tester connections Standard values Starter switch ON NOx sensor 2 vehicle side connector CANH C...

Page 911: ...16F020400235 Measurement conditions Tester connections Standard values Starter switch LOCK NOx sensor 2 vehicle side connector GND Ground 1 or less Do the measurements meet the standard value Go to step 4 Repair or replace the harness Perform After inspection work of INFOR MATION section 4 Inspect the NOx sensor 2 harness Power supply line VCC GND SAPH16F020400236 Measurement conditions Tester con...

Page 912: ...nsor SCR inlet NO YES 5 Inspect exhaust gas temperature sensor SCR inlet connector Was any failure found Connect securely repair if needed Perform After inspection work of INFOR MATION section Go to step 6 6 Inspect the exhaust gas temperature sensor SCR inlet Was any failure found Clean the exhaust gas temperature sensor SCR inlet and install it properly If damaged replace the exhaust gas tempera...

Page 913: ...seness and poor contact 7 Inspect the exhaust gas temperature sensor SCR inlet unit FAT FAT SAPH16F020400237 Measurement conditions Tester connections Standard values Starter switch LOCK Exhaust gas temperature sensor SCR upstream FAT FAT 20 C 68 F 220 Do the measurements meet the standard value Go to step 8 Replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of INFO...

Page 914: ... 9 9 Inspect the engine coolant temperature sensor Was any failure found Clean the engine coolant temperature sensor and install it properly If damaged replace the engine coolant temperature sensor Perform After inspection work of INFOR MATION section Go to step 10 10 Inspect the engine coolant temperature sensor unit WTM WTM SAPH16F020400239 Measurement conditions Tester connections Standard valu...

Page 915: ...history and perform a DPR forced regenera tion 6 Select DCU and check if P2222 has been detected in Fault Infor mation NO YES 11 Check the NOx sensor 2 Hino DX Select DCU SAPH16F020400240 Has DTC P2222 been detected Replace the DCU After replacing operate DPR forced regeneration Perform After inspection work of INFOR MATION section Procedure completed Perform After inspection work of INFOR MATION ...

Page 916: ...ct the NOx sensor 2 harness GND line Measure the resistance between the GND terminal in the NOx sen sor 2 vehicle side connector and the ground Tester connections NOx sensor 2 vehicle side con nector GND Ground Standard values 1 or less The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 4 Repair or replace the harness Perform A...

Page 917: ...exhaust gas temperature sensor SCR inlet Tester connections Exhaust gas temperature sensor SCR inlet FAT FAT Standard values 20 C 68 F 220 The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 8 Replace the exhaust gas temperature sensor SCR inlet Perform After inspection work of INFORMA TION section 8 Inspect the engine cool ant ...

Page 918: ...M Standard values 20 C 68 F 2 59 2 32 k 80 C 176 F 0 326 0 310 k The measure ments meet the standard value Go to YES The measure ments do not meet the stan dard value Go to NO Go to step 11 Replace the engine cool ant tempera ture sensor Perform After inspection work of INFORMA TION section 11 Check the NOx sensor 2 Hino DX 1 Replace the NOx sensor 2 with a new and erase the malfunction history in...

Page 919: ...Hino Motors Sales U S A Inc PRINTED IN JAPAN 41180 Bridge Street Novi MI 48375 Telephone 248 699 9300 S7 UNAE10A 2 4 S7 UNAE10B 2 4 S7 UNAE10C 2 4 Pub No 12 12 13 3 13 4 ...

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Hino 238, Workshop Manual

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