S7-Unae13a 3

S7-UNAE13A_3 print.
book 1 ページ２０１５年１１月６日　金曜日　午後７時４３分
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 238, 258LP, 268, 338, 358 series, equipped with J08E-VB and J08E-WU engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Driver’s / Owner's Manual.
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.
Please note that the publications below have also been prepared as relevant workshop manuals for the components and
systems in these vehicles.
Manual Name Pub. No.

S1-UNAE13A 1/2
Chassis Workshop Manual
S1-UNAE13A 2/2
J08E-VB, WU Engine Workshop Manual S5-UJ08E13A
S7-UNAE13A 1/3
Trouble Shooting Workshop Manual
S7-UNAE13A 2/3
S7-UNAE13A_3 print.book 2 ページ２０１５年１１月６日　金曜日　午後７時４３分
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL No. S7-UNAE13A 3/3 (U.S.A.), S7-CNAE13A 3/3 (CANADA)
CHAPTER MODELS HINO 238, 258LP, 268, 338, 358
Production Code NE8J, NF8J, NJ8J, NV8J, NH8J
GENERAL INTRODUCTION 1-001

TROUBLE SHOOTING - COMPONENTS 2-001
TROUBLE SHOOTING -
3-001
ELECTRICAL CONTROL SYSTEM
ENGINE CONTROL SYSTEM (J08E) 4-001
DEF SCR SYSTEM (DCU) 5-001
9-001 9-002
BRAKE CONTROL SYSTEM
(ABS:HYDRAULIC (E VERSION)) (ABS:FULL AIR)
VEHICLE CONTROL SYSTEM (VCS) 11-001
CAN COMMUNICATION 12-001
This manual does not contain items on half-tone dot meshing.

INDEX: TROUBLE SHOOTING
GENERAL INTRODUCTION
TROUBLE SHOOTING - COMPONENTS

TROUBLE SHOOTING -
ELECTRICAL CONTROL SYSTEM
WORKSHOP ENGINE CONTROL SYSTEM (J08E)
MANUAL DEF SCR SYSTEM (DCU)
VEHICLE CONTROL SYSTEM (VCS)
CAN COMMUNICATION
Y186_17MY_DIA5.fm 1 ページ２０１５年１１月９日　月曜日　午後６時２７分
DEF SCR SYSTEM (DCU) 5–1
DEF SCR SYSTEM (DCU)

5
5-001
DEF SCR SYSTEM ......................................................5-2 DTC: P208C........................................................5-158

PRECAUTIONS FOR DIAGNOSIS .........................5-2 DTC: P208D........................................................5-162
SYSTEM BLOCK DIAGRAM...................................5-4 DTC: P20A0 ........................................................5-166
SYSTEM DIAGRAM................................................5-5 DTC: P20A1 ........................................................5-172
SENSOR LOCATION ..............................................5-6 DTC: P20A2 ........................................................5-176
COMPUTER (DCU) WIRE HARNESS DTC: P20A3 ........................................................5-182
CONNECTOR PIN ASSIGNMENT .........................5-9 DTC: P20B1 ........................................................5-188
SIGNAL CHECK HARNESS .................................5-10 DTC: P20B2 ........................................................5-193
INSPECTION ........................................................5-10 DTC: P20B3 ........................................................5-201
MALFUNCTION INDICATOR LIGHT DTC: P20B4 ........................................................5-206
ILLUMINATION PATTERN ....................................5-11 DTC: P20BD, P20B9 and P20C1 ........................5-211
DIAGNOSIS USING THE PC DIAGNOSIS DTC: P20C0, P20BC and P20C4 .......................5-219
TOOL.....................................................................5-12 DTC: P20FC........................................................5-225
DIAGNOSTIC TROUBLE CODE (DTC) DTC: P20FD........................................................5-230
TABLE ...................................................................5-13 DTC: P20FE........................................................5-234
DTC: P0071 ..........................................................5-18 DTC: P20E8 ........................................................5-238
DTC: P0072 ..........................................................5-29 DTC: P20E9 ........................................................5-249
DTC: P0073 ..........................................................5-37 DTC: P20F4 ........................................................5-254
DTC: P0562 ..........................................................5-45 DTC: P2201 ........................................................5-258
DTC: P0563 ..........................................................5-48 DTC: P2202 ........................................................5-262
DTC: P060C..........................................................5-51 DTC: P2203 ........................................................5-265
DTC: P062F ..........................................................5-53 DTC: P2204 ........................................................5-268
DTC: P0667 ..........................................................5-55 DTC: P2209 ........................................................5-275
DTC: P0668 ..........................................................5-57 DTC: P2212 ........................................................5-282
DTC: P0669 ..........................................................5-59 DTC: P2214 ........................................................5-290
DTC: P068A ..........................................................5-61 DTC: P2215 ........................................................5-294
DTC: P142A ..........................................................5-66 DTC: P2216 ........................................................5-297
DTC: P142B ..........................................................5-75 DTC: P2222 ........................................................5-300
DTC: P202E ..........................................................5-85 DTC: P2481 ........................................................5-308
DTC: P203C..........................................................5-89 DTC: P2482 ........................................................5-313
DTC: P203D..........................................................5-92 DTC: P2483 ........................................................5-319
DTC: P2044 ..........................................................5-95 DTC: P2510 ........................................................5-332
DTC: P2045 ..........................................................5-98 DTC: P2BAE .......................................................5-337
DTC: P2047 ........................................................5-101 DTC: U0029 ........................................................5-340
DTC: P2048 ........................................................5-104 DTC: U0038 ........................................................5-343
DTC: P2049 ........................................................5-109 DTC: U0100 ........................................................5-346
DTC: P204B ........................................................5-115 DTC: U029D........................................................5-350
DTC: P204C........................................................5-118 DTC: U029E........................................................5-353
DTC: P204D........................................................5-124 DTC: U02A2........................................................5-356
DTC: P205B ........................................................5-130 DTC: U0597 ........................................................5-359
DTC: P205C........................................................5-139
DTC: P205D........................................................5-142
DTC: P206C........................................................5-145
DTC: P206D........................................................5-148
DTC: P208A ........................................................5-151
DTC: P208B ........................................................5-155
5–2 DEF SCR SYSTEM (DCU)
Symptom Related Diagnostic Procedures
DEF SCR SYSTEM
PRECAUTIONS FOR DIAGNOSIS

EN01H16F02040F03001001
• Ensure that individual connectors are certainly connected before

start of checking works.
• Make sure to set the starter switch to the "LOCK" position before dis-
connecting 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 anal-
ysis.
1. ILLUSTRATION OF CONNECTOR AND MEASUREMENT ON

TERMINAL
LOCK
ILLUSTRATION OF CONNECTOR
The illustration of a connector contained in this document
represents an image of a connector with its lock positioned
on top as viewed from the connecting face.
TO BE CONNECTED
MALE FEMALE
CONNECTOR CONNECTOR
NUMBERING OF CONNECTOR TERMINALS

3 2 1 1 2 3 The terminals are symmetrically numbered (symmetrically
6 5 4 4 5 6 reversed numbering) as viewed on the connecting faces of a
pair of connectors.
The terminal #1 is located at the top right corner of a male
connector and at the top left corner of a female connector
MALE FEMALE respectively in this document.
CONNECTOR CONNECTOR
PRECAUTIONS FOR TERMINAL MEASUREMENT

INCORRECT Unless otherwise specified in this document, the illustration
of a connector represents an image of a connector as viewed
from the connecting face. A test probe must access the back
CORRECT 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.
CORRECT
As to a connector that is designed to use the signal check
harness for terminal measurement, do not place a test probe
INCORRECT directly onto the front or back face. Use a contact box of the
connected signal check harness to take measurement on
terminals.
WATERPROOF CONNECTOR
ILLUSTRATION OF CONNECTOR AND

MEASUREMENT SURFACE
A The illustration of a connector contained in this document
1 2
4 3 represents an image of a connector as viewed from the
5 6 connecting face. For example, the terminal #1 of a female
VIEW A connector is located at the top left corner of a connector as
viewed from the connecting face.
3 2
6 1 In actual measurement on the terminal #1 of a female
5 4 connector, a test probe must be placed onto the top right
corner on the back face of a connector.
VIEW B
B
SAPH16F020400001
SYSTEM BLOCK DIAGRAM

EN01H16F02040F03001002
Power source FUSE FUSE DEF heater relay
- +
Battery
CAN communication(Diagnosis, Engine ECU)
Vehicle ECU
O
Starter switch signal T
H
E
R
S CAN communication(Engine ECU, NOx sensor, DEF quality sensor)
Engine ECU
Coolant cut off valve drive signal
I Coolant cut off valve

N
P DEF injector drive signal
Ambient air temperature sensor U
T
T DEF pump motor drive power
O DEF pump motor drive signal

U
T Reverting valve drive signal
DCU P
temperature DEF heater relay drive signal
sensor 1 U
(DCU built-in) T DEF heater 3 drive signal
Exhaust gas temperature sensor (SCR Inlet) DCU
DEF heater 2 drive signal
temperature
DEF pump temperature sensor 1 sensor 2 DEF heater 1 drive signal
(DCU built-in)
DEF pump temperature sensor 2
DEF line pressure sensor

DEF heater power supply
T
DEF pump
T
DEF line with heater 1

DEF tank level sensor
T DEF tank temperature sensor 1
T DEF tank temperature sensor 2

Q DEF quality sensor
DEF tank sensor DEF injector
T
SCR
Muffler
NOx sensor (SCR downstream) N N NOx sensor (SCR upstream)
SAPH16F020400002
SYSTEM DIAGRAM
EN01H16F02040F03001003
(FAT+)
LE4 0.75 R- LFG
(EXT+) (ATSS) LNM
0.50 R- Y LGJ (HH1+) Ambient air
LE5 0.75 G- LFH temperature
(FAT-) (EXT-) DCU (ATS-) LNN LGK (HH1-)
0.50 B- Y 0.50 W- G sensor
LES (IGSW)
0.50 GR-
LQV
LQU
Exhaust gas
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
temperature
%NL
(ER-)
(ER+)
sensor FUSE NOx2 A99 0.85 Y- #PH #PH 0.85 Y-
(3GLD)
(SCR inlet) FUSE NOx1 A8V 0.85 R- L #PG #PG
%NL
0.85 R- L
External
0.50 GR-
(6BLD)
0.50 W-
0.50 GR-
0.50 B-
resistance
#AQ
#AR
0.50 W-
0.50 G-
0.50 R-
#GV #GV
#AQ
#AR
(CANL)
NOx
(CANH) %JU
%JZ
sensor 1
%JR 0.75 V- LE9 LE6 0.75 B- W
H (VCC)
0.50 L-W (CANH) (CANH) LGU 0.75 W- B
(GND)
0.75 B- R
%JW 0.75 W- LE8 L LE7 0.75 W- B
#GX
(GND)
(CANL) (CANL)
Fuel H L
Boost pressure temperature
sensor %JS 0.75 V- LED H LEA
sensor Common rail_ (CANH) (CANH) (VCC)
#GX
0.50 B- %JQ (CANH)

(THF+)
(THF-)
CAN_J/C3 %JX 0.75 W- LEC L LEB

(GND)
K2A (VCC)
0.50 L-W
(SIG)
(CANL) (CANL) (GND)

%NM
%NN
Engine NOx
(CANL)
%JV
K8Q
coolant
sensor 2
K2C
K2B
temperature
%NM
%NN
A7R sensor 1 0.50 W-

(49LD)
0.50L-B
0.50 GR-
FUSE
0.50 R- B
(CANH)
(CANL)
DCU(M)
0.75 W- B
%KF
%KE
Air flow sensor Common rail_

H L %KP (CANH)
CAN_J/C1
0.50 B-
(CANH) %KR H L %KN 0.50 W-
(WTM-) E24
(WTM+) E23
(AFT+) KTT
(AFT-) KTU
(AFVB) KTS
(AFGD) KTR
(AFSG) KTQ
Intake
manifold %KQ ( CANL ) (CANL)
0.50 B-
%NQ
%NP
0.50 W-
temperature
sensor
(CANH)
(CANL)
%KM
%KL
0.50 P- #AW #AW 0.50 G-
0.50 R-
(THG)
%NP
0.50 B-
0.50 W- %NQ
(E2)
0.50 W-
0.50 R- L
0.50 L- B
0.50 Y- R
0.50 G- Y
0.50 L- Y
0.50 Y- B
0.50 L- Y
0.50 L-
0.50 Y-
0.50 B-
#CP #CP
K6W #SF #SF 0.50 W- #CQ #CQ
#AV #AV
LB7
LB8
LEL
LEK H(VCC)
(CANH)
(CANL)
(CANH) LEM
LEJ L(GND)
0.50 L- W
E23 K0U
0.50 L- B
L0N
L0K
KTT K0W
0.50 L- Y KTU KTD
LCH 0.50 Y- R KTQ LCH

LUG 0.50 L- B KTR L2P
0.50 R- L KTS L75
(CANL)
DEF
#SD #SD 0.50 R-
0.50 V-
sensor 1.25 W-B

%NH
1.25 W-B
PM
0.50 G- Y
(CA1H) LCM #S5 #S5
(CA1L) LCN #S7 #S7

K0W 0.50 Y- B
sensor
%NH
#AU #AU
H L H L
(ATI+) KQY
LUH
K6G
LSR
(THW+) K0U
LUF
K6V
LUJ
L75
(THA+)
(AG5)
(AFVB)
(AG4)
(AFSI)
(AG3)
(PIM)
(AV3)
(AG6)
(CANH)
(CANL)
2.00 BR-
&1D 5.00 B-
(G4-A)
(ADG3)
(ET3+)
ECU Z30
(G4C)
KRB
LCF
0.50 LG-B KSE LCF 0.50 LG-B KSE LCF 0.50 LG- Battery
0.50 R- ground
0.50 R- KSL KRB 0.50 R- KSL KRB 0.50 R-
Exhaust gas
KSL
KSF
KSE
temperature
Differential
(TEX1)
(GND)
(VCC)
(VOUT)
(GND1)
sensor 3
pressure sensor (DOC outlet)
SAPH16F020400003
SENSOR LOCATION
EN01H16F02040F03001004
DEF tank SCR catalyst front exhaust gas

DEF tank temperature sensor
DEF level sensor
DCU (Dosing NOx sensor 2
control unit)
DEF heater Exhaust gas
temperature
DEF pump sensor 4
(DPR outlet)
DEF injector
NOx sensor 1
Bumper Ambient air temperature

sensor
Exhaust gas Exhaust gas
temperature sensor 2 temperature sensor 3
(DOC inlet) (DOC outlet)
SAPH16F020400004
SCR catalyst PM sensor

front exhaust gas controller
temperature sensor Wire harness NOx sensor NOx sensor
DEF tank
controller 2 controller 1
Differential
DCU (Dosing pressure sensor
control unit)
NOx sensor 2
DEF heater 2
Exhaust gas
DEF supply temperature sensor 4
pump (DPR outlet)
DEF heater 3
Dosing module
DEF heater 1 (DEF injector)
Coolant cut off NOx sensor 1

valve
Wire harness Exhaust gas Exhaust gas

temperature sensor 2 temperature sensor 3
(DOC inlet) (DOC outlet)
SAPH16F020400005
Exhaust gas temperature sensor 1

(ATC upstream)
Coolant Injector Coolant
PM sensor
NOx sensor 1 Exhaust gas NOx sensor 2

temperature sensor 4
(DPR outlet)
SAPH16F020400006
COMPUTER (DCU) WIRE HARNESS CONNECTOR PIN ASSIGNMENT

EN01H16F02040F03001005
HH1-
LFX
HH2
LFZ
+B2 GND4 GND1

LEP LEW LET HH3- WMV-
LG2 LFA
+B3 GND5 GND2

LEQ LEX LEU
+B4 +B1 GND3

LER LEN LEV
DMH DML
LF8 LF9
EXT+
LFG
CAH1
LF5 EXT-
LFH
CAL1
LF6
TE1B
LF2
TE1A CAH0
LF1 LEY PSRS
LFR
TE2B CAL0
LF4 LEZ ATS- PSR-
LNN LFP
TE2A
LF3 ATSS PSR+
LNM LFQ
IGSW HHR- HHR+

LES LV2 LV1
PMPS
LFL
WMV- PMV-
LFB LFN
PMV+ PMP+ PMP-

LFM LFJ LFK
53P connecter 86P connecter

SAPH16F020400007
SIGNAL CHECK HARNESS

EN01H16F02040F03001006
1. MENTION OF THE SIGNAL CHECK HARNESS

(1) HINO provides a signal check harness to check the DCU.
! CAUTION
To prevent damage of the DCU connector, connect the signal
check harness and perform measuring by bringing the test probe
into contact with the signal check harness side.
09843-E9030
SAPH16F020400008
INSPECTION
EN01H16F02040F03001007
MALFUNCTION INDICATOR LIGHT STATUS
1. INSPECTION PROCEDURE
(1) Set the starter switch to the "ON" position (Do not start the
engine) and confirm that the MIL (malfunction indicator light)
in the indicator area light up.
HINT
• If the MIL (Malfunction Indicator Light) is lit, perform a system
check to see if the malfunction is of the past or present.
• In the case of the past malfunction, this light will turn off if a sta-
tus is judged to be normal in 3 times of driving.
• DTC must be cleared on the HINO DX Ⅱ , after MIL comes off.
(Definition of 1 time of driving)
SAPH16F020400009 a. Begins with engine start and ends with engine shut off.
b. Begins with engine start and ends after four hours of con-
tinuous engine-on operation.
c. Begins at end of the previous four hours of continuous
engine on operation and ends after four hours of continu-
ous engine-on operation.
d. Begins at the end of the previous four hours of continuous
engine-on operation and ends with engine shut off.
• Since the normal judgment method and time differ according to the
malfunction code, a proper definition will be selected from the above
4 definitions.
• If the MIL (malfunction indicator light) does not go out, the system is
abnormal. Check the system according to diagnosis on the following
page.
MALFUNCTION INDICATOR LIGHT ILLUMI-

NATION PATTERN
EN01H16F02040F03001008
START
STARTER ON
SWITCH
LOCK
RUNNING
ENGINE
STOP
MALFUNCTION ON
INDICATOR
LIGHT OFF
TIME
SAPH16F020400010
DIAGNOSIS USING THE PC DIAGNOSIS

TOOL
EN01H16F02040F03001009
1. DIAGNOSIS TOOL
(1) Trouble diagnosis can be performed using the PC diagnosis
tool. By connection to the trouble diagnosis connector, the
trouble location is indicated.
PC:
Laptop computer
Complete function of HINO DX Ⅱ is conformed on "Pana-
sonic CF-D1".
SST:
Computer interface
(DENSO DST-i set without LCD)
SAPH16F020400011
Without Bluetooth (95171-01021)
With Bluetooth (95171-01041)
(DENSO DST-i set with LCD)
Diagnosis software: Hino Diagnostic explorer Ⅱ (HINO DX
Ⅱ)
NOTICE
Only ECU reprogramming can be performed by authorized HINO
dealer.
2. CONNECT THE PC DIAGNOSIS TOOL

(1) Set the starter switch to the “LOCK” position.
(2) Connect the PC diagnosis tool to the trouble diagnosis con-
nector on the left side of steering column.
Trouble diagnosis
connector
SAPH16F020400012
DIAGNOSTIC TROUBLE CODE (DTC) TABLE

EN01H16F02040F03001010
SCR DTC NO.

MALFUNC-
MAL- REFER
TION INDI-
FUNC- DIAGNOSIS ITEM INSPECTION ITEM PAGE
CATOR ECU DCU
TION
LIGHT
LIGHT
• Ambient air tempera-

Ambient air temperature sensor - ratio- ture sensor
Light P204F P0071 5-18
nality • Wire harness
• DCU connector
Ambient air temperature sensor - out ture sensor
Light P204F P0072 5-29
of range (Out of range low) • Wire harness
• DCU connector
Ambient air temperature sensor - out ture sensor
Light Blinking P204F P0073 5-37
of range (Out of range high) • Wire harness
• DCU connector
• Battery
Sensor supply voltage - out of range
Light P204F P0562 • DCU connector 5-45
(Out of range low)
• Wire harness
• Battery
Sensor supply voltage - out of range
(Out of range high)
• Wire harness
Light P204F P060C DCU abnormality • DCU 5-51
Internal Control Module EEPROM

Light P204F P062F • DCU 5-53
Error
DeNOx ECU temperature sensor 1, 2 -

Light P204F P0667 • DCU 5-55
rationality
DeNOx ECU temperature sensor (Out

Light P204F P0668 • DCU 5-57
of range low)
DeNOx ECU temperature sensors -

Light P204F P0669 • DCU 5-59
out of range (Out of range high)
Light P204F P068A Malfunction of main relay • DCU 5-61
• DEF pump
DEF pump temperature sensor (Out of
Light P204F P142A • DCU 5-66
range)
• Wire harness
DEF pump temperature sensor - ratio-
Light P204F P142B • DEF pump 5-75
nality
• DEF injector
Light Blinking P204F P202E Reductant Delivery Performance 5-85
• DEF piping
SCR DTC NO.

MALFUNC-
MAL- REFER
TION INDI-
CATOR ECU DCU
TION
LIGHT
LIGHT
• DEF tank level sensor

DEF tank level sensor - out of range
Light P204F P203C • DCU connector 5-89
(Out of range low)
• Wire harness
• DEF tank level sensor
DEF tank level sensor - out of range
Light P204F P203D • DCU connector 5-92
(Out of range high)
• Wire harness
• DEF tank temperature
No light P204F P2044 DEF tank temp. sensor failure (Low) 5-95
sensor 2

No light P204F P2045 DEF tank temp. sensor failure (High) 5-98
sensor 2
Light P204F P2047 DEF injector - functional • DEF injector 5-101
• DEF injector
DEF injector - disconnection (Discon-
nection (low side))
• Wire harness
• DEF injector
DEF injector - disconnection (Discon-
Light Blinking P204F P2049 • DCU connector 5-109
nection (high side))
• Wire harness
Light P204F P204B DEF pressure sensor - rationality • DCU pump 5-115
• DEF pump
DEF pressure sensor - out of range
Light P204F P204C • DCU 5-118
(Out of range low)
• Wire harness
• DEF pump
DEF pressure sensor - out of range
Light Blinking P204F P204D • DCU 5-124
(Out of range high)
• Wire harness
DEF tank temperature sensor - ratio- sensor
Light P204F P205B 5-130
nality • DCU connector
• Wire harness
DEF tank temperature sensor - out of sensor
Light P204F P205C 5-139
range (Out of range low) • DCU connector
• Wire harness
DEF tank temperature sensor - out of sensor
Light P204F P205D 5-142
range (Out of range high) • DCU connector
• Wire harness
• DEF sensor (DEF tank
Light P204F P206C DEF quality sensor - short circuit 5-145
level sensor)
SCR DTC NO.

MALFUNC-
MAL- REFER
TION INDI-
CATOR ECU DCU
TION
LIGHT
LIGHT
• DEF sensor (DEF tank

Light P204F P206D DEF quality sensor - open circuit 5-148
level sensor)
• DEF pump
Light Blinking P204F P208A DEF pump motor - circuit (Open load) • DCU 5-151
• Wire harness
Light P204F P208B DEF pump motor - functional • DEF pump 5-155
• DEF pump
Light P204F P208C DEF pump motor - circuit (Circuit low) • DCU 5-158
• Wire harness
• DEF pump
Light P204F P208D DEF pump motor - circuit (Circuit high) • DCU connector 5-162
• Wire harness
• DEF pump
Reverting valve for DEF pump - circuit
Light Blinking P204F P20A0 • DCU connector 5-166
(Open load)
• Wire harness
Reverting valve for DEF pump stuck
Light P204F P20A1 • DEF pump 5-172
close
• DEF pump
Light P204F P20A2 • DCU connector 5-176
(Circuit low)
• Wire harness
• DEF pump
Light P204F P20A3 • DCU connector 5-182
(Circuit high)
• Wire harness
• Coolant shutoff valve
DEF tank heater valve - circuit (Open
Light Blinking P204F P20B1 • Wire harness 5-188
load)
• DCU connector
Light P204F P20B2 DEF tank heater valve stuck 5-193
• DCU connector
DEF tank heater valve - circuit (Circuit
Light P204F P20B3 • Wire harness 5-201
low)
• DCU connector
DEF tank heater valve - circuit (Circuit
Light P204F P20B4 • Wire harness 5-206
high)
• DCU connector
• DEF heater
Light Blinking P204F P20BD DEF heater 1 failure (Open load / low) • DEF heater pipe 5-211
• Wire harness
SCR DTC NO.

MALFUNC-
MAL- REFER
TION INDI-
CATOR ECU DCU
TION
LIGHT
LIGHT
• DEF heater
Light Blinking P204F P20B9 DEF heater 2 failure (Open load / low) • DEF heater pipe 5-211
• Wire harness
• DEF heater
Light Blinking P204F P20C1 DEF heater 3 failure (Open load / low) • DEF heater pipe 5-211
• Wire harness
• DEF heater
Light Blinking P204F P20C0 DEF heater 1 failure (High) • DEF heater pipe 5-219
• Wire harness
• DEF heater
Light Blinking P204F P20BC DEF heater 2 failure (High) • DEF heater pipe 5-219
• Wire harness
• DEF heater
Light Blinking P204F P20C4 DEF heater 3 failure (High) • DEF heater pipe 5-219
• Wire harness
• DEF heater relay
Light Blinking P204F P20FC DEF heater relay failure (Open load) 5-225
• Wire harness
Light Blinking P204F P20FD DEF heater relay failure (Low) 5-230
• Wire harness
Light Blinking P204F P20FE DEF heater relay failure (High) 5-234
• Wire harness
• DEF piping (pressure
backflow)
Light Blinking P204F P20E8 Suction line pressure build up check 5-238
• DEF pump
• Suction line
• DEF piping (pressure
Back flow line and pressure line Pres- backflow)
Light Blinking P204F P20E9 5-249
sure check
• DEF pump
• DEF injector (Clog-
Light Blinking P204F P20F4 DEF injector abnormal ging) 5-254
• DEF pipe (Clogging)
• NOx sensor 1
NOx sensor (SCR upstream) and
Light P204F P2202 • DCU 5-262
Heater - Circuit
• Wire harness
Light P204F P2203 SCR inlet NOx sensor failure (High) • NOx sensor 1 5-265
• NOx sensor 1
Light P204F P2204 SCR inlet NOx sensor abnormal 5-268
• Wire harness
NOx sensor (SCR upstream) Heater
Light P204F P2209 • NOx sensor 1 5-275
Sense Circuit Range/Performance
SCR DTC NO.

MALFUNC-
MAL- REFER
TION INDI-
CATOR ECU DCU
TION
LIGHT
LIGHT
• NOx sensor 2
Light P204F P2212 SCR outlet NOx sensor abnormal 5-282
• Wire harness
• NOx sensor 2
NOx sensor (SCR downstream) and
Light P204F P2215 • DCU 5-294
Heater-Circuit
• Wire harness
Light P204F P2216 SCR outlet NOx sensor failure (High) • NOx sensor 2 5-297
NOx sensor (SCR downstream)

Light P204F P2222 Heater Sense Circuit Range/Perfor- • NOx sensor 2 5-300
mance
• Exhaust gas tempera-

Exhaust gas temperature sensor (SCR ture sensor
Light P204F P2481 5-308
inlet) - out of range (Out of range low) • Wire harness
• DCU connector
Light Blinking P204F P2482 5-313
inlet) - out of range (Out of range high) • Wire harness
• DCU connector
Light P204F P2483 5-319
inlet) - rationality • Wire harness
• DCU connector
DeNOx Power Relay Sense Circuit
Light P204F P2510 • DCU 5-332
Range/Performance
• DEF
Light P204F P2BAE Feedback control 5-337
• NOx sensor
Vehicle Communication Bus A Perfor- • DCU connector

No light P204F U0029 5-340
mance • Wire harness
Vehicle Communication Bus B Perfor- • DCU connector

No light P204F U0038 5-343
mance • Wire harness
DeNOx ECU CAN communication • DCU connector

No light P204F U0100 5-346
(ECM) • Wire harness
DeNOx ECU CAN communication • NOx sensor

Light Blinking P204F U029D 5-350
(NOx sensor (SCR upstream)) • Wire harness
DeNOx ECU CAN communication • NOx sensor

Light Blinking P204F U029E 5-353
(NOx sensor (SCR downstream)) • Wire harness
Communication disrupt (DEF tank • DEF sensor

Light Blinking P204F U02A2 5-356
sensor) • Wire harness
Invalid Data Received From AC to DC
Light P204F U0597 • DCU 5-359
Converter (DeNOx ECU)
DTC: P0071
EN01H16F02040F03001011
DTC: P0071 Ambient air temperature sensor - rationality

INFORMATION
Engine coolant
K0U E23 K0U (WTM+) E23
(THW+)
LUH KTU KTD (WTM-) E24
(AG5)
DCU
Exhaust gas
LF5 (CAH1) temperature
(CA1H) LCM #S5 #S5 #AW #AW %NM %NM
H H sensor
LF6 (CAL1) (SCR inlet)
(CA1L) LCN #S7 #S7 #AV #AV %NM %NM
L L
Twist
Twist
Twist
Twist
(EXT+) LFG LE4 (FAT+)
Engine
(EXT-) LFH LE5 (FAT-)
ECU
LEY
(CAH0)
(CANH) K6V #SD #SD #CP #CP LEZ
(CAL0)
(CANL) K6W #SF #SF #CQ #CQ Twist (ATSS+) LNM LGJ (HH1+)
(ATS-) LNN LGK (HH1-)

Twist
Twist
Ambient air
temperature
LQU
LQV
sensor
(ER-)
(ER+)
Common rail_
Common rail_ CAN_J/C3
CAN_J/C1
%KM %KF %JQ (CANH) H (CANH) %JU
External
(CANH) H (CANH)
%KL %KE %JV L %JZ resistance
(CANL) L (CANL) (CANL) (CANL)
Twist
Twist
Twist
(CANH)
(CANH)
(CANL)
(CANL)
%JS
%JX
(CANH)
(CANL)
%JR
%KP
%JW
%KN
Twist Twist Twist
Twist
(CANH)
(CANL)
(CANH)
(CANH)
(CANL)
(CANL)
LEJ
LEK
LEC
LED
LE9
LE8
L H H H
L L
DEF sensor NOx NOx

(DEF tank temperature sensor) sensor 2 sensor 1
SAPH16F020400013
1. Technical description
• Ambient air temperature sensor rationality is checked by comparison with Engine coolant temperature.
<Description of malfunction>
• Malfunction of ambient air temperature sensor is detected.
2. DTC set condition

(1) DTC detection condition
Starter switch ON.
Difference between DEF pump temperature and exhaust gas temperature (SCR inlet): < 8 C {46.4 F} and dif-
ference of DEF pump temperature between engine coolant temperature (from Engine ECU): < 8 C {46.4 F}
and difference between exhaust gas temperature (SCR inlet) and engine coolant temperature (from Engine
ECU): < 8 C {46.4 F}.
(2) Judgement criteria
Difference between ambient air temperature and engine coolant temperature (from Engine ECU): > 25 C {77
F} for 10 sec.
3. Reset condition
• When the starter switch is ON, and when the temperature difference between the DEF pump, the exhaust gas tem-
perature and the engine coolant temperature is within 8 C {46.4 F}, the difference with the engine coolant temper-
ature should be less than 25 C {77 F}.
4. Indication, warning or system control regulation 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. Estimated failure factors

• Irregular contact (disconnection or poor fit of connector)
• Malfunction of ambient air temperature sensor
• Malfunction of engine coolant temperature sensor
• Malfunction of exhaust gas temperature sensor (SCR inlet)
• Malfunction of DEF pump temperature sensor
INSPECTION PROCEDURE: P0071
1 Inspect the ambient air temperature sensor connector
1. Check the connection of the ambient air temperature sensor con-

nector (Looseness and poor contact).
Ambient air
temperature
sensor
Bumper
SAPH16F020400014
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 2

Perform "After-inspection work" of INFOR-
MATION section.
2 Inspect the connector of the external resistor
1. Check the connection of the external resistor connector (Loose-

ness and poor contact).
YES NO
Connect securely, repair if needed. Go to step 3.

MATION section.
3 Inspect the DCU 86P connector
1. Check the connection of the DCU 86P connector (Looseness and

poor contact).
YES NO

MATION section.
4 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 tempera-

ture sensor.
YES NO
Clean the ambient air temperature sensor Go to step 5.

and install it properly. If damaged, replace
the ambient air temperature.
MATION section.
5 Inspect the ambient air temperature sensor unit
1. Set the starter switch to the "LOCK" position.
HH1+ HH1-
2. Disconnect the ambient air temperature sensor connector.
3. Use the electrical tester to measure the resistance between the

terminals of the ambient air temperature sensor.
Measurement Tester
Standard values
conditions connections
Ambient air tem-

Starter switch: 25 C {77 C}:
perature sensor
LOCK 1.7 k
SAPH16F020400015 HH1+ – HH1-
Do the measurements meet the standard value?
YES NO
Go to step 6. Replace the ambient air temperature sensor.

MATION section.
6 Inspect the external resistor unit
1. Disconnect the external resistor connector.

ER- ER+
terminals of the external resistor.
Measurement Tester
Standard values
Starter switch: External resistor

2 k
LOCK ER+ – ER-
SAPH16F020400016
YES NO
Go to step 7. Replace the external resistor.

MATION section.
7 Inspect the sensor power supply
1. Connect the external resistor connector.
HH1+ HH1-
2. Set the starter switch to the "ON" position.
HH1+ HH1-
LJK LGK
3. Use the electrical tester to measure the voltage between the termi-
nals of the ambient air temperature sensor vehicle-side connector.
Measurement Tester
Standard values
Ambient air tem-

perature sensor
SAPH16F020400017 Starter switch: ON vehicle-side con- 4.5 – 5.5 V
nector
HH1+ – HH1-
YES NO
Go to step 10. Go to step 8.

8 Inspect for short-circuit in the ambient air temperature sensor harness
2. Disconnect the DCU 86P connector.
3. Connect the signal check harness and use the electrical tester to
measure the resistance between the terminals of the DCU 86P
vehicle-side connector and the ground.
ATS- ATSS
SAPH16F020400018
Measurement Tester
Standard values
DCU 86P vehicle-

Starter switch: side connector

LOCK ATSS – Ground
ATS- – Ground
YES NO
Go to step 9. Repair or replace the harness.

MATION section.
9 Inspect for disconnections of the ambient air temperature sensor harness
1. Connect the ambient air temperature sensor connector.
vehicle-side connector.
ATS- ATSS
SAPH16F020400019
Measurement Tester
Standard values
DCU 86P vehicle-

Starter switch: 25 C {77 F}:
side connector
LOCK 3.7 k
ATSS – ATS-
YES NO

MATION section.
10 Inspect the engine coolant temperature sensor connector
1. Check the connection of the engine coolant temperature sensor

connector (Looseness and poor contact).
YES NO

MATION section.
11 Inspect the engine coolant temperature sensor
1. Check the installation of the engine coolant temperature sensor.
2. Make sure there is no dirt or damage to the engine coolant tem-

perature sensor.
YES NO
Clean the engine coolant temperature sensor Go to step 12.

the engine coolant temperature sensor.
MATION section.
12 Inspect the engine coolant temperature sensor unit
1. Disconnect the engine coolant temperature sensor connector.
WTM- WTM+
terminals of the engine coolant temperature sensor.
Measurement Tester
Standard values
Engine coolant 20 C {68 F}:

Starter switch: temperature sen- 2.32 – 2.59 k
LOCK sor 80 C {176 F}:
WTM+ – WTM- 0.310 – 0.326 k
SAPH16F020400020
YES NO
Go to step 13. Replace the engine coolant temperature sen-

sor.
MATION section.
13 Inspect the exhaust gas temperature sensor (SCR inlet) connector
1. Check the connection of the exhaust gas temperature sensor

(SCR inlet) connector (Looseness and poor contact).
YES NO

MATION section.
14 Inspect the exhaust gas temperature sensor (SCR inlet)
1. Check the installation of the exhaust gas temperature sensor

(SCR inlet).
2. Make sure there is no dirt or damage to the exhaust gas tempera-

ture sensor (SCR inlet).
YES NO
Clean the exhaust gas temperature sensor Go to step 15.

the exhaust gas temperature sensor (SCR
inlet).
MATION section.
15 Inspect the exhaust gas temperature sensor (SCR inlet) unit
FAT- FAT+ 2. Disconnect the exhaust gas temperature sensor (SCR inlet) con-
nector.

terminals of the exhaust gas temperature sensor (SCR inlet).
Measurement Tester
Standard values
Exhaust gas tem-

SAPH16F020400021 Starter switch: perature sensor 20 C {68 F}:
LOCK (SCR inlet) 220 
FAT+ – FAT-
YES NO
Go to step 16. Replace the exhaust gas temperature sensor

(SCR inlet).
MATION section.
16 Inspect the DEF pump temperature sensor connector
1. Check the connection of the DEF pump temperature sensor con-

YES NO

MATION section.
17 Check the DTC detected (DCU) [HINO DX Ⅱ ]
1. Perform an engine warm-up. (Water temperature: 60 C {140 F}

or more)
2. Stop the engine.
4. Select [DCU] and check if P0071 has been detected.
SAPH16F020400022
Has DTC P0071 been detected?
YES NO
Replace the DCU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
DTC: P0072
EN01H16F02040F03001012
DTC: P0072 Ambient air temperature sensor - out of range (Out of range low)
INFORMATION
Exhaust gas temperature

sensor (SCR inlet)
LFG LE4
(EXT+) (FAT+)
LFH LE5
(EXT-) (FAT-)
Ambient air temperature

DCU sensor
LNM LGJ (HH1+)
(ATSS)
LNN LGK (HH1-)
(ATS-)
LQV
LQU
(ER-)
(ER+)
External
resistance
SAPH16F020400023
• The ambient air temperature sensor inputs the outside air temperature data into the DCU to determine the heating
time when performing thawing or thermal insulation of the DEF in the DEF system pipes.
• The ambient air temperature sensor is connected to the external resistor at 2 k to reduce the current flowing value
through the sensor circuit.
• Ambient air temperature sensor malfunction detected.

Starter switch ON.
Ambient air temperature sensor voltage: Less than 3.4 V
3. Reset condition
• After having restored to the normal condition.

• MIL: ON
• Each temperature sensors failure diagnosis is stopped.

• –

• –

• 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

Ambient air
temperature
sensor
Bumper
SAPH16F020400024
YES NO

MATION section.

YES NO

MATION section.
2. Make sure there is no dirt or damage to the sensing unit of the

ambient air temperature sensor.
YES NO

the ambient air temperature.
MATION section.
HH1+ HH1-

Measurement Tester
Standard values
Ambient air tem-

perature sensor
LOCK 1.7 k
SAPH16F020400025 HH1+ – HH1-
YES NO

MATION section.

ER- ER+
Measurement Tester
Standard values

2 k
LOCK ER+ – ER-
SAPH16F020400026
YES NO

MATION section.
HH1+ HH1-
HH1+ HH1-
LJK LGK
nals of the ambient air temperature vehicle-side connector.
Measurement Tester
Standard values
Ambient air tem-

perature sensor
nector
HH1+ – HH1-
YES NO
ATS- ATSS
SAPH16F020400028
Measurement Tester
Standard values
DCU 86P vehicle-

side connector –
Starter switch:
ground 
LOCK
ATSS – Ground
ATS- – Ground
YES NO

MATION section.
8 Inspect for disconnection in the ambient air temperature sensor harness
ATS- ATSS
SAPH16F020400029
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 3.7 k
ATSS – ATS-
YES NO

MATION section.
2. Connect the vehicle to HINO DX Ⅱ .
SAPH16F020400030
YES NO

DTC: P0073
EN01H16F02040F03001013
DTC: P0073 Ambient air temperature sensor - out of range (Out of range high)
INFORMATION

sensor (SCR inlet)
LFG LE4
(EXT+) (FAT+)
LFH LE5
(EXT-) (FAT-)
Ambient air temperature

DCU sensor
LNM LGJ (HH1+)
(ATSS)
LNN LGK (HH1-)
(ATS-)
LQV
LQU
(ER-)
External (ER+)
resistance
SAPH16F020400031
• The ambient air temperature sensor inputs the outside air temperature data into the DCU to determine the heating
time when performing thawing or thermal insulation of the DEF in the DEF system pipes.
• The ambient air temperature sensor is connected to the external resistance at 2 k to reduce the current flowing
value through the sensor circuit.
• Ambient air temperature sensor malfunction detected.

Starter switch ON.
Ambient air temperature sensor voltage: More than 4.783 V
3. Reset condition
• After having restored to the normal condition.

• MIL: ON
• SCR malfunction light: ON
• 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.

• Lack of engine power (If the failure is not corrected within 500 miles).
• Vehicle speed does not increase (If the failure is not corrected within 2,000 miles).

• –
• Reset "Urea SCR related memory".

• 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

Ambient air
temperature
sensor
Bumper
SAPH16F020400032
YES NO

MATION section.

YES NO

MATION section.
2. Make sure there is no dirt or damage to the sensing unit of the

ambient air temperature sensor.
YES NO

the ambient air temperature sensor.
MATION section.
HH1+ HH1-

Measurement Tester
Standard values
Ambient air tem-

perature sensor
LOCK 1.7 k
SAPH16F020400033 HH1+ – HH1-
YES NO

MATION section.

ER- ER+
Measurement Tester
Standard values

2 k
LOCK ER+ – ER-
SAPH16F020400034
YES NO

MATION section.
HH1+ HH1-
HH1+ HH1-
LJK LGK
nals of the ambient air temperature sensor vehicle-side connector.
Measurement Tester
Standard values
Ambient air tem-

perature sensor
nector
HH1+ – HH1-
YES NO

terminals of the DCU 86P vehicle-side connector and the ground.
ATS- ATSS
SAPH16F020400036
Measurement Tester
Standard values
DCU 86P vehicle-


LOCK ATSS – Ground
ATS- – Ground
YES NO

MATION section.
8 Inspect for disconnection in the ambient air temperature sensor harness
2. Connect the signal check harness, and use the electrical tester to
ATS- ATSS
SAPH16F020400037
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 3.7 k
ATSS – ATS-
YES NO

MATION section.
9 Check the DTC detected (DCU)
SAPH16F020400038
YES NO

DTC: P0562
EN01H16F02040F03001014
DTC: P0562 Sensor supply voltage - out of range (Out of range low)
INFORMATION
FUSE DCU(B)
Z12 #GW #GW

Ground DCU
(G4)
%NJ
(2ALD)
A8P
LET
(GND1)
LEU
%NJ
(GND2) %NK %NK #GU #GU #GT #GT

LEV (+B1) LEN
(GND3)
LEW (+B2) LEP
(GND4)
LEX (+B3) LEQ
(GND5)
(+B4) LER
SAPH16F020400039
• DCU receives electric power from battery.
• Low voltage malfunction is detected in battery voltage (DCU power circuit).

Starter switch ON.
Battery voltage is less than 9 V.
3. Reset condition
• After having restored to the normal conditions.

• MIL: ON
• DEF injection is stopped.
• NOx reduction quantity monitoring is aborted.
<Symptoms on the vehicle due to backup control (fail safe function)>

• NOx reduction function is prevented.

• –

• Battery terminal harness is disconnected.
• Battery is dead.
• Harness connection is faulty.

poor contact).
YES NO

MATION section.
2 Inspect the voltage of the DCU power supply

GND1
+B3 2. Disconnect the DCU 53P connector.
measure the voltage between the terminals of the DCU 53P vehi-
cle-side connector.
Measurement Tester
Standard values
DCU 53P vehicle-

Starter switch:
SAPH16F020400040 side connector 9 – 16 V
LOCK
+B3 – GND1
YES NO
Go to step 3. Repair or replace the DCU power supply cir-

cuit (FUSE to DCU).
MATION section.
3. Select [DCU] and check if the P0562 has been detected.
SAPH16F020400041
YES NO
Replace the DCU. (After replacing the DCU, Procedure completed.

perform a forced regeneration.) Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
DTC: P0563
EN01H16F02040F03001015
DTC: P0563 Sensor supply voltage - out of range (Out of range high)
INFORMATION
FUSE DCU(B)
Z12 #GW #GW

Ground DCU
(G4)
%NJ
(2ALD)
A8P
LET
(GND1)
LEU
%NJ
(GND2) %NK %NK #GU #GU #GT #GT

LEV (+B1) LEN
(GND3)
LEW (+B2) LEP
(GND4)
LEX (+B3) LEQ
(GND5)
(+B4) LER
SAPH16F020400042
• DCU receives electric power from battery.
• High voltage malfunction detected in battery voltage (DCU power circuit).

Starter switch ON.
Battery voltage is more than 16 V.
3. Reset condition

• MIL: ON


• –

• Battery terminal harness is disconnected.
• Battery is dead.
• Harness connection is faulty.

poor contact).
YES NO

MATION section.
2 Inspect the voltage of DCU power supply

GND1
+B3 2. Disconnect the DCU 53P connector.
cle-side connector.
Measurement Tester
Standard values
DCU 53P vehicle-

Starter switch:
SAPH16F020400043 side connector 9 – 16 V
LOCK
+B3 – GND1
YES NO
Go to step 3. Repair or replace DCU power supply circuit

(FUSE to DCU).
MATION section.
SAPH16F020400044
YES NO

perform a forced regeneration.) Perform "After-inspection work" of INFOR-
MATION section.
DTC: P060C
EN01H16F02040F03001016
DTC: P060C DCU abnormality

INFORMATION
• DCU internal chip error is being checked in DCU.
• DCU internal malfunction has been detected.

Starter switch ON.
DCU internal chip errors are judged by DCU itself.
3. Reset condition

• MIL: ON


• –
• Check if the DTC is stored after test drive.

• DCU malfunction
INSPECTION PROCEDURE: P060C
3. Select [DCU] and check if HINO DX Ⅱ is communicating with the

DCU.
4. Erase the malfunction history.

When communicat-
ion with the engine 6. Check if the DCU main relay is OFF in the HINO DX Ⅱ menu. (This
ECU is interrupted cuts off the communication between HINO DX Ⅱ and the DCU.)
while the engine
NOTICE
ECU is connected
to the HINO DXⅡ,
The main relay turns OFF 1 minute after the exhaust gas tempera-
the connection ture (SCR inlet) drops below 200 °C {392 °F}.
symbol at the left
bottom of the HINO 7. Set the starter switch to the "ON" position.
DXⅡ screen
(figure on the left) 8. Select [DCU] and check if P060C has been detected.
becomes
disconnected.
SAPH16F020400045
Has DTC P060C been detected?
YES NO
Replace the DCU. (After replacing the DCU, Erase the malfunction history and recheck
perform a DPR forced regeneration.) the DTC.
DTC: P062F
EN01H16F02040F03001017
DTC: P062F Internal Control Module EEPROM Error

INFORMATION
• DCU internal ROM is being checked in DCU.
• DCU internal malfunction has been detected.

Starter switch ON.
DCU internal chip errors are judged by DCU itself.
3. Reset condition

• MIL: ON


• –

• DCU malfunction
NOTICE
If the DCU power supply is shut off forcibly, such as by disconnecting the battery before the pump operation
ends, and the DCU main relay turns off after the starter switch is turned OFF, P062F may be detected.
INSPECTION PROCEDURE: P062F
3. Select [DCU] and check if the menu is communicating with the

DCU.

When communicat-
ion with the engine 6. Check if the DCU main relay is OFF in the HINO DX Ⅱ menu. (This
ECU is interrupted cuts off the communication between HINO DX Ⅱ and the DCU.)
while the engine
NOTICE
ECU is connected
to the HINO DXⅡ,
the connection ture (SCR inlet) drops below 200 °C {392 °F}.
symbol at the left
bottom of the HINO 7. Set the starter switch to the "ON" position.
DXⅡ screen
(figure on the left) 8. Select [DCU] and check if P062F has been detected.
becomes
disconnected.
SAPH16F020400046
Has DTC P062F been detected?
YES NO
Replace the DCU. (After replacing the DCU, Erase the malfunction history and recheck
perform a DPR forced regeneration.) the DTC.
DTC: P0667
EN01H16F02040F03001018
DTC: P0667 DeNOx ECU temperature sensor 1, 2 - rationality

INFORMATION
• Sensor values of the 2 temperature sensors in the DCU are compared.
• Malfunction is indicated if the temperature differential exceeds a set value.
• DCU temperature sensor malfunction has been detected.

Starter switch ON.
Battery voltage range is in the 9 V to 16 V range.
The absolute value of (temperature sensor 1 - temperature sensor 2) > 15°C (59°F) for more than 10 sec.
3. Reset condition

• MIL: ON
• DCU failure inspection is stopped.


• –

• DCU (Internal temperature sensor) malfunction
SAPH16F020400047
YES NO
Replace the DCU. (After replacing the DCU, Erase the malfunction history. Procedure
perform a DPR forced regeneration.) completed.
DTC: P0668
EN01H16F02040F03001019
DTC: P0668 DeNOx ECU temperature sensor (Out of range low)

INFORMATION
• DCU internal temperature sensor is being checked in DCU.
• DCU internal temperature sensor malfunction is detected.

Starter switch ON.
Battery voltage is in the 9 V to 16 V range.
DCU (Internal temperature sensor) voltage:
- Voltage of the Sensor 1 is less than 0.85 V for 0.4 sec or more.
- Voltage of the Sensor 2 is less than 0.85 V for 0.4 sec or more.
3. Reset condition

• MIL: ON
• DCU malfunction diagnosis has been stopped.

• –

• –

• DCU (Internal temperature sensor) malfunction.
SAPH16F020400048
YES NO
DTC: P0669
EN01H16F02040F03001020
DTC: P0669 DeNOx ECU temperature sensors - out of range (Out of range high)
INFORMATION
• DCU internal temperature sensor is being checked in DCU.
• DCU internal temperature sensor malfunction is detected.

Starter switch ON.
Battery voltage is in the 9 V to 16 V range.
DCU (Internal temperature sensor) voltage:
- Voltage of the Sensor 1 is more than 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

• MIL: ON
• DCU malfunction diagnosis has been stopped.

• –

• –

• DCU (Internal temperature sensor) malfunction.
SAPH16F020400049
YES NO
DTC: P068A
EN01H16F02040F03001021
DTC: P068A Malfunction of main relay

INFORMATION
DCU
FUSE DCU(B)
#GT #GT #GU #GU %NK %NK LEN (+B1)
MAIN FR
W/H W/H
LEP (+B2)
LEQ (+B3)
LER (+B4)
Main
relay
control
DEF pump
power supply
SAPH16F020400050
• After turning off the starter switch, the DCU stays active for few minutes to evacuation DEF from lines to tank, then
writes the data to the DCU ROM before shut-down.
• After ROM data writing is complete, the DCU switches the main relay (built-in into the DCU) off.
• The DCU confirms the ROM and checks that the preceding ROM data writing as being completed correctly.
NOTICE
If the battery switch is turned OFF or a battery terminal is disconnected during the DCU shutdown process, Diag-
nostic Code P068A may be detected.
• ROM data reading error detected.

Engine running.
If the ROM data writing status was incomplete before the preceding DCU shut-down.
3. Reset condition
• DCU detects normal termination prior to operation.

• MIL: ON


• –

• 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
INSPECTION PROCEDURE: P068A
3. Select [DCU] and check if any DTC other than P068A (for exam-
ple, P0562) has been detected.
NOTICE
If the battery switch is turned OFF or a battery terminal is discon-
nected during the DCU shutdown process, Diagnostic Code
P068A may be detected.
SAPH16F020400051
Has a DTC other than P068A been detected?
YES NO
Go to the diagnosis procedure of a related Go to step 2.

DTC.
2 Inspect the DCU power supply circuit

DCU 53 Pin connector
+B2 GND4 GND1
LEP LEW LET
+B2
LEP
GND4
LEW
GND1
LET
+B3 GND5 GND2
+B3 GND5 GND2
LEQ LEX LEU LEQ LEX LEU
+B4
LER
+B1
LEN
GND3
LEV
nals of the DCU 53P connector (Engine sub harness side) and
+B4 +B1 GND3
LER LEN LEV battery minus (BAT-).
CAH1
LF5
Measurement Tester
CAL1
LF6 Standard values
TE1B
LF2
TE1A CAH0
LF1 LEY
TE2B CAL0
DCU 53P connec-
LF4 LEZ
TE2A
LF3
tor (Engine sub
harness side)
Starter switch: ON +B1 – BAT- 9 V – 16 V (All)
IGSW
LES +B2 – BAT-
+B3 – BAT-
Battery +B4 – BAT-
SAPH16F020400052

YES NO
Go to step 3. Repair or replace the battery power supply-

ing circuit (harness, fuse etc).
MATION section.
3 Inspect the DCU harness

2. Disconnect the connector between the cab main harness and the
chassis front harness.
Between cab
main harness
and chassis
front harness
SAPH16F020400053
3. Using the electrical tester, measure the resistance between the

DCU 53 Pin connector terminals from the DCU 53P chassis side connector to the chassis
side connector of the cab main harness connector to chassis front
+B2
LEP
GND4
LEW
GND1
LET harness connector.
+B2 GND4 GND1
LEP LEW LET
+B3 GND5 GND2

+B3
LEQ
GND5
LEX
GND2
LEU LEQ LEX LEU Measurement Tester
Standard values
+B4
LER
+B1
LEN
GND3
LEV
+B4 +B1 GND3
LER LEN LEV
DCU 53P connec-
CAH1
LF5
tor (vehicle-side)
CAL1
LF6
to cab main har-
TE1B
LF2 ness to chassis
TE1A
LF1
CAH0
LEY front harness con-
Starter switch:
1  or less
TE2B CAL0
LF4 LEZ
nector (chassis-
TE2A LOCK
LF3
side)
+B1 – #GT
IGSW
LES
+B
#GS
1
#J7
+B2 – #GT
6
#96
IG 14 16 9 5 2
3
#93 +B3 – #GT
#GX #FE #MG #M9 #JB #J8
+B
#GR 5 22 13 12 10 6 3
4
#94
+B4 – #GT
#F5 #FN #MD #MC #MA #JC #J9
+B 21 14 15 11 4 5
#GT #FM #ME #MF #MB #JA #95
Cab main harness to

chassis front harness
connector (chassis side)
SAPH16F020400054

YES NO
Reconnect DCU 53P connector and cab main Repair or replace the battery power supply-
harness connector. Go to step 4. ing circuit (harness).
MATION section.
3. Erase the malfunction history using HINO DX Ⅱ .
4. Start the engine.
5. Select [DCU] and check if P068A has been detected.
When communicat- 6. Turn the starter switch OFF while still connected to HINO DX Ⅱ .
ion with the engine
ECU is interrupted 7. After checking that the communication between the HINO DX Ⅱ
while the engine and the DCU has been disconnected, turn the starter switch ON
ECU is connected again.
to the HINO DXⅡ,
the connection
symbol at the left 8. Select [DCU] and check if P068A has been detected.
bottom of the HINO
DXⅡ screen
(figure on the left)
becomes
disconnected.
SAPH16F020400055
Has P068A been detected?
YES NO
Replace the DCU. Confirm DCU is pro- Procedure completed.

grammed to latest software level. Perform "After-inspection work" of INFOR-
MATION section.
DTC: P142A
EN01H16F02040F03001022
DTC: P142A DEF pump temperature sensor (Out of range)

INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400056
• There are 2 temperature sensors in the DEF pump.
• The DEF pump temperature sensor is judged with the DEF pump temperature sensor voltage by the DCU via har-
ness.
• Failure of temperature sensor inside DEF pump is detected.

Engine ON.
DEF Supply module Temperature Sensor duty:– Temperature sensor 1 duty: Below 15% for 5 sec. or longer–
Temperature sensor 1 duty: Over 85% for 5 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

• MIL: ON

• –

• Control will not work properly if the DEF freezes.

• Disconnection or short-circuit in sensor harness
1 Check the DTC detected 1 (DCU) [HINO DX Ⅱ ]
4. Select [DCU] and check if P20B2 has been detected.
SAPH16F020400057
Has DTC P20B2 been detected?
YES NO
Go to diagnosis procedure of the related Go to step 2.

DTC.
1. Check if P060C has been detected in [DCU].
SAPH16F020400058
YES NO

DTC.
1. Check if any following DTCs have been detected in [DCU].

P208A, P208B, P208C or P208D
SAPH16F020400059
Have any DTCs (P208A, P208B, P208C or P208D) been detected?
YES NO

DTC.
4 Check the temperature detected by the DEF pump temperature sensor [HINO DX Ⅱ ]
1. Keep the engine off until you can touch the surface of the DEF
pump and confirm that there is no difference between the pump
temperature and the outside temperature.
4. Select [DCU].
5. Select [DEF pump temperature #1] and [DEF pump temperature

#2] on [Data monitor Setting], and start the monitor.
SAPH16F020400060
6. Compare the monitor value and the ambient temperature.

NOTICE
The information of DEF pump internal temperature is transmitted
to the DCU via the electrical circuit which is commonly used with
the information of DEF pump opening. Therefore, DEF pump inter-
nal temperature displayed on the HINO DX Ⅱ will not be updated
while the DEF pump is activated. The current temperature will be
updated 6 seconds after the starter switch has been turned on.
Standard values
Difference between monitor value and ambient temperature:

Within  15 C { 59 F}
Is the difference between the monitor value and ambient temperature within  15 C { 59 F}?
YES NO
5 Inspect the exhaust pipe/muffler
1. Check the exhaust pipe/muffler and make sure it has no cracks or

exhaust leaks (soot leaks), and verify that coupling flanges are
properly tightened.
YES NO
Repair or replace the exhaust pipe/muffler. Go to step 6.

MATION section.
6 Check if DEF heater installation has been modified
1. Check if the DEF heater installation in the DEF pump has been
modified.
Has the electric heater installation been modified?
YES NO
Remove the DEF heater. (There may be DEF Go to step 7.

temperature problems due to the DEF
heater.)
MATION section.
7 Inspect the DEF pump connector
1. Check the DEF connector connection (fit, faulty contact) and the
state of the terminal (bent pin, electrolytic corrosion, water entry).
YES NO

MATION section.
8 Inspect the power supply of the DEF pump

PMP-
PMP+
PMPS 2. Disconnect DEF pump connector.
4. Using an electrical tester, measure the voltage between each ter-

minal in the DEF pump vehicle-side connector while gently jiggling
the harness.
Measurement Tester
Standard values
SAPH16F020400061
DEF pump vehi-

cle-side connector (1) 12 V
Starter switch: ON (1) PMP- – PMP+ (2) 2.82 – 4.03 V
(2) PMP- – PMPS (3) 7.97 – 9.18 V
(3) PMP+ – PMPS
YES NO
9 Check for short-circuit in wire harness of DEF pump (temperature sensor)

PMP-
PMPS 2. Disconnect the DCU 86P connector and the DEF pump connector.
BODY GND
PMP+
Measurement Tester
Standard values
DCU 86P vehicle-

SAPH16F020400062 side connector
(signal check har-
Starter switch: ON ness) 
PMP+ – Ground
PMP- – Ground
PMPS – Ground

YES NO

MATION section.
10 Check for disconnection in wire harness of DEF pump (temperature sensor)
1. Use the electrical tester to measure the resistance between each

PMP- PMP- terminal of the DEF pump vehicle-side connector and the DCU
PMP+ 86P vehicle-side connector (signal check harness).
PMPS PMPS
Measurement Tester
Standard values
PMP+
DEF pump vehi-

cle-side connec-
tor – DCU 86P
vehicle-side con-
Starter switch: ON nector (signal Less than 1 
SAPH16F020400063
check harness)
PMP+ – PMP+
PMP- – PMP-
PMPS – PMPS
YES NO
Replace the DCU. Repair or replace the harness.

11 Check the DEF pump pressure
(1) 2. Connect the vehicle to HINO DX Ⅱ .

(2)
(3)
4. Select [DCU].
5. Perform [Leak test] from the [DEF solution addition test].

And read the DEF pump pressure on the DX Ⅱ screen.
SAPH16F020400064 <Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [DEF solution addition test].
(3) Click [Start inspection] and then [leak test].
Measurement
Standard values
conditions
The DEF pressure is stable

in the 850 to 950 kPa {123.3
Starter switch: ON
to 137.8 psi} range for 60
seconds.
YES NO
Procedure completed. Replace the DCU.

12 Check the DEF pump opening [HINO DX Ⅱ ]
(1) 2. Connect the vehicle to HINO DX Ⅱ .

(2)
(3)
4. Select "DCU".
5. Perform [Leak test] from the [DEF solution addition test]. And con-
firm the "DEF pump opening" value on the DX Ⅱ screen once the
SAPH16F020400065 DEF pressure has stabilized between 850 - 950 kPa {123.3 - 137.8
psi}.
<Inspection procedure>
HINT
The information of DEF pump internal temperature will be trans-
mitted to the DCU, via the shared circuit with the information of
DEF pump opening, when the pump is not in operation.
This test will determine that the circuit (DCU) is working properly if
the information of DEF pump opening is normally recognized
when the DEF pump motor is functioning normally (DEF pressure
is stable).
Standard values
16  6.5 %
YES NO
Replace the DEF pump. Replace the DCU.

(Since the DCU is normally recognizing the (Since the DCU is not normally recognizing
information of DEF pump opening, the circuit the information of DEF pump opening, even
(DCU) is normal and the DEF pump internal though the DEF pump motor is operating
temperature sensor is deemed to be mal- normally, the DCU is deemed to be malfunc-
functioning.) After replacing the pump, tioning.) After replacing the DCU, return to
return to step 4. step 4.
DTC: P142B
EN01H16F02040F03001023
DTC: P142B DEF pump temperature sensor - rationality

INFORMATION
Engine coolant
(THW+)
LFJ LG8
LUH KTU KTD (WTM-) E24 (PMP+) (PMP+)
(AG5)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
(PMV+)
LFM LGB
(PMV+) Supply
(PMV-)
LFN LGC module
(PMV-)
LFQ LGD (DEF
ECU (PSR+) (PSR+)
pump)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
LF5 (CAH1)
(CA1H) LCM #S5 #S5 #AW #AW %NM %NM
H H
LF6 (CAL1)
(CA1L) LCN #S7 #S7 #AV #AV %NN %NN
L L
DCU
Exhaust gas
temperature
(EXT-) LFH LE5 (FAT-) sensor
(SCR inlet)
(ATSS+) LNM LGJ (HH1+) Ambient air

temperature
(ATS-) LNN LGK (HH1-) sensor
LQU
LQV
(ER-)
(ER+)
External
resistance
SAPH16F020400066
• DEF pump temperature sensor checks for validity by comparing with the outside temperature.
• DEF pump temperature sensor checks for validity by monitoring whether the temperature rises when the coolant
shutoff valve is released (when DEF defrosts).
• While the engine is cold, engine coolant will be sent to the pump to defrost the DEF.
• Failure of temperature sensor inside DEF pump is detected.

When the starter switch is ON, difference among the outside temperature, exhaust temperature (SCR inlet) and
coolant 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.
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}
3. Reset condition
• When the starter switch is ON and the difference among the outside temperature, exhaust temperature, and coolant
temperature is less than 8 °C {46.7 F}, the difference from the coolant temperature will be less than 22 C {71.6
F}.
• When the shutoff valve is open (defrosting), the temperature rise after 10 minutes will be at least 2 C {35.6 F}.

• MIL: ON

• –


• Coolant shutoff valve: Stuck closed
• Coolant piping: Clogging or leaks
• Malfunction of ambient air temperature sensor
• Malfunction of exhaust gas temperature sensor (SCR inlet)
• Malfunction of engine coolant temperature sensor
NOTICE
Also see the malfunction codes of the shutoff valve.
INSPECTION PROCEDURE: P142B

Ambient air
temperature
sensor
Bumper
SAPH16F020400067
YES NO

MATION section.

YES NO

MATION section.

poor contact).
YES NO

MATION section.
2. Make sure there is no dirt or damage to the ambient temperature

sensor.
YES NO

MATION section.
HH1+ HH1-

Measurement Tester
Standard values
Ambient air tem-

perature sensor
LOCK 1.7 k
SAPH16F020400068 HH1+ – HH1-
YES NO

MATION section.

ER- ER+
Measurement Tester
Standard values

2 k
LOCK ER+ – ER-
SAPH16F020400069
YES NO

MATION section.
7 Inspect disconnection of the ambient air temperature sensor harness
ATS- ATSS
SAPH16F020400070
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 3.7 k
ATSS – ATS-

YES NO

MATION section.

Exhaust gas
temperature
sensor (SCR inlet)
SAPH16F020400071
YES NO

MATION section.

(SCR inlet).

YES NO

(SCR inlet) and install it properly. If damaged,
replace the exhaust gas temperature sensor
(SCR inlet).
MATION section.
FAT- FAT+
2. Disconnect the exhaust gas temperature sensor (SCR inlet) con-
nector.

Measurement Tester
Standard values
Exhaust gas tem-

FAT+ – FAT-
YES NO

(SCR inlet).
MATION section.

Engine coolant temperature sensor 1

SAPH16F020400073

YES NO

MATION section.

perature sensor.
YES NO

MATION section.
WTM+ WTM-
Measurement Tester
Standard values

LOCK sor 80 C {176 F}:
WTM+ – WTM- 0.310 – 0.326 k
SAPH16F020400074
YES NO

sor.
MATION section.
14 Check the operation of the coolant shutoff valve [HINO DX Ⅱ ]
3. Select [DCU] from the menu.
4. Select [Coolant shutoff valve] from the [Active test Setting] menu
and operate the coolant shutoff valve.
(1) When the valve is open: Check if the pressure inside the
downstream coolant line is rising by feeling the line with your
hand.
(2) When the valve is closed: Check if the pressure inside the
SAPH16F020400075
downstream coolant line is dropping by feeling the line with
your hand.
! CAUTION
Be careful not to burn yourself when the coolant is hot.
Is operation normal?
YES NO
Go to step 15. Replace the coolant shutoff valve.

MATION section.
15 Inspect the engine coolant lines & hoses
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.
YES NO
Repair or replace the faulty part. Go to step 16.

MATION section.
16 Inspect the DEF pump
1. Disconnect the coolant hoses (upstream and downstream) from

the DEF pump.
2. Blow air from one side and make sure it comes out from the other
side.
YES NO
Replace the DEF pump. Replace the coolant shutoff valve.

DTC: P202E
EN01H16F02040F03001024
DTC: P202E Reductant Delivery Performance

INFORMATION
Back flow Line Pressure Line
Suction Line
DEF Pump Pressure sensor
DEF Injector
Inside the muffler
DEF Tank
SAPH16F020400076
• The amount of added DEF is diagnosed as abnormal.
• The amount of added DEF is controlled by the DEF pressure and the opening of the DEF injector.
• Failure of DEF injector at system startup is detected.

<At system start up>
The engine is ON.
Exhaust gas temperature sensor (SCR inlet) > 150 C {302 F}
DEF pump pressure is stable for 8 sec. when it is between 850 kPa {123 psi} and 950 kPa {138 psi}.
<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

• MIL: ON
• Output restricted instantaneously.
• If malfunction does not improve within 50 min.: vehicle speed is restricted.

• Exhaust gas purification function is declined.
• Engine output is insufficient.
• Vehicle does not speed up (when malfunction does not improve within 50 min.).

• –

• Clogging of the DEF injector
• Clogging of the DEF pipe
INSPECTION PROCEDURE: P202E
1 Inspect the DEF pipe (pressure line) between the DEF pump and the DEF injector.
1. Check the DEF pipe (pressure line) and check if there are no dis-
connections, clogging, corrosion, or cracks.
YES NO
Replace the DEF pipe. Go to step 2.

MATION section.
2 Inspect DEF injector (1) [HINO DX Ⅱ ]
NOTICE
Prepare a beaker or similar, plus a larger measuring vessel for
measuring the DEF to be injected, before perform this inspection.
(1) (If the vessel is small, there is dispersion at the time of injection
(2)
from the injector, and the measuring quantity decreases.)

(3)
2. Remove the DEF injector from the muffler.

HINT
Refer to the workshop manual "SELECTIVE CATALYTIC REDUC-
SAPH16F020400077
TION (SCR)" in the chapter "EMISSION CONTROL (J08E)" (S5-
CJ08E12* or S5-UJ08E12*) for removal and installation of the DEF
injector.
5. Select [DCU].
6. Select [Inspection Menu] on HINO DX Ⅱ menu and check the oper-

ation of the DEF injector.
(3) Perform addition test as instructed on the HINO DX Ⅱ 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.
YES NO
Procedure completed. DEF crystal clogging Go to step 3.

is considered resolved.
MATION section.
3 Inspect the DEF injector (2) [HINO DX Ⅱ ]
2. Replace DEF injector with a new one. (Do not install it on the muf-
fler.)
3. Perform step 2 again.
SAPH16F020400078
YES NO
New injector installed in the muffler, proce- Replace the DEF pipe (pressure line). After
dure completed. After installing the injector, replacing the pipe, idle the engine (for about
idle the engine (for about 10 min.) and on the 10 min.) and on the menu [Data monitor Set-
menu [Data monitor Setting] check if the DEF ting] check if the DEF pressure is stable
pressure is stable between 800 kPa {116 psi} between 800 kPa {116 psi} and 1,051 kPa {152
and 1,051 kPa {152 psi}. psi}.
DTC: P203C
EN01H16F02040F03001025
DTC: P203C DEF tank level sensor - out of range (Out of range low)
INFORMATION
#S5 #S5 #AW #AW LF5 (CAH1)

(CA1H) LCM
H H
#S7 #S7 #AV #AV LF6 (CAL1)
(CA1L) LCN
L L
Twist
Twist
Twist
Engine DCU
ECU
LEY
(CAH0)
(CAL0)
(CANL) K6W #SF #SF #CQ #CQ

Twist
Twist
Twist
Common rail_CAN_J/C1 Common rail_CAN_J/C3

(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
%KN
(CANL)
%KP
(CANH)
%KR
(CANH)
%KQ
(CANL)
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
Twist
Twist (CANH)
(CANH)
Twist
(CANL)
(CANL)
LEC
LED
LE9
(CANH)
LE8
(CANH)
(CANL)
(CANL)
DEF sensor
LEJ
LEK
LQN
LQK
L H L H
(DEF tank H
L
level sensor)
NOx NOx
PM sensor 2 sensor 1
sensor
SAPH16F020400079
• The DEF tank level sensor is connected via the engine ECU, DCU, and CAN communication, and it sends and
receives data.
• Failure of DEF tank level sensor is received from CAN data.

Starter switch ON.
Failure of DEF tank level sensor (flag) is received from CAN data.
3. Reset condition

• MIL: ON
• DEF level indicator is stopped.

• –

• DEF level indicator is OFF.

• DEF tank level sensor failure.
1 Check the DTC detected (Engine) [HINO DX Ⅱ ]
3. Select [Engine] and check if a CAN communication system mal-

function (U02A2) has been detected.
SAPH16F020400080
Has DTC U02A2 been detected?
YES NO
Go to the diagnostic procedure of a related Replace the DEF tank level sensor.
DTC. Perform "After-inspection work" of INFOR-
MATION section.
DTC: P203D
EN01H16F02040F03001026
DTC: P203D DEF tank level sensor - out of range (Out of range high)
INFORMATION

(CA1H) LCM
H H
(CA1L) LCN
L L
Twist
Twist
Twist
Engine DCU
ECU
LEY
(CAH0)
(CAL0)

Twist
Twist
Twist

(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
%KN
(CANL)
%KP
(CANH)
%KR
(CANH)
%KQ
(CANL)
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
Twist
Twist
(CANH)
(CANH)
Twist
(CANL)
(CANL)
LEC
LED
LE9
(CANH)
LE8
(CANH)
(CANL)
(CANL)
DEF sensor
LEJ
LEK
LQN
LQK
L H L H
(DEF tank H
L
level sensor)
NOx NOx
sensor
SAPH16F020400081
• The DEF tank level sensor is connected via the engine ECU and DCU through CAN communication, and it sends
and receives data.
• Failure of DEF tank level sensor is received from CAN data.

Starter switch ON.
Failure of DEF tank level sensor (High failure flag) is received from CAN data.
3. Reset condition

• MIL: ON

• –


• DEF tank level sensor failure.
INSPECTION PROCEDURE: P203D

SAPH16F020400082
YES NO
Go to diagnosis procedure of a related DTC. Replace the DEF tank level sensor.
MATION section.
DTC: P2044
EN01H16F02040F03001027
DTC: P2044 DEF tank temp. sensor failure (Low)

INFORMATION

(CA1H) LCM
H H
(CA1L) LCN
L L
Twist
Twist
Twist
Engine DCU
ECU
LEY
(CAH0)
(CAL0)

Twist
Twist
Twist

(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
%KN
(CANL)
%KP
(CANH)
%KR
(CANH)
%KQ
(CANL)
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
Twist
Twist (CANH)
(CANH)
Twist
(CANL)
(CANL)
LEC
LED
LE9
(CANH)
LE8
(CANH)
(CANL)
(CANL)
DEF sensor
LEJ
LEK
LQN
LQK
L H L H
(DEF tank H
L
level sensor)
NOx NOx
sensor
SAPH16F020400083
• The DEF tank temperature sensor is connected via the engine ECU and DCU through CAN communication, and it
sends and receives data.
• Failure of DEF tank temperature sensor 2 is received from CAN data.

Starter switch ON.
Failure of DEF tank temperature sensor 2 (Low failure flag) is received from CAN data.
3. Reset condition



• –

• DEF tank temperature sensor 2 failure.

SAPH16F020400084
Has DTC U02A2 detected?
YES NO
Go to diagnosis procedure of a related DTC. Replace the DEF tank temperature sensor.
MATION section.
DTC: P2045
EN01H16F02040F03001028
DTC: P2045 DEF tank temp. sensor failure (High)

INFORMATION

(CA1H) LCM
H H
(CA1L) LCN
L L
Twist
Twist
Twist
Engine DCU
ECU
LEY
(CAH0)
(CAL0)

Twist
Twist
Twist

(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
%KN
(CANL)
%KP
(CANH)
%KR
(CANH)
%KQ
(CANL)
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
Twist
Twist
(CANH)
(CANH)
Twist
(CANL)
(CANL)
LEC
LED
LE9
(CANH)
LE8
(CANH)
(CANL)
(CANL)
DEF sensor
LEJ
LEK
LQN
LQK
L H L H
(DEF tank H
L
level sensor)
NOx NOx
sensor
SAPH16F020400085

Starter switch ON.
Failure of DEF tank temperature sensor 2 (High failure flag) is received from CAN data.
3. Reset condition



• –


SAPH16F020400086
YES NO
Go to diagnosis procedure of a related DTC. Replace the DEF tank temperature sensor.
MATION section.
DTC: P2047
EN01H16F02040F03001029
DTC: P2047 DEF injector - functional

INFORMATION
Dosing
LG6 LF8
module (DMH) (DMH)
(DEF (DML)
LG7 LF9 DCU
(DML)
injector) Twist Twist
SAPH16F020400087
• DEF dosing valve is controlled by DCU.
• Operation of the DEF dosing valve is checked by DCU based on the circuit current waveform.
• DEF injector failure is detected.

The engine is ON.
DEF injector duty cycle: > 0%, and DEF Pressure > 350 kPa {51 psi}, and 9 V < Battery < 16 V, and Time
elapsed since DEF injector opening ≤ 0.0025 sec.
Second order differential in the DEF injector circuit current waveform: Below 80 A/sec^2 detected 50 times con-
secutively.
3. Reset condition

• MIL: 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.

• 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).

• –

• DEF injector: Malfunction of injector
* Clogging of crystallized DEF is suspected.
1 Inspect DEF injector (1) [HINO DX Ⅱ ]
NOTICE
(2)

(3)

HINT
SAPH16F020400088
injector.
5. Select [DCU].

NOTICE
YES NO
Procedure completed. Replace the DEF injector. (Perform DPR

Perform "After-inspection work" of INFOR- forced regeneration after replacement.)
MATION section. Perform "After-inspection work" of INFOR-
MATION section.
DTC: P2048
EN01H16F02040F03001030
DTC: P2048 DEF injector - disconnection (Disconnection (low side))

INFORMATION
Dosing
LG6 LF8
module (DMH) (DMH)
(DEF (DML)
LG7 LF9 DCU
(DML)
SAPH16F020400089
• DEF dosing valve detects disconnection and short-circuit based on the circuit voltage and signals in DCU.

Starter switch ON.
DEF injector duty cycle > 0%
DEF dosing valve circuit voltage (Low side): Below 0.2 V for more than 0.05 sec.
3. Reset condition

• MIL: ON


• –

• Abnormal resistance of DEF injector
• Malfunction in DEF injector
1 Inspect for short-circuit in the DEF injector harness
1. Check the connection of the DEF injector connector (Looseness

and poor contact).
YES NO

MATION section.
2 Inspect the DEF injector unit
DML DMH
2. Disconnect the DEF injector connector.

terminals of the DEF injector.
Measurement Tester
Standard values
Starter switch: DEF injector 20 C {68 F}:

LOCK DML – DMH 11.4 – 12.6 
SAPH16F020400090
YES NO
Go to step 3. Replace the DEF injector.

MATION section.
DMH DML
SAPH16F020400091
Measurement Tester
Standard values
DCU 86P vehicle-


LOCK DML – Ground
DMH – Ground
YES NO

MATION section.
4 Inspect disconnection of the DEF injector harness
1. Connect the DEF injector connector.
DMH DML
SAPH16F020400092
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 11.4 – 12.6 
DML – DMH
YES NO

MATION section.

or more)
2. Stop the engine and set the starter switch to the "LOCK" position.
SAPH16F020400093
YES NO
Replace the DCU. (Perform DPR forced Procedure completed.

regeneration after replacement.) Perform "After-inspection work" of INFOR-
MATION section.
DTC: P2049
EN01H16F02040F03001031
DTC: P2049 DEF injector - disconnection (Disconnection (high side))

INFORMATION
Dosing
LG6 LF8
module (DMH) (DMH)
(DEF (DML)
LG7 LF9 DCU
(DML)
SAPH16F020400094
• DEF dosing valve detects disconnection and short-circuit based on the circuit voltage and signals in DCU.

Starter switch ON.
DEF injector duty cycle > 0 %
DEF dosing valve circuit voltage (High side): Below 2 V for more than 0.05 sec.
3. Reset condition

• MIL: ON


• –

• Disconnection or short-circuit in sensor harness.
• Abnormal resistance of DEF injector.
• Malfunction in DEF injector.
1 Inspect the DEF injector connector
1. Check the connection of the DEF injector connector (Looseness

and poor contact).
YES NO

MATION section.
2 Inspect the DEF injector unit
DML DMH
2. Disconnect the DEF injector connector.

terminals of the DEF injector.
Measurement Tester
Standard values
Starter switch: DEF injector 20 C {68 F}:

LOCK DML – DMH 11.4 – 12.6 
SAPH16F020400095
YES NO
Go to step 3. Replace the DEF injector.

MATION section.
DMH DML
SAPH16F020400096
Measurement Tester
Standard values
DCU 86P vehicle-


LOCK DML – Ground
DMH – Ground
YES NO

MATION section.
4 Inspect disconnection of the DEF injector harness
1. Connect the DEF injector connector.
DMH DML
SAPH16F020400097
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 11.4 – 12.6 
DML – DMH
YES NO

MATION section.
5 DTC the DTC detected (DCU) [HINO DX Ⅱ ]

or more)
SAPH16F020400098
YES NO
Replace the DCU. (Perform DPR forced Procedure completed.

MATION section.
DTC: P204B
EN01H16F02040F03001032
DTC: P204B DEF pressure sensor - rationality

INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-) Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400099
• The pressure sensor in the DEF pump is used to confirm the pressure in the DEF pipe.
• DEF pressure sensor failure is detected.

The DCU power supply voltage is in the range of 10 to 16 V
Minimum DEF pressure during previous after-run > -50 kPa {-7.3 psi}
DEF defrosting is completed, and
Exhaust Gas Temperature (SCR inlet) < 150 C {302 F}, and
the exhaust gas temperature (SCR inlet) is below 150 C {302 F}
DEF pressure > 50 kPa {7.3 psi} or < -50 kPa {-7.3 psi} for 1 sec.
3. Reset condition

• MIL: ON


• –

• DEF pump (pressure sensor) malfunction
3. After three minutes, set the starter switch to the "ON" position.
4. Select [DCU] and check whether P204B is past error code.
SAPH16F020400100
Is DTC P204B post error code?
YES NO
Procedure completed. Go to step 2.

MATION section.
1. Select [DCU] and check if any DTC below has been detected.
P2047, P2049, P202E
Has DTC P2047, P2049 and P202E been detected?
YES NO
Go to diagnosis procedure of a related DTC. Replace the DEF pump filter.

Go to step 3.
3 Check the DEF pump
1. Conduct the DEF pump pressure monitor test by using HINO DXⅡ.
YES NO
Replace the DEF pump. Procedure completed.

DTC: P204C
EN01H16F02040F03001033
DTC: P204C DEF pressure sensor - out of range (Out of range low)
INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400101
• The pressure sensor in the DEF pump is used to confirm the pressure in the DEF pump.
• A short-circuit or disconnection in the DEF pump pressure sensor is detected with the DCU.
• Failure of the pressure sensor in the DEF pump is detected.

Starter switch ON.
DEF pump pressure sensor circuit voltage < 0.25 V for more than 0.4 sec.
3. Reset condition

• MIL: ON


• –

• Harness disconnection or short-circuit
• Malfunction of DEF pump (pressure sensor)
- Internal circuit disconnection or short-circuit
- Abnormal output voltage
1. Check the connection of the DEF pump connector (Looseness and

poor contact).
YES NO

MATION section.
2 Inspect the DEF pump (pressure sensor) unit

PSR+
PSRS
PSR- 2. Remove the DEF pump connector.

terminals of the DEF pump pressure sensor.
Measurement Tester
Standard values
DEF pump con-

nector (1) 185 – 215 k
Starter switch:
SAPH16F020400102 (1) PSR+ – PSR- (2) 148 – 172 k
LOCK
(2) PSR+ – PSRS (3) 333 – 387 k
(3) PSR- – PSRS
YES NO
Go to step 3. Replace the DEF pump.

MATION section.
3 Check for short-circuit in wire harness of DEF pump (pressure sensor)
PSR- PSR+
PSRS
SAPH16F020400103
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
Starter switch:
PSR+ – Ground 
LOCK
PSRS – Ground
PSR- – Ground
YES NO

MATION section.
4 Check for disconnection in wire harness of DEF pump (pressure sensor)
1. Connect the DEF pump connector.
PSR- PSR+
PSRS
SAPH16F020400104
Measurement Tester
Standard values
DCU 86P vehicle-

side connector (1) 185 – 215 k
Starter switch:
(1) PSR+ – PSR- (2) 148 – 172 k
LOCK
(2) PSR+ – PSRS (3) 333 – 387 k
(3) PSR- – PSRS
YES NO

MATION section.
4. Select [DCU] and check if DTC P204C has been detected.
SAPH16F020400105
YES NO

DTC: P204D
EN01H16F02040F03001034
DTC: P204D DEF pressure sensor - out of range (Out of range high)
INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400106
• The pressure sensor in the DEF pump is used to confirm the pressure in the DEF pump.
• A short-circuit or disconnection in the DEF pump pressure sensor is detected with the DCU.
• Failure of the pressure sensor in the DEF pump is detected.

Starter switch ON.
DEF pump pressure sensor circuit voltage > 4.75 V for more than 0.4 sec.
3. Reset condition

• MIL: ON


• –
• Reset "Urea SCR related memory" by HINO DX Ⅱ "Data monitor and Activation test".

• Malfunction of DEF pump (pressure sensor)
- Internal circuit disconnection or short-circuit
- Abnormal output voltage
1. Check the connection of the DEF pump connector. (Looseness

and poor contact).
YES NO

MATION section.
2 Inspect the DEF pump (pressure sensor) unit

PSR+
PSRS
PSR- 2. Disconnect the DEF pump connector.

terminals of the DEF pump pressure sensor.
Measurement Tester
Standard values
DEF pump con-

nector (1) 185 – 215 k
Starter switch:
SAPH16F020400107 (1) PSR+ – PSR- (2) 148 – 172 k
LOCK
(2) PSR+ – PSRS (3) 333 – 387 k
(3) PSR- – PSRS
YES NO

MATION section.
3 Check for short-circuit in wire harness of DEF pump (pressure sensor)
PSR- PSR+
PSRS
SAPH16F020400108
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
Starter switch:
PSR+ – Ground 
LOCK
PSRS – Ground
PSR- – Ground
YES NO

MATION section.
4 Check for disconnection in wire harness of DEF pump (pressure sensor)
PSR- PSR+
PSRS
SAPH16F020400109
Measurement Tester
Standard values
DCU 86P vehicle-

side connector (1) 185 – 215 k
Starter switch:
(1) PSR+ – PSR- (2) 148 – 172 k
LOCK
(2) PSR+ – PSRS (3) 333 – 387 k
(3) PSR- – PSRS
YES NO

MATION section.
4. Select [DCU] and check if P204D has been detected.
SAPH16F020400110
Has P204D been detected?
YES NO

DTC: P205B
EN01H16F02040F03001035
DTC: P205B DEF tank temperature sensor - rationality

INFORMATION
Engine coolant
(THW+)
LUH KTU KTD (WTM-) E24
(AG5)
DCU
Exhaust gas
LF5 (CAH1) temperature
(CA1H) LCM #S5 #S5 #AW #AW
H H sensor
LF6 (CAL1) (SCR inlet)
(CA1L) LCN #S7 #S7 #AV #AV
L L
Twist
Twist
Twist
Engine
(EXT-) LFH LE5 (FAT-)
ECU
LEY
(CAH0)
(CAL0)
(CANL) K6W #SF #SF #CQ #CQ Twist (ATSS+) LNM LGJ (HH1+)
(ATS-) LNN LGK (HH1-)

Twist
Twist
Ambient air
temperature
LQU
LQV
sensor
(ER-)
(ER+)
Common rail_
CAN_J/C1
External
(CANH) H (CANH)
%KL %KE %JV L %JZ resistance
Twist
Twist
Twist
(CANH)
(CANH)
(CANL)
(CANL)
%JS
%JX
(CANH)
(CANL)
%JR
%KP
%JW
%KN
Twist Twist Twist
Twist
(CANH)
(CANL)
(CANH)
(CANH)
(CANL)
(CANL)
LEJ
LEK
LEC
LED
LE9
LE8
L H H H
L L
DEF sensor NOx NOx

SAPH16F020400111
• DEF tank temperature sensor rationality is checked by comparison with Ambient air temperature.
• Failure of DEF tank temperature sensor is detected.

Starter switch ON.
Difference between Ambient air temperature and Exhaust gas temperature (SCR inlet): < 8 C {46.4 F}
Difference of Ambient air temperature between Engine coolant temperature (from Engine ECU): < 8 C {46.4 F}
Difference between Exhaust gas temperature (SCR inlet) and Engine coolant temperature (from Engine ECU): <
8 C {46.4 F}
Difference between DEF tank temperature and Ambient air temperature: > 50 C {122 F} for 2 sec.
3. Reset condition
• When the starter switch is ON and the difference among the outside temperature, exhaust temperature, and coolant
temperature is less than 8 C {46.4 F}, the difference between the DEF tank temperature and the outside tempera-
ture is less than 50 C {122 F}.

• MIL: ON

• –

• Control does not work properly when DEF freezes.

• Poor connector contact or faulty connector fit
• Failure of DEF tank temperature sensor
• Failure of ambient air temperature sensor
• Failure of exhaust gas temperature sensor (SCR inlet)
• Failure of engine coolant temperature sensor
1 Inspect the DEF tank temperature sensor connector
1. Check the connection of the DEF tank temperature sensor con-

YES NO

MATION section.

Ambient air
temperature
sensor
Bumper
SAPH16F020400112
YES NO

MATION section.

ture sensor.

YES NO

MATION section.

HH1- HH1+
HH1- HH1+
LGK LJK
Measurement Tester
Standard values
Ambient air tem-

Starter switch:
perature sensor 1.7 k
LOCK
SAPH16F020400113 HH1+ – HH1-
YES NO

MATION section.

poor contact).
YES NO

MATION section.
6 Inspect the ambient air temperature sensor harness
measure the resistance between the terminals of DCU 86P vehi-
cle-side connector.
ATS- ATSS
SAPH16F020400114
Measurement Tester
Standard values
DCU 86P vehicle-

Starter switch:
side connector 3.7 k
LOCK
ATSS – ATS-
YES NO

YES NO

MATION section.
8 Inspect the external resistor connector unit

ER- ER+
Measurement Tester
Standard values

2 k
LOCK ER+ – ER-
SAPH16F020400115
YES NO
Repair or replace the harness. Replace the external resistor.


YES NO

MATION section.

(SCR inlet).


YES NO

(SCR inlet).
MATION section.
1. Disconnect the exhaust gas temperature sensor connector.
FAT- FAT+
Measurement Tester
Standard values
Exhaust gas tem-

Starter switch: perature sensor
220 
LOCK (SCR inlet)
FAT+ – FAT-
SAPH16F020400116
YES NO

(SCR inlet).
MATION section.

YES NO

MATION section.

perature sensor.
YES NO

MATION section.
1. Disconnect an engine coolant temperature sensor connector.
WTM- WTM+
Measurement Tester
Standard values

LOCK sor 80 C {176 F}:
WTM+ – WTM- 0.310 – 0.326 k
SAPH16F020400117
YES NO

sor.
MATION section.
3. Select [DCU] and check if P205B has been detected.
SAPH16F020400118
Has DTC P205B been detected?
YES NO

DTC: P205C
EN01H16F02040F03001036
DTC: P205C DEF tank temperature sensor - out of range (Out of range low)
INFORMATION
Engine
ECU
DCU
#S5 #S5 #AW #AW LF5
(CA1H) LCM (CAH1)
H H
#S7 #S7 #AV #AV LF6
(CA1L) LCN (CAL1)
L L
Twist
Twist
Twist
(EXT+)
(CANH) K6V #SD #SD #CP #CP
(EXT-)
(CANL) K6W #SF #SF #CQ #CQ LEY

(CAH0)
LEZ
Twist
Twist
(CAL0)
Twist
Common rail_
CAN_J/C1
(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
Twist
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
%KP
(CANH)
%KN
(CANL)
Twist Twist Twist
Twist
(CANH)
(CANL)
(CANH)
(CANH)
(CANL)
(CANL)
LEJ
LEK
LEC
LED
LE9
LE8
L H H H
L L
DEF sensor NOx NOx

SAPH16F020400119

Starter switch ON.
Failure of DEF tank temperature sensor 1 (Low failure flag) is received from CAN data.
3. Reset condition

• MIL: ON


• –


SAPH16F020400120
YES NO
Go to diagnosis procedure of a related DTC. Replace the DEF tank temperature sensor 1.
MATION section.
DTC: P205D
EN01H16F02040F03001037
DTC: P205D DEF tank temperature sensor - out of range (Out of range high)
INFORMATION
Engine
ECU
DCU
#S5 #S5 #AW #AW LF5
(CA1H) LCM (CAH1)
H H
#S7 #S7 #AV #AV LF6
(CA1L) LCN (CAL1)
L L
Twist
Twist
Twist
(EXT+)
(CANH) K6V #SD #SD #CP #CP
(EXT-)
(CANL) K6W #SF #SF #CQ #CQ LEY

(CAH0)
LEZ
Twist
Twist
(CAL0)
Twist
Common rail_
CAN_J/C1
(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
Twist
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
%KP
(CANH)
%KN
(CANL)
Twist Twist Twist
Twist
(CANH)
(CANL)
(CANH)
(CANH)
(CANL)
(CANL)
LEJ
LEK
LEC
LED
LE9
LE8
L H H H
L L
DEF sensor NOx NOx

SAPH16F020400121

Starter switch ON.
Failure of DEF tank temperature sensor 1 (High failure flag) is received from CAN data.
3. Reset condition

• MIL: ON


• –


SAPH16F020400122
YES NO
Go to diagnosis procedure of a related DTC. Replace the DEF tank temperature sensor 1.
MATION section.
DTC: P206C
EN01H16F02040F03001038
DTC: P206C DEF quality sensor - short circuit

INFORMATION

(CA1H) LCM
H H
(CA1L) LCN
L L
Twist
Twist
Twist
Engine DCU
ECU
LEY
(CAH0)
(CAL0)

Twist
Twist
Twist

(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
%KN
(CANL)
%KP
(CANH)
%KR
(CANH)
%KQ
(CANL)
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
Twist
Twist (CANH)
(CANH)
Twist
(CANL)
(CANL)
LEC
LED
LE9
(CANH)
LE8
(CANH)
(CANL)
(CANL)
DEF sensor
LEJ
LEK
LQN
LQK
L H L H
(DEF tank H
L
level sensor)
NOx NOx
sensor
SAPH16F020400123
• The DEF quality sensor is connected via the engine ECU and DCU through CAN communication, and it sends and
receives data.
• Short circuit of DEF quality sensor is received from CAN data.

Starter switch ON.
Failure of DEF quality sensor (flag) is received from CAN data.
3. Reset condition

• MIL: ON


• –

• DEF quality sensor failure.

SAPH16F020400124
YES NO
Go to diagnostic procedure of a related DTC. Replace the DEF sensor.

MATION section.
DTC: P206D
DTC: P206D DEF quality sensor - open circuit
INFORMATION

(CA1H) LCM
H H
(CA1L) LCN
L L
Twist
Twist
Twist
Engine DCU
ECU
LEY
(CAH0)
(CAL0)

Twist
Twist
Twist

(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
%KN
(CANL)
%KP
(CANH)
%KR
(CANH)
%KQ
(CANL)
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
Twist
Twist
(CANH)
(CANH)
Twist
(CANL)
(CANL)
LEC
LED
LE9
(CANH)
LE8
(CANH)
(CANL)
(CANL)
DEF sensor
LEJ
LEK
LQN
LQK
L H L H
(DEF tank H
L
level sensor)
NOx NOx
sensor
SAPH16F020400125
• The DEF quality sensor is connected via the engine ECU and DCU through CAN communication, and it sends and
receives data.
• Open circuit of DEF quality sensor is received from CAN data.

Starter switch ON.
Failure of DEF quality sensor (flag) is received from CAN data.
3. Reset condition

• MIL: ON


• –

• DEF quality sensor failure.

SAPH16F020400126
YES NO
Go to diagnostic procedure of a related DTC. Replace the DEF sensor.

MATION section.
DTC: P208A
EN01H16F02040F03001039
DTC: P208A DEF pump motor - circuit (Open load)

INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400127
• DCU determines failure of DEF pump motor based on DEF pump circuit voltage.
• Actuator malfunction of DEF pump module is detected.

Starter switch ON.
DEF pump module actuator Duty cycle > 0 %
DEF pump module actuator voltage is in 2.7 V to 5 V range for 2 sec. or more.
3. Reset condition

• MIL: ON

• 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)

• Looseness or poor contact of connector
• DEF pump motor malfunction

poor contact).
YES NO

MATION section.

poor contact).
YES NO

MATION section.
3 Inspect the DEF pump harness

PMP- PMP-
PMP+
PMPS PMPS 2. Disconnect DCU 86P connector.
measure the resistance between the DEF pump vehicle-side con-
PMP+
nector and each terminal of the DCU 86P vehicle-side connector.
Measurement Tester
Standard values
DEF pump vehi-

SAPH16F020400128 cle-side connec-
tor – DCU 86P
Starter switch: vehicle-side con-
1  or less
LOCK nector
PMP+ – PMP+
PMP- – PMP-
PMPS – PMPS

YES NO
Replace the DEF pump, and go to step 4. Repair or replace the harness.
MATION section.
3. Select [DCU] and check if P208A has been detected.
SAPH16F020400129
Has DTC P208A been detected?
YES NO

perform a DPR forced regeneration.) Perform "After-inspection work" of INFOR-
MATION section.
DTC: P208B
EN01H16F02040F03001040
DTC: P208B DEF pump motor - functional

INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400130
• DEF pump motor is used to send DEF to the DEF injector.
• DEF pump motor operates according to the command values from DCU.
• Motor malfunction of DEF pump is detected.

Engine is running.
DEF has finished thawing and SCR inlet temperature > 150 C {302 F}
|Target pump speed – actual speed| > 300 rpm for 5 sec. continuously.
3. Reset condition

• MIL: ON


• –

• DEF pump motor malfunction.
1 Inspection of the DEF pump pressure [HINO DX Ⅱ ]
2. Replace the DEF pump with a new one.
4. Start up the engine and keep the engine idling (about 10 minutes).
5. Select [DCU].
6. Select [DEF pump pressure] from the [Data monitor Setting] and
check if the DEF pressure is maintained around 900 kPa (800 kPa
SAPH16F020400131
– 1050 kPa) {131 psi (116 psi – 152 psi)}.
Standard values
DEF pressure:
900 kPa (800 kPa – 1,050 kPa) {131 psi (116 psi – 152 psi)}
YES NO
Procedure completed. Replace the DCU.

DTC: P208C
EN01H16F02040F03001041
DTC: P208C DEF pump motor - circuit (Circuit low)

INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400132

Engine is running.
DEF pump is operating.
DEF pump motor voltage: Less than 0.66 V for 2 sec. or more
DEF pump is actuating.
3. Reset condition

• MIL: ON



poor contact).
YES NO

MATION section.

poor contact).
YES NO

MATION section.
3 Check the DEF pump wire harness

PMP- PMP-
PMP+
PMPS PMPS 2. Disconnect the DCU 86P connector and the DEF pump connector.
measure the resistance between the DEF pump and each terminal
PMP+
of the DCU 86P vehicle-side connector.
Measurement Tester
Standard values
DEF pump vehi-

tor – DCU 86P
1  or less
LOCK nector
PMP+ – PMP+
PMP- – PMP-
PMPS – PMPS

YES NO
MATION section.
4. Select [DCU] and check if P208C has been detected.
SAPH16F020400134
YES NO
Replace the DCU. (After replacing, perform Procedure completed.

DPR forced regeneration.) Perform "After-inspection work" of INFOR-
MATION section.
DTC: P208D
EN01H16F02040F03001042
DTC: P208D DEF pump motor - circuit (Circuit high)

INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400135

Engine is running.
DEF pump is operating.
DEF pump motor voltage: 2.7 V for 2 sec. or more
DEF pump is actuating.
3. Reset condition

• MIL: ON



poor contact).
YES NO

MATION section.

poor contact).
YES NO

MATION section.
3 Check the DEF pump wire harness

PMP- PMP-
PMP+
PMPS PMPS 2. Disconnect the DCU 86P connector and the DEF pump connector.
measure the resistance between the DEF pump and each terminal
PMP+
of the DCU 86P vehicle-side connector.
Measurement Tester
Standard values
DEF pump vehi-

tor – DCU 86P
1  or less
LOCK nector
PMP+ – PMP+
PMP- – PMP-
PMPS – PMPS

YES NO
MATION section.
4. Select [DCU] and check if P208D has been detected.
SAPH16F020400137
Has DTC P208D been detected?
YES NO

MATION section.
DTC: P20A0
EN01H16F02040F03001043
DTC: P20A0 Reverting valve for DEF pump - circuit (Open load)
INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400138
• DCU detects the circuit failure based on the circuit voltage of the DEF pump reverting valve.
• Failure of reverting valve inside DEF pump is detected.

Starter switch ON.
DEF reverting valve is activated.
DEF reverting valve voltage: > 2.7 V, and < 5 V for 2.0 sec.
3. Reset condition

• MIL: 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.


• –

• Malfunction of DEF reverting valve
INSPECTION PROCEDURE: P20A0
1 Inspect the DEF pump (reverting valve) connector
1. Check the connection of the DEF pump (reverting valve) connector

(Looseness and poor contact).
YES NO

MATION section.
2 Inspect the DEF pump (reverting valve) unit

PMV+
PMV- 2. Disconnect the DEF pump connector.

terminals of the DEF pump (reverting valve).
Measurement Tester
Standard values
DEF pump (revert-

Starter switch: ing valve) connec- 23 C {73.4 F}:
SAPH16F020400139 LOCK tor 2.05 – 12.05 
PMV+ – PMV-
YES NO

MATION section.
3 Inspect for short-circuit in the DEF pump (reverting valve) harness

PMV-
PMV+
SAPH16F020400140
Measurement Tester
Standard values
DCU 86P vehicle-


LOCK PMV+ – Ground
PMV- – Ground
YES NO

MATION section.
4 Inspect disconnection of the DEF pump (reverting valve) harness
PMV-
PMV+
SAPH16F020400141
Measurement Tester
Standard values
DCU 86P vehicle-

Starter switch: 23 C {73.4 F}:
side connector
LOCK 2.05 – 12.05 
PMV+ – PMV-
YES NO

MATION section.
3. Select [DCU] and check if P20A0 has been detected.
SAPH16F020400142
Has DTC P20A0 been detected?
YES NO
Replace the DCU. (Perform a DPR forced Procedure completed.

MATION section.
DTC: P20A1
EN01H16F02040F03001044
DTC: P20A1 Reverting valve for DEF pump stuck close

INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400143
• Reverting valve for DEF pump stuck close is checked by DEF pressure.
• Failure of reverting valve inside DEF pump is detected.

Battery voltage is in the range of 10V to 16V.
800 kPa {116 psi} < DEF pressure < 1,050 kPa {152 psi}.
The pressure sensor indicates 50 kPa {7.3 psi} or higher 25 seconds after the starter switch is turned OFF.
3. Reset condition
• DEF pump pressure sensor drop to 50 kPa {7.3 psi} is detected within 25 seconds after starter switch is turned
OFF.

• MIL: ON
• DEF injector and DEF pipe may rupture when DEF freezes.

• –

• –

• Malfunction of reverting valve for DEF pump
1 Check the operation of the DEF pump (reverting valve) [HINO DX Ⅱ ]
5. Select [DEF pump reverting valve] from [Active test Setting] in the
[Data monitor and Active test] menu and check the operating
sound of the reverting valve.
SAPH16F020400144
Did you hear the operating sound?
YES NO
Go to step 2. Replace DEF pump.

MATION section.
2 Inspect the DEF pump (reverting valve) [HINO DX Ⅱ ]
1. Select [DEF pump position] from the [Active test Setting] menu
and operate the DEF pump.
2. Select [DEF pump pressure] from the [Data monitor Setting] menu
and check the DEF pressure.
Standard values
DEF pressure: less than 50 kPa {7.3 psi}
SAPH16F020400145
YES NO

MATION section.
3 Inspect the DEF tank
1. Disconnect the breather hose and check if it is not clogged, punc-

tured, or cracked.
YES NO
Replace the breather hose. Go to step 4.

MATION section.
1. Start the engine and idle it for 10 minutes while you check if the
DEF pressure is maintained around 900 kPa {131 psi} in [Data
monitor Setting] (800 kPa – 1,050 kPa) {(116 psi – 152 psi)}.
3. Check if the DCU main relay is OFF in the HINO DX Ⅱ menu. (This
cuts off the communication between HINO DX Ⅱ and the DCU.)
4. Select [DCU] and check if P20A1 is detected.

When communicat-
ion with the engine
ECU is interrupted
while the engine
ECU is connected
to the HINO DXⅡ,
the connection
symbol at the left
bottom of the HINO
DXⅡ screen
becomes
disconnected.
SAPH16F020400146
YES NO

DTC: P20A2
EN01H16F02040F03001045
DTC: P20A2 Reverting valve for DEF pump - circuit (Circuit low)
INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400147
• Failure of reverting valve in DEF pump is detected.

Starter switch ON.
DEF reverting valve voltage: < 0.66 V for 2 sec.
3. Reset condition

• MIL: ON


• –


poor contact).
YES NO

MATION section.

PMV+

Measurement Tester
Standard values
DEF pump
Starter switch: (Reverting valve) 23 C {73.4 F}:
SAPH16F020400148 LOCK connector 2.05 – 12.05 
PMV+ – PMV-
YES NO

MATION section.

PMV-
PMV+
SAPH16F020400149
Measurement Tester
Standard values
DCU 86P vehicle-


PMV- – Ground
YES NO

MATION section.
PMV-
PMV+
SAPH16F020400150
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 2.05 – 12.05 
PMV+ – PMV-
YES NO

MATION section.
SAPH16F020400151
YES NO

MATION section.
DTC: P20A3
EN01H16F02040F03001046
DTC: P20A3 Reverting valve for DEF pump - circuit (Circuit high)
INFORMATION
LFJ LG8
(PMP+) (PMP+)
LFL LG9
(PMPS) (PMPS)
LFK LGA
(PMP-) (PMP-)
LFM LGB
(PMV+) (PMV+)
LFN LGC
(PMV-) (PMV-)
Supply module
(DEF pump)
DCU
LFQ LGD
(PSR+) (PSR+)
LFR LGE
(PSRS) (PSRS)
LFP LGF
(PSR-) (PSR-)
SAPH16F020400152
• Failure of reverting valve in DEF pump is detected.

Starter switch ON.
DEF reverting valve voltage: ≤ 2.7 V for 2 sec.
3. Reset condition

• MIL: ON
• DEF injector and DEF pipe may rupture when DEF freezes.

• –

• –


poor contact).
YES NO

MATION section.

PMV+

Measurement Tester
Standard values
DEF pump
Starter switch: (Reverting valve) 23 C {73.4 F}:
SAPH16F020400153 LOCK connector 2.05 – 12.05 
PMV+ – PMV-
YES NO

MATION section.
PMV-
PMV+
SAPH16F020400154
Measurement Tester
Standard values
DCU 86P vehicle-


PMV- – Ground
YES NO

MATION section.
PMV-
PMV+
SAPH16F020400155
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 2.05 – 12.05 
PMV+ – PMV-
YES NO

MATION section.
5 Check the DTC detected [DCU]
SAPH16F020400156
YES NO

MATION section.
DTC: P20B1
EN01H16F02040F03001047
DTC: P20B1 Coolant cut off valve - circuit (Open load)

INFORMATION
Coolant cut LDU LFA

(+) (WMV+)
off valve
LDV LFB DCU
(DEF tank (E) (WMV-)
heater valve) Twist Twist
SAPH16F020400157
• DCU detects malfunctions based on the coolant cut off valve (DEF tank heater valve) circuit voltage.
• Malfunction of coolant cut off valve (DEF tank heater valve) is detected.

Starter switch ON.
Coolant cut off valve (DEF tank heater valve) duty > 0%
Coolant cut off valve (DEF tank heater valve) voltage is more than 2.7 V and less than 5 V for 0.5 sec.
3. Reset condition

• MIL: ON


• –

• Looseness or unsteady contact of connectors
• Coolant cut off valve (DEF tank heater valve) malfunction
INSPECTION PROCEDURE: P20B1
1 Inspect the coolant cut off valve (DEF tank heater valve) connector
1. Check the connection of the coolant cut off valve (DEF tank heater
valve) connector (Looseness and poor contact).
YES NO

MATION section.
2 Check the coolant cut off valve (DEF tank heater valve) unit

LDV LDU
2. Disconnect the connector of the coolant cut off valve (DEF tank
heater valve).

terminals of the coolant cut off valve (DEF tank heater valve).
Measurement Tester
Standard values
Coolant cut off

SAPH16F020400158 valve (DEF tank
heater valve) con-
LOCK 9.04 – 9.52 
nector
LDU – LDV
YES NO
Go to step 3. Replace the coolant cut off valve (DEF tank

heater valve).
MATION section.
3 Check for short-circuit in the coolant cut off valve (DEF tank heater valve) wire harness
measure the resistance between the ground and each terminal of
the DCU 86P vehicle-side connector.
WMV+
WMV-
SAPH16F020400159
Measurement Tester
Standard values
DCU 86P vehicle-


LOCK WMV+ – Ground
WMV- – Ground
YES NO

MATION section.
4 Check for disconnection in the coolant cut off valve (DEF tank heater valve) wire harness
1. Connect the coolant cut off valve (DEF tank heater valve) connec-
tor.
WMV+
WMV-
SAPH16F020400160
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 9.04 – 9.52 
WMV+ – WMV-
YES NO

MATION section.
3. Select [Engine] and check if P20B1 has been detected.
SAPH16F020400161
YES NO

MATION section.
DTC: P20B2
EN01H16F02040F03001048
DTC: P20B2 Coolant cut off valve stuck

INFORMATION
Coolant cut LDU LFA

(+) (WMV+)
off valve
LDV LFB DCU
SAPH16F020400162
• Coolant cut off valve (DEF tank heater valve) malfunction is judged by using the value of DEF tank temperature
sensor.
• There are 2 types of coolant cut off valve (DEF tank heater valve) malfunction: "stuck open" and "stuck closed".
• Malfunction of coolant cut off valve (DEF tank heater valve) is detected.

When stuck in open position
1. Starter switch ON.
When stuck in closed position
2. Coolant cut off valve (DEF tank heater valve) open (DEF defrosts)
Coolant temperature is more than 40 C {104 F}.
When stuck in open position
1. DEF tank temperature is more than 75 C {167 F} for 10 seconds (Judged by whether the DEF tank is abnor-
mally heated.)
When stuck in closed position
2. Rise in the DEF tank temperature after 1,000 to 1,200 seconds in condition 2. above: Within 1 C {33.8 F}
(Judged by the fact that the temperature does not rise even when the DEF tank is heated.)
3. Reset condition
• When stuck in open position
After having restored to the normal conditions.
• When stuck in closed position
Temperature rises at least 1°C {33.8 F} 1,000 to 1,200 seconds after valve opens (defrosts).

• MIL: ON


• –
• If DTC P20B1 is detected simultaneously, start DTC P20B1 inspection first.

• Coolant cut off valve (DEF tank heater valve) closed stuck or open stuck
• Blockage or leakage of coolant pipes
• Looseness or unsteady contact of connector
• DEF tank temperature sensor malfunction
• Engine coolant temperature sensor malfunction
NOTICE
.
1. If the heat source is brought close to the DEF tank or the heated DEF is supplied, P20B2 may be detected.
2. "Stuck closed" will be detected only at low temperatures where defrosting of DEF is necessary.
4. Select [DCU] and check if any DTC other than P20B2 (for exam-
ple, P20B1, U02A2) has been detected.
SAPH16F020400163
Has a DTC other than P20B2 been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.
2 Inspect the DEF tank temperature sensor connector
1. Check if the connection of the DEF tank temperature sensor con-

nector (Looseness or poor contact).
YES NO

MATION section.
3 Inspect the engine coolant system (pipes or hoses)
1. Check for leakage 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).
YES NO

MATION section.
1. Check the connection of the engine coolant sensor connector

(Looseness or poor contact).
YES NO
Connect securely. Repair if needed. Go to step 5.

MATION section.

perature sensor.
YES NO

MATION section.
WTM- WTM+
Measurement Tester
Standard values

LOCK sor 80 C {176F}:
WTM + – WTM- 0.310 – 0.326 k
SAPH16F020400164

YES NO

sor.
MATION section.
7 Inspect the coolant cut off valve (DEF tank heater valve) connector
1. Check the connection of the coolant cut off valve (DEF tank heater
valve) connector.
YES NO
Connect securely. Repair if needed. Go to step 8.

MATION section.
8 Coolant cut off valve (DEF tank heater valve) actuation test [HINO DX Ⅱ ]
3. Select [Coolant shutoff valve] from the [Active test Setting] menu
and check the coolant cut off valve (DEF tank heater valve) operat-
ing noise.
SAPH16F020400165
Operating noise is heard?
YES NO

heater valve).
MATION section.
9 Inspect the engine coolant temperature [HINO DX Ⅱ ]
1. Select [DEF tank temperature] and [Engine coolant temperature]

from [Data monitor Setting].
3. Check if the DEF tank temperature rises when the coolant temper-
ature is 40 C {104 F} or higher.
SAPH16F020400166
Did DEF tank temperature rise?
YES NO
heater valve).
MATION section.
10 Inspect the coolant cut off valve (DEF tank heater valve) unit

LDV LDU
2. Disconnect the coolant cut off valve (DEF tank heater valve) con-
nector.
3. Use the electrical tester to measure the resistance of the terminals

of the coolant cut off valve (DEF tank heater valve).
Measurement Tester
Standard values
Coolant cut off

SAPH16F020400167 valve (DEF tank
heater valve) con-
LOCK 9.04 – 9.52 
nector
LDU – LDV

YES NO
heater valve).
MATION section.
11 Inspect the coolant cut off valve (DEF tank heater valve)
1. Twenty seconds after the engine has started, grasp the pipe down-
stream of the coolant cut off valve (DEF tank heater valve) and
check if the pressure drops.
Did the pressure drop?
YES NO
heater valve).
MATION section.
12 Inspect the DEF sensor
1. Remove the coolant hose (upstream, downstream) from DEF sen-

sor.
side.
YES NO
Replace the DEF sensor. Go to step 13.

MATION section.
13 Inspect the DEF pump
1. Remove the coolant hose (upstream, downstream) from DEF

pump.
side.
YES NO
Replace the DEF pump. Go to step 14.

MATION section.
14 Replace the DEF tank temperature sensor
1. Replace the DEF tank temperature sensor.
2. Warm up the engine. (engine coolant temperature: 60 C {140 F}

or more)
3. Stop the engine.
SAPH16F020400168
Has the DTC P20B2 been detected?
YES NO

DTC: P20B3
EN01H16F02040F03001049
DTC: P20B3 Coolant cut off valve - circuit (Circuit low)

INFORMATION
Coolant cut LDU LFA

(+) (WMV+)
off valve
LDV LFB DCU
SAPH16F020400169
• DCU detects malfunctions based on the coolant cut off valve (DEF tank heater valve) circuit voltage.
• Malfunction of coolant cut off valve is detected.

Starter switch ON.
Coolant cut off valve duty > 0%
Coolant cut off valve voltage < 0.66 V for 0.05 sec.
3. Reset condition

• MIL: ON

• –


• Coolant cut off valve malfunction
1 Inspect the coolant cut off valve connector
1. Check the connection of the coolant cut off valve connector

YES NO
2 Inspect the coolant cut off valve unit

LDV LDU
2. Remove the connector of the coolant cut off valve.

terminals of the coolant cut off valve.
Measurement Tester
Standard values
Coolant cut off

valve connector
LOCK 9.04 – 9.52 
SAPH16F020400170 LDU – LDV
YES NO
Go to step 3. Replace the coolant cut off valve.

MATION section.
3 Check for short-circuit in the coolant cut off valve wire harness
WMV+
WMV-
SAPH16F020400171
Measurement Tester
Standard values
DCU 86P vehicle-


WMV- – Ground
YES NO

MATION section.
4 Check for disconnection in the coolant cut off valve wire harness
1. Connect the coolant cut off valve connector.
measure resistance between the terminals of the DCU 86P vehi-
cle-side connector.
WMV+
WMV-
SAPH16F020400172
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 9.04 – 9.52 
WMV+ – WMV-
YES NO

MATION section.
SAPH16F020400173
YES NO

MATION section.
DTC: P20B4
EN01H16F02040F03001050
DTC: P20B4 Coolant cut off valve - circuit (Circuit high)

INFORMATION
Coolant cut LDU LFA

(+) (WMV+)
off valve
LDV LFB DCU
SAPH16F020400174
• DCU detects malfunctions based on the coolant cut off valve circuit voltage.
• Malfunction of coolant cut off valve is detected.

Starter switch ON.
Coolant cut off valve duty > 0%
Coolant cut off valve voltage = 2.7 V for 0.1 sec.
3. Reset condition

• MIL: ON

• –


• Coolant cut off valve malfunction
1 Inspect the coolant cut off valve connector
1. Check the connection of the coolant cut off valve connector

YES NO

MATION section.
2 Check the coolant cut off valve unit

LDV LDU
2. Remove the connector of the coolant cut off valve.

terminals of the coolant cut off valve.
Measurement Tester
Standard values
Coolant cut off

valve connector
LOCK 9.04 – 9.52 
SAPH16F020400175 LDU – LDV
YES NO
Go to step 3. Replace the coolant cut off valve.

MATION section.
3 Check for short-circuit in the coolant cut off valve wire harness
WMV+
WMV-
SAPH16F020400176
Measurement Tester
Standard values
DCU 86P vehicle-


WMV- – Ground
YES NO

MATION section.
4 Check for disconnection in the coolant cut off valve wire harness
1. Connect the coolant cut off valve connector.
WMV+
WMV-
SAPH16F020400177
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 9.04 – 9.52 
WMV+ – WMV-
YES NO

MATION section.
SAPH16F020400178
YES NO

MATION section.
DTC: P20BD, P20B9 and P20C1

EN01H16F02040F03001051
DTC: P20BD DEF heater 1 failure (Open load / low)

DTC: P20B9 DEF heater 2 failure (Open load / low)
DTC: P20C1 DEF heater 3 failure (Open load / low)
INFORMATION
DEF heater relay DEF heater 3

FUSE DEF HTR #GN #GN &TM &TM &TJ &TJ
A8M KLC KLD (HTR+) (HTR-)
(29LD) (B ) (LD ) L0F L0J
KLA KLB #GQ #GQ &TK &TK &TG &TG
(S+ ) (S- ) DEF heater 2
#GP #GP &TL &TL &TH &TH (HTR+) (HTR-)
L0E L0H
DEF heater 1
(HTR+) (HTR-)
L0D L0G
LG2
LFX
LV1
LFZ
LV2
(HH1-)
(HH2-)
(HH3-)
(HHR+)
(HHR-)
DCU 53P DCU 86P
SAPH16F020400179
• Electrify the DEF heater to prevent the freezing of DEF pipings.
• DCU detects harness disconnection or short-circuit based on the DEF heater circuit voltage.
• Malfunction of DEF heater is detected.

• Starter switch ON.
• When the DEF defrosting control is disabled (DCU detects the ambient temperature > -5 C {23 F})
Voltage difference of DEF heater 1 drive FET (DCU internal element) is less than 2 V. (P20BD)
Voltage difference of DEF heater 2 drive FET (DCU internal element) is less than 2 V. (P20B9)
Voltage difference of DEF heater 3 drive FET (DCU internal element) is less than 2 V. (P20C1)
3. Reset condition

• MIL: ON
• SCR malfunction light: Blink
• "SCR malfunction" appears on the multi-information.


• Deterioration of the function to prevent the freezing of DEF pipings.
• Clear all past DTCs. (Also clear DTC P204F (DEF SCR system failure) of the engine ECU side.)
• Using HINO DX Ⅱ , set DEF heater ON for 10 seconds and after this set to OFF.

• Harness disconnection or short-circuit of GND
• DEF heater (1, 2 or 3) malfunction
• DEF heater relay malfunction
• FUSE DEF HTR malfunction
• Harness short-circuit
• DCU malfunction
INSPECTION PROCEDURE: P20BD, P20B9 and P20C1
1 Inspect the fuse
1. Check the fuse (FUSE DEF HTR) for fusing or improper fit.
YES NO
Connect the fuse properly or replace. Go to step 2.

MATION section.
2 Inspect the DEF heater relay
1. Check the connection of the DEF heater relay (inside cab) (Loose-
ness or poor contact).
YES NO

MATION section.
3 Inspect the DEF heater relay unit
2. Disconnect the DEF heater relay.

terminals of the DEF heater relay.
Tester connections Standard values
1 in the figure: 320 

DEF heater relay terminals
2 in the figure:  
SAPH16F020400180
YES NO
Go to step 4. Replace the DEF heater relay.

MATION section.
4 Inspect the DEF heater relay power supply circuit

DEF HTR RLY
B
B S+ 2. Use the electrical tester to measure the voltage between each ter-
KLC
S+
KLA
minal in the DEF heater relay vehicle-side connector (inside the
cab) and ground.
Measurement Tester
Standard values
DEF heater relay

Starter switch: ON vehicle-side con-
Disconnect DEF nector 10 V or more
SAPH16F020400181 heater relay B – Ground
S+ – Ground
YES NO
Go to step 5. Repair or replace the DEF heater relay power

supply circuit.
MATION section.
5 Inspect the DEF heater (1, 2 or 3) connector
1. Check the connection of the DEF heater (1, 2 or 3) connector

DEF heater 1 (Looseness and poor contact).
DEF heater 2
DEF heater 3
SAPH16F020400182
YES NO

MATION section.
6 Inspect the DEF heater (1, 2 or 3) pipe
1. Check for cracks (leakage of DEF, etc) in the DEF heater (1, 2 or
3) pipe.
YES NO
Replace the DEF heater pipe. Go to step 7.

MATION section.
7 Inspect the DEF heater (1, 2 or 3) power supply circuit (1)
3. Disconnect the DEF heater (1, 2 or 3) connector.
4. Use the electrical tester to measure the continuity between the ter-
minals of the DEF heater relay vehicle-side connector (inside the
cab) and the DEF heater (1, 2 or 3) vehicle-side connector.
HTR+ HTR+
DEF HTR RLY HTR+
S-
KLB
B LD
KLC KLD
S+
KLA
LD
DEF HTR RLY DEF heater 1 DEF heater 2 DEF heater 3

SAPH16F020400183
Measurement Tester
Standard values
Starter switch: DEF heater relay

LOCK vehicle-side con-
Disconnect the nector – DEF
DEF heater relay heater (1, 2 or 3) Continue
Disconnect the vehicle-side con-
DEF heater connector
nector LD – HTR+

YES NO

MATION section.
minals of the DEF heater (1, 2 or 3) vehicle-side connector and the
terminals of the DCU 86P vehicle-side connector.
HH1-
HTR-
LFX
HH3-
LG2
HH1-
HH2- WMV+
LFZ LFA
HH3-
HH1- DEF heater 1
LFX
DMH DML
LF8 LF9
EXT+
LFG
EXT-
LFH HH3-
LG2
HTR- HTR-
PSRS
LFR
ATS- PSR-
LNN LFP
ATSS PSR+
LNM LFQ
HH2- WMV+
LFZ LFA
DEF heater 2 DEF heater 3

PMPS
LFL
WMV-
LFB
PMV-
LFN
HH2-
PMV+ PMP+ PMP-
LFM LFJ LFK
SAPH16F020400184
Measurement Tester
Standard values
Starter switch:
DEF heater (1, 2 or
LOCK
3) connector –
Disconnect the
DCU 86P vehicle-
DEF heater con-
side connector Continue
nector
HTR- – HH1-
Disconnect the
HTR- – HH2-
DCU 86P connec-
HTR- – HH3-
tor

YES NO

MATION section.
9 Inspect the DEF heater (1, 2 or 3) unit
minals of the DEF heater (1, 2 or 3).
HTR+ HTR- HTR+ HTR-

HTR+ HTR-
DEF heater 1 DEF heater 2 DEF heater 3

SAPH16F020400185
Measurement Tester
Standard values
Starter switch:
LOCK DEF heater (1, 2 or
Disconnect the 3) Continue
DEF heater con- HTR+ – HTR-
nector
YES NO
Replace the DCU. Replace the DEF heater (1, 2 or 3).

Go to step 10. Perform "After-inspection work" of INFOR-
MATION section.
1. Start the engine and keep the engine idling for about 10 minutes at
room temperature (Around 20 C {68 F}).
4. Select [DCU].
5. Set up data monitor [DEF tank temperature], [DEF pump tempera-

ture #1] and [Outside temperature].
6. Go to next [7], if every temperature values are exceeding -5 C {23

SAPH16F020400186
F}. Go back to [1], if either temperature value is not exceeding -5
C {23 F}.
7. Set the starter switch to the "LOCK" position for 30 second.
Has DTC P20BD, P20B9 and P20C1 been detected?
YES NO

DTC: P20C0, P20BC and P20C4

EN01H16F02040F03001052
DTC: P20C0 DEF heater 1 failure (High)

DTC: P20BC DEF heater 2 failure (High)
DTC: P20C4 DEF heater 3 failure (High)
INFORMATION

(29LD) (B ) (LD ) L0F L0J
L0E L0H
DEF heater 1
(HTR+) (HTR-)
L0D L0G
LG2
LFX
LV1
LFZ
LV2
(HH1-)
(HH2-)
(HH3-)
(HHR+)
(HHR-)
DCU 53P DCU 86P
SAPH16F020400187
• DCU detects +B short-circuit based on the DEF heater circuit voltage.
• Malfunction of DEF heater is detected.

• DEF defrosting control ON.
Voltage difference of DEF heater 1 drive FET (DCU internal element) is more than 0.1 V. (P20C0)
Voltage difference of DEF heater 2 drive FET (DCU internal element) is more than 0.1 V. (P20BC)
Voltage difference of DEF heater 3 drive FET (DCU internal element) is more than 0.1 V. (P20C4)
3. Reset condition

• MIL: ON

• -

(Also clear DTC P204F (DEF SCR system failure) of the engine ECU side.)
• Using HINO DX Ⅱ , set DEF heater ON for 10 seconds.

• Harness disconnection or short-circuit of +B
• DEF heater (1, 2 or 3) malfunction
INSPECTION PROCEDURE: P20C0, P20BC and P20C4
4. Select [DCU] and check if any DTC below (related with DEF heater
relay) has been detected.
P20FC, P20FD, P20FE
SAPH16F020400188
Has any DTC been detected?
YES NO
2 Inspect the DEF heater (1, 2 or 3) connector
1. Check the connection of the DEF heater (1, 2 or 3) connector

DEF heater 1 (Looseness and poor contact).
DEF heater 2
DEF heater 3
SAPH16F020400189
YES NO

MATION section.
3 Inspect the DEF heater (1, 2 or 3) pipe
1. Check for cracks (leakage of DEF, etc) in the DEF heater (1, 2 or
3) pipe.

YES NO
Replace the DEF heater pipe. Go to step 4.

MATION section.
3. Disconnect the DEF heater (1, 2 or 3) connector.

(P20FD is detected, but it is no problem as it is caused by the dis-
connection of the DEF heater relay.)
nals of the DEF heater (1, 2 or 3) vehicle-side connector and the
ground.
HTR+ HTR+
HTR+

SAPH16F020400190
minals of the DEF heater (1, 2 or 3) vehicle-side connector and the
ground.
HTR+ HTR+
HTR+

SAPH16F020400191
Measurement Tester
Standard values
Starter switch: ON DEF heater (1, 2 or

Disconnect DEF 3) vehicle-side
5: 0 V
heater relay connector –
6: No Continuity
Disconnect DEF Ground
heater connector HTR+ – Ground
YES NO

MATION section.
2. Connect the DEF heater (1, 2 or 3) connector.

(P20FD is detected, but it is no problem as it is caused by the dis-
connection of the DEF heater relay.)
nals of the DCU 86P vehicle-side connector and the ground.
HH1-
LFX
HH3-
LG2
HH1- (DEF heater 1)
HH2- WMV+
LFZ LFA
HH3- (DEF heater 3)

HH1-
LFX HH2- (DEF heater 2)
DMH DML
LF8 LF9
EXT+
LFG
EXT-
LFH HH3-
LG2
PSRS
LFR
ATS- PSR-
LNN LFP
ATSS PSR+
LNM LFQ
HH2- WMV+
LFZ LFA
PMPS
LFL
WMV- PMV-
LFB LFN
PMV+ PMP+ PMP-

LFM LFJ LFK
SAPH16F020400192
minals of the DCU 86P vehicle-side connector and the ground.
HH1-
LFX
HH3-
LG2
HH1- (DEF heater 1)
HH2- WMV+
LFZ LFA
HH3- (DEF heater 3)

HH1-
LFX HH2- (DEF heater 2)
DMH DML
LF8 LF9
EXT+
LFG
EXT-
LFH HH3-
LG2
PSRS
LFR
ATS- PSR-
LNN LFP
ATSS PSR+
LNM LFQ
HH2- WMV+
LFZ LFA
PMPS
LFL
WMV- PMV-
LFB LFN
PMV+ PMP+ PMP-

LFM LFJ LFK
SAPH16F020400193
Measurement Tester
Standard values
DCU 86P vehicle-

side connector –
Starter switch: ON
Ground 5: 0 V
Disconnect DEF
HH1- – Ground 6: No Continuity
heater relay
HH2- – Ground
HH3- – Ground
YES NO

DTC: P20FC
EN01H16F02040F03001053
DTC: P20FC DEF heater relay failure (Open load)

INFORMATION

(29LD) (B ) (LD ) L0F L0J
L0E L0H
DEF heater 1
(HTR+) (HTR-)
L0D L0G
LG2
LFX
LV1
LFZ
LV2
(HH1-)
(HH2-)
(HH3-)
(HHR+)
(HHR-)
DCU 53P DCU 86P
SAPH16F020400194
• DCU detects harness disconnection based on the DEF heater circuit voltage.
• Malfunction of DEF heater relay is detected.

Starter switch ON.
DEF heater relay is in active condition.
DEF heater relay voltage more than 2.7 V and less than 5 V.
3. Reset condition

• MIL: ON
• "SCR malfunction" appears on the multi-information.



• Harness disconnection
INSPECTION PROCEDURE: P20FC
YES NO

MATION section.


SAPH16F020400195
YES NO

MATION section.

DEF HTR RLY
B
KLC
S+
KLA
cab) and ground.
Measurement Tester
Standard values
DEF heater relay

S+ – Ground
YES NO

supply circuit.
MATION section.
4 Check the harness between the DEF heater relay and the DCU

+B2 GND4 GND1 DEF HTR RLY
LEP LEW LET
+B3
LEQ
GND5
LEX
GND2
LEU
S
+B4
LER
+B1
LEN
GND3
LEV
HHR- 2. Disconnect the DCU 53P connector.
S-
CAH1
LF5
CAL1
LF6
IGSW HHR- HHR+
TE1B
LF2
TE1A CAH0
LES LV2 LV1
LF1 LEY
TE2B
LF4
TE2A
CAL0
LEZ cab) and the terminals of the DCU 53P connector.
LF3
IGSW HHR- HHR+

Measurement Tester
Standard values
LES LV2 LV1

SAPH16F020400197 LOCK vehicle-side con-
Disconnect DEF nector – DCU 53P
Continue
heater relay vehicle-side con-
Disconnect DCU nector
53P connector S- – HHR-
YES NO

DTC: P20FD
EN01H16F02040F03001054
DTC: P20FD DEF heater relay failure (Low)

INFORMATION

(29LD) (B ) (LD ) L0F L0J
L0E L0H
DEF heater 1
(HTR+) (HTR-)
L0D L0G
LG2
LFX
LV1
LFZ
LV2
(HH1-)
(HH2-)
(HH3-)
(HHR+)
(HHR-)
DCU 53P DCU 86P
SAPH16F020400198
• Electrify the DEF heater relay to prevent the freezing of DEF pipings.
• DCU detects DEF heater relay failure (low) based on the DEF heater circuit voltage.

Starter switch ON.
DEF heater relay circuit voltage is less than 0.66 V.
3. Reset condition

• MIL: ON

• -


• Harness short-circuit of GND
INSPECTION PROCEDURE: P20FD
YES NO

MATION section.


SAPH16F020400199
YES NO

MATION section.

DEF HTR RLY
B
KLC
S+
KLA
cab) and ground.
Measurement Tester
Standard values
DEF heater relay

S+ – Ground
YES NO

supply circuit.
MATION section.

LEP LEW LET
+B3
LEQ
GND5
LEX
GND2
LEU
S
+B4
LER
+B1
LEN
GND3
LEV
HHR- 2. Disconnect the DEF heater relay.
S-
CAH1
LF5
CAL1
LF6
IGSW HHR- HHR+
TE1B LES LV2 LV1
LF2
TE1A CAH0
LF1 LEY
TE2B
LF4
TE2A
CAL0
LEZ
LF3

IGSW
LES
HHR-
LV2
HHR+
LV1
cab) and the terminals of the DCU 53P connector.
Measurement Tester
Standard values
SAPH16F020400201

Continue
YES NO

DTC: P20FE
EN01H16F02040F03001055
DTC: P20FE DEF heater relay failure (High)

INFORMATION

(29LD) (B ) (LD ) L0F L0J
L0E L0H
DEF heater 1
(HTR+) (HTR-)
L0D L0G
LG2
LFX
LV1
LFZ
LV2
(HH1-)
(HH2-)
(HH3-)
(HHR+)
(HHR-)
DCU 53P DCU 86P
SAPH16F020400202
• Electrify the DEF heater relay to prevent the freezing of DEF pipings.
• DCU detects +B short-circuit based on the DEF heater circuit voltage.

Starter switch ON.
DEF heater relay circuit voltage is less than 2.7 V.
3. Reset condition

• MIL: ON

• -


• Harness short-circuit
INSPECTION PROCEDURE: P20FE
YES NO

MATION section.


SAPH16F020400203
YES NO

MATION section.

DEF HTR RLY
B
KLC
S+
KLA
cab) and ground.
Measurement Tester
Standard values
DEF heater relay

S+ – Ground
YES NO

supply circuit.
MATION section.

LEP LEW LET
+B3
LEQ
GND5
LEX
GND2
LEU
S
+B4
LER
+B1
LEN
GND3
LEV
HHR- 2. Disconnect the DEF heater relay.
S-
CAH1
LF5
CAL1
LF6
IGSW HHR- HHR+
TE1B LES LV2 LV1
LF2
TE1A CAH0
LF1 LEY
TE2B
LF4
TE2A
CAL0
LEZ
LF3

IGSW
LES
HHR-
LV2
HHR+
LV1
cab) and the terminals of the DCU 53P connector.
Measurement Tester
Standard values
SAPH16F020400205

Continue
YES NO

DTC: P20E8
EN01H16F02040F03001056
DTC: P20E8 Suction line pressure build up check

INFORMATION
Breather hose Coolant outlet

Harness connector
DEF back flow

(To DEF tank)
DEF suction line Coolant inlet DEF suction line

DEF tank Coolant inlet
DEF back flow (To DEF tank)
DEF back flow
(To DEF tank) DEF pressure line (outlet) Coolant outlet
DEF pressure line (outlet)
DEF suction line
DEF pump
DEF sensor
(strainer) DEF pump
DEF Injector
To DEF SCR
catalyst
Inside muffler
DEF tank
DEF circuit
SAPH16F020400206
• DEF line pressure depends on ejection of the DEF pump.
• DEF pump ejection is determined by value of DEF pressure sensor which is built in DEF pump.
• Abnormal pressure in the DEF pipe is detected.

Exhaust gas temperature (SCR inlet) > 150 C {302 F}
DEF defrosting is done.
DEF pressure does not rise to 650 kPa {94 psi} or more for approx. 6 minutes during "Pressure Build Up Mode".
<Sample: Normal DEF Pressurizing Manner>
Monitoring Condition
(1) SCR inlet temp > 150 ˚C {302 ˚F}
(2) DEF defrosting is done.
Starter switch-On Starter switch-Off
Standby Detection Mode DEF injection start

Metering Control After-run
Pressure Build Up
Pump Opening: 75% Emptying start
950 kPa {138 psi}
DEF pressure
850 kPa {123 psi}
650 kPa {94 psi}
SCR inlet Temp

150 ˚C {302 ˚F}
SAPH16F020400207
3. Reset condition

• MIL: ON


• –

• DEF in the DEF tank is empty.
• Strainer in the DEF sensor is clogged.
• Air is entering into DEF suction line.
• DEF suction line is clogged (frozen), or DEF leaks from DEF suction line.
• DEF pump main filter element is clogged.
• DEF pump inlet connector filter is clogged.
• Leak from DEF pump.
• DEF pump malfunction.
• Clogged DEF tank breather hose.
NOTICE
DEF -SCR system can be damaged by Diesel filling up to the tank.
If DEF pump main filter has a yellow slime, it is an evidence of biodiesel filled to the tank.
INSPECTION PROCEDURE: P20E8
1 Inspect the DEF quantity, Check the DTC history
3. Select [Engine] and check if P203F has been detected.
4. Check the DEF quantity in the DEF tank visually.

HINT
P203F is detected when remaining DEF level in the DEF tank is
less than 5%
Has DTC P203F been detected? Is the DEF tank empty?
YES NO
Refill the DEF. Go to step 2.

The unit can be released after DEF tank
breather hose cleaning.
MATION section.
2 Check DEF leaks from the filter cap
1. Check the tightening torque of the DEF pump filter cap.

(Check for the DEF leakage or crystallization from the DEF tank fil-
ter cap.)
Tightening torque:
20 – 25 Nm {204 – 255 kgfcm, 15 – 18 lbfft}
SAPH16F020400208
Was the filter cap tightened correctly with the correct torque?
YES NO
<The cap is tightened to the correct torque Tighten the filter cap with specified torque.
and no DEF leaks.> The unit can be released after DEF tank
Go to step 3. breather hose cleaning.
MATION section.
3 Inspect the DEF pump electrical connector
1. Check DEF pump electrical connectors visually.
SAPH16F020400209
YES NO
Repair or replace the connectors. Go to step 4.

If the connector corroded, replace both DEF
pump and wire harness.
MATION section.
4 Inspect the DEF line between DEF tank and pump
1. Check all connectors and DEF hoses between DEF tank and DEF
pump and check if they are free of leaks and DEF crystals.
Connector
DEF hose 2. Gently pull on connectors and make sure they are securely con-
DEF pump
nected.
- DEF hose connector (DEF pump side)
- DEF hose (suction side)
HINT
If DEF leaks, deposits of DEF crystals will form around the muffler.
Connector
SAPH16F020400210
Were DEF leaks found?
YES NO
Replace the DEF line (connector and hose) Go to step 5.

between DEF tank and pump.
MATION section.
5 Inspect the DEF line between DEF tank and pump
1. Check condition of the O-ring inside the DEF connector.

(No crack on O-ring, No contaminant on sealing surface.)
O-ring
SAPH16F020400211
YES NO
Replace the DEF line (connector and hose) Go to step 6.

MATION section.
6 Inspect the inside of DEF tank and DEF pick-up unit (DEF sensor)
1. Remove the DEF tank from the vehicle.

DEF
sensor 2. Remove the DEF pick-up assembly (DEF sensor) from the DEF
tank.
DEF sensor
3. Drain the DEF from the DEF tank and check if large debris which
DEF
tank can cover DEF suction area are found or fibrous debris are found
Float in the DEF tank, strainer of DEF pick-up unit (in the DEF sensor)
or drained DEF.
Strainer is within
this box
SAPH16F020400212
YES NO
Replace DEF, DEF pump inlet connector, DEF Go to step 7.

pick-up unit (DEF sensor) and DEF line
Remove the foreign objects and clean the
DEF tank.
NOTICE
The DEF tank must be cleaned with fresh
water or diluted DEF.
MATION section.
7 DEF pump opening check [HINO DX Ⅱ ]
Replace the DEF pump inlet connector and check the DEF pressure.
HINT
(1) If the inlet connector is clogged with debris, the debris will be
(2)
moved to the strainer side by the after-run process. Therefore, use
the following procedure to replace the inlet connector so that an
after-run is not executed.
(3)
4. Select [DCU].
Electrical 5. Perform [Leak test] for 3 minutes from the [DEF solution addition
connector test] in [Inspection Menu] on HINO DX Ⅱ .
NOTICE
Inlet connector Make sure to confirm no frozen DEF within DEF tank, pump and
line prior this test.
Otherwise, DEF pump may be damaged.
6. Close HINO DX Ⅱ .
φ22 mm 88 mm {3.39 in.}

7. Disconnect the electrical connector from the DEF pump (with
{0.87 in.}
starter switch ON position) and wrap the disconnected connector
by the plastic bag for prevention of water/DEF entering.
Filter
8. Set the starter switch to the “LOCK” position and wait for 1 minute.
9. Disconnect the electrical connector from the DCU and wrap the
disconnected connector by the plastic bag for prevention of water/
SAPH16F020400213
DEF entering.
10. Disconnect the DEF suction line from inlet connector of the DEF
pump.
11. Replace the inlet connector of the DEF pump to new one (Oil the
O-ring with Mobil velocite oil No. 6 or equivalent).
Tightening torque for connector:

4.0 – 5.0 Nm {41 – 51 kgfcm, 3.0 – 3.6 lbfft}
12. Connect the DEF suction line to inlet connector of the DEF pump.
13. Connect the electrical connector to the DCU and the DEF pump.
14. Set the starter switch to the "ON" position, and conduct the DEF
pump leak test with HINO DX Ⅱ again. And read the DEF pump
pressure on the DX Ⅱ screen.
HINT
Why DEF inlet connector should be replaced?
DEF inlet connector has a filter, and intermittently DEF pressure
won’t build up can be made by contaminated DEF inlet connector.
Normal DEF pressure occasionally happened although there is 90
% of restriction in the filter.
NOTICE
As DEF is highly corrosive, take care that it does not get onto sur-
rounding parts. Special care is required as this may cause a mal-
function, particularly when DEF comes in contact with electric
wiring or connectors. If DEF gets onto a component, wipe it off
immediately, using a rag moistened with hot water; if necessary,
rinse it off with hot water, and then dry completely. Before connec-
tor installation, check visually and make sure that no signs of cor-
rosion etc. are present.
Measurement
Standard values
conditions

in the 850 to 950 kPa (123.3
Starter switch: ON
to 137.8 psi) range for 60
seconds.
YES NO
The cause is clogged DEF inlet connector. Go to step 8.

MATION section.
8 Inspect the DEF suction line [HINO DX Ⅱ ]
2. Disconnect the DEF suction line between the DEF tank (1) and the
DEF pump (2) and connect the SST as the picture shown.
SST : HOSE SUB-ASSY, UREA (S0920-E0020)
SST
5. Select [DCU].
(1)
(2) 6. Perform [Leak test] from the [DEF solution addition test].
DEF tank
DEF
sensor <Inspection procedure>
SST
DEF pump
Measurement conditions Standard values

in the 850 to 950 kPa (123.3
Starter switch: ON
seconds.
(1)
(2)
(3)
SAPH16F020400214
YES NO
The cause is clogged DEF suction line. Go to step 9.

Replace DEF suction line.
MATION section.
9 Inspect the DEF pick-up unit (DEF sensor)
(2)
2. Fill a clean small container with clean DEF.
DEF
sensor 3. Disconnect the SST DEF tank-side connector (1) and put the con-
nector into the container containing the DEF.

DEF pump SST
DEF
5. Perform the [Leak test].
(1)
SAPH16F020400215
Measurement
Standard values
conditions

in the 850 to 950 kPa (123.3
Starter switch: ON
seconds.
YES NO
The cause is clogged DEF pick-up unit (DEF Replace DEF pump.
sensor). Replace DEF sensor. The unit can be released after DEF tank
The unit can be released after DEF tank breather hose cleaning.
breather hose cleaning. Perform "After-inspection work" of INFOR-
MATION section.
DTC: P20E9
EN01H16F02040F03001057
DTC: P20E9 Back flow line and pressure line Pressure check
INFORMATION
Breather hose Coolant outlet

Harness connector
DEF back flow

(To DEF tank)
DEF suction line Coolant inlet DEF suction line

DEF tank Coolant inlet
DEF back flow (To DEF tank)
DEF back flow
(To DEF tank) DEF pressure line (outlet) Coolant outlet
DEF pressure line (outlet)
DEF suction line
DEF pump
DEF sensor
(strainer) DEF pump
DEF Injector
To DEF SCR
catalyst
Inside muffler
DEF tank
DEF circuit
SAPH16F020400216
• DEF line pressure depends on flow quantity of DEF pump.
• DEF pump flow quantity is determined by the value supplied from the DEF pressure sensor which is integrated with
the DEF pump.
• Abnormal pressure in the DEF pipe is detected.

Exhaust gas temperature (SCR inlet) > 150 C {302 F}
Defrosting DEF is done.
DEF pressure build up-to 650 kPa {94 psi} is successfully completed.
During "Detection Mode"

• DEF line pressure does not decrease or is stable at more than 1,000 kPa {145.0 psi} for 2 seconds at 7 % of
DEF pump opening.
• DEF pressure was not stable for 8 seconds from 850 to 950 kPa {123.3 to 137.8 psi} in detection mode (300
seconds).
After "DEF Injection Start"

• DEF line pressure is more than 1,250 kPa {181.3 psi} for 5 sec.
<Sample: Normal DEF Pressurizing Manner>
Monitoring Condition
(1) SCR inlet temp > 150 ˚C {302 ˚F}
(2) DEF defrosting is done.
Starter switch-On Starter switch-Off
Standby Detection Mode DEF injection start

Metering Control After-run
Pressure Build Up
Pump Opening: 75% Emptying start
950 kPa {138 psi}
DEF pressure
850 kPa {123 psi}
650 kPa {94 psi}
SCR inlet Temp

150 ˚C {302 ˚F}
SAPH16F020400217
3. Reset condition

• MIL: ON


• –

• DEF in the DEF tank is empty.
• Strainer in the DEF sensor is clogged.
• Air is entering into DEF suction line.
• DEF suction line is clogged (frozen), or DEF leaks from DEF suction line.
• DEF pump filter element is clogged.
• DEF pump inlet connector is clogged.
• DEF pump back flow connector is clogged.
• DEF back flow line is clogged.
• Leak from DEF pump.
• DEF pump malfunction.
• Clogged DEF tank breather hose.
NOTICE
DEF -SCR system can be damaged by Diesel filling up to the tank.
If DEF pump main filter has a yellow slime, it is an evidence of biodiesel filled to the tank.
INSPECTION PROCEDURE: P20E9
1 Check the DEF pressure ramping up curve
4. Select [Engine].
5. Select "DPR deposition quantity" from the customization items and

change the PM deposition quantity to [3.0 g/L].
6. Exit from [Engine] and connect to [DCU] on HINO DX Ⅱ menu.
7. Select [DEF pump pressure] in [Data monitor Setting] and read

(record) the data (values) during DPR manual regeneration. (Start
the monitor and then push the DPR manual regeneration button.)
8. After Manual regeneration completed, stop monitoring and save

the data.
9. Make a graph for collected DEF pressure and check the condition
with reference to the sample graph.
Sample graph
Condition (1): Pressure raises over 1,000 kPa {145.0 psi} for more than 2 seconds.
Condition (2): Pressure raises up and not dropped.
Condition (3): Pressure raises over 1,250 kPa {181.3 psi} for more than 5 seconds.
SAPH16F020400218
Is the condition (1), (2) or (3) found in the corrected data?
YES NO
Go to step 2. Go to diagnosis procedure for the DTC

P20E8.
2 Inspect the DEF backflow line.

DEF hose
(backflow line) 2. Disconnect the DEF hose (backflow line) between the DEF tank
and the DEF pump.
3. Blow air from upstream side (DEF pump side) of the DEF hose
and check if the hose is clogged.
4. Remove the DEF pick-up unit (DEF sensor) from the DEF tank.
5. Blow air from upstream side (DEF hose side) of the DEF connec-
tor on the DEF sensor and check if the connector/pipe is clogged.
SAPH16F020400219
YES NO

And then perform same test with step 1.
If the result is OK (pressure curve is normal
behavior), the unit can be released after DEF
tank breather hose cleaning.
MATION section.
If the result is not OK (condition (1),(2) or (3)
was found.), go to step 3.
3 Inspect the DEF backflow line
1. Replace the DEF pump backflow connector to new one, then per-
form same test with step 1 again.
Tightening torque for connector:

4.0 – 5.0 Nm {41 – 51 kgfcm, 3.0 – 3.6 lbfft}
Back flow
connector
f25 mm 81 mm {3.19 in.}

{0.98 in.}
SAPH16F020400220
Is the condition (1), (2) or (3) found in the corrected data?
YES NO
Go to diagnosis procedure for the DTC Procedure completed. The unit can be
P20E8. released after DEF tank breather hose clean-
ing.
MATION section.
DTC: P20F4
EN01H16F02040F03001058
DTC: P20F4 DEF injector abnormal

INFORMATION
Back flow line Pressure line
Suction line
DEF pump Pressure sensor
DEF injector
Inside muffler
DEF tank
SAPH16F020400221
• The amount of added DEF is diagnosed as abnormal.
• The amount of added DEF is controlled by the DEF pressure and the opening of the DEF injector.
• Failure of DEF injector during system operation is detected.

<During system operation>
DEF injector duty is > 15%
Accumulated DEF injector duty is > 25,000
Ratio (= Accumulated DEF pump duty/ Accumulated DEF injector duty) is < 0.12
<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.

• MIL: ON
• Output restricted instantaneously.
• If malfunction does not improve within 50 min.: vehicle speed is restricted.

• Engine output is insufficient.
• Vehicle does not speed up (when malfunction does not improve within 50 min.).

• –

• Clogging of the DEF injector
• Clogging of the DEF pipe
INSPECTION PROCEDURE: P20F4
1 Inspect the DEF pipe (pump  injector)
1. Check the DEF pipe (pressure line) and check if there are no dis-
connections, clogging, corrosion, or cracks.
YES NO
Replace the DEF pipe. Go to step 2.

MATION section.
2 Inspect DEF injector 1 [HINO DX Ⅱ ]
NOTICE
(2)

(3)

HINT
SAPH16F020400222
injector.
5. Select [DCU].

NOTICE
YES NO
Procedure completed. DEF crystal clogging Go to step 3.

is considered resolved.
MATION section.
3 Inspect the DEF injector 2 [HINO DX Ⅱ ]
2. Replace DEF injector with a new one. (Do not install it on the muf-
fler.)
4. Perform DEF addition test as same as step 2.
SAPH16F020400223
YES NO
New the DEF injector installed in the muffler. Re-install the DEF injector and replace the
Procedure completed. After installing the DEF pipe (pressure line). After replacing the
injector, idle the engine (for about 10 min.) pipe, idle the engine (for about 10 min.) and
and from the menu [Data monitor Setting] from the menu [Data monitor Setting] check
check if the DEF is stable between 800 kPa if the DEF is stable between 800 kPa {116 psi}
{116 psi} and 1,051 kPa {152 psi}. and 1,051 kPa {152 psi}.
DTC: P2201
DTC: P2201 NOx sensor (SCR upstream) - Performance
INFORMATION
FUSE NOx2
A99
FUSE NOx1 (3GLD)
A8V
(6BLD)
#PG
#PH
DCU
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
#AQ #PG
#AR #PH
Twist
Boost pressure
sensor
(CANL)
NOx
K2C (GND)
(VCC)
Common rail
#AQ
#AR
(SIG)
(CANH) %JU
%JZ
pressure sensor sensor 1
Twist
%JR LE9 LE6
K2B
K2A
GND2
GND1
(VCC)
LLJ VCC2
VCC1
H
SIG2
SIG1
(CANH) (CANH) LGU

(GND)
Twist
%JW LE8 L LE7
(GND)
(CANL) (CANL)
LLK
H L H L
%JS LED H LEA
Engine (CANH) (CANH) (VCC)
(PCR+)
(PCR-)
coolant Common rail_ %JX LEC L LEB
%JQ (12)
temperature (CANL) (CANL) (GND)
CAN_J/C3
Twist
Intake sensor 1
manifold NOx
(CANL)
Twist
tempera- %JV sensor 2
ture
sensor
Twist
(THG)
(CANH)
(CANL)
Air flow sensor

(E2)
%KF
%KE
PM
E24
E23
Twist
sensor LQN
Twist Twist
KTT
KTU
KTS
KTR
KTQ
LB7
LB8
(CANH) (CA3H) (CANH)
H
LQK %KP LEK
(CANL)
H
L
(AFT+)
(AFT-)
(AFVB)
(AFGD)
(AFSG)
(CA3L) (CANL) LEM

(WTM-)
(WTM+)
#AW #AW
#AV #AV
Common rail_ %KN LEJ L

CAN_J/C1
%NH %NH
(CANH)
(CANL)
DEF sensor
%KM
%KL
(DEF tank
#AU #AU
KTT K0W
KTR LUG
KTU LUH
KTQ LCH
KTS L75
Twist #CP #CP Twist temperature

sensor)
E23 K0U
#CQ #CQ
#SD #SD
#SF #SF
(CA1H) LCM #S5 #S5
(CA1L) LCN #S7 #S7
H L
Twist
H L
K0W
K6W
(ATI+) KQY
LUG
LUQ
LUH
LCH
(PIM) K6G
(AV3) LSR
LUE
(THW+) K0U
&1D
LUF
K6V
(AG6) LUJ
L75
(G4-A)
(THA+)
(AG5)
(AFVB)
(AG4)
(AFSI)
(AG3)
(AV2)
(AG2)
(CANH)
(CANL)
Z30
ECU (G4C)
BATTERY GND
SAPH16F020400224
• NOx sensor 1 (SCR upstream) confirms correct value by comparing with the actual NOx sensor 1 (SCR upstream)
value, the NOx sensor 2 (SCR downstream) value and the NOx model value calculated by the ECU.
• NOx model value is calculated according to the engine's state and properties.
• At low NOx concentration, NOx sensor 1 (SCR upstream) confirms correct value by comparing with the Judgement
criteria.
Description of malfunction
• Characteristics failure of NOx sensor 1 (SCR upstream) is detected.

• DPR active regeneration in process
• SCR catalyst temperature (from DCU) ≥ 440 C {824 F} for 100 sec
• DPR upstream temperature ≥ 400 C {752 F}
• 75 kPa ≤ Barometric pressure ≤ 112 kPa
• -7 C {19.4 F} ≤ Intake air temperature (build-in air flow sensor) ≤ 49 C {120 F}
• 55 C {131 F} ≤ Engine coolant temperature ≤ 100 C {212 F}
• NOx sensor (SCR upstream) is valid.
• NOx sensor (SCR downstream) is valid.
After above conditions are met, DEF dosing is stopped.
Cumulative NOx mass flow (calculated NOx) from DEF dosing stop ≥ 10 g
Conditions below continue for 5 sec
• 100 ppm ≤ Calculated NOx (SCR upstream) ≤ 1,500 ppm
• |∆Calculated NOx (SCR upstream)| ≤ 1,172 ppm/sec
• 300 kg/h ≤ Exhaust gas mass flow < 1,000 kg/h
• Fuel injection quantity ≥ 5 mm3/st
<At low NOx concentration>
• 120 C {248 F} < SCR catalyst temperature < 170 C {338 F}
• DPR active regeneration in not process
• Estimated current NH3 load in SCR – Normal value of NH3 load in SCR ≤ 0 g
• -0.5 C {31 F}/sec ≤ SCR catalyst temperature gradient ≤ 0.25 C {32 F}/sec
• 1,000 r/min ≤ Engine speed ≤ 3,000 r/min
Cumulative Exhaust gas mass flow > 1,000 g from Fuel injection quantity ≤ 0 mm3/st.
(2) Judgment criteria
All of the three conditions described below are formed. (judgment time : 10 sec)
• Average actual NOx (from NOx sensor 1 (SCR upstream)) / Average calculated NOx (SCR upstream)
: Out of range (< 0.4 or > 4)
• Average Actual NOx (from NOx sensor 2 (SCR downstream)) / Average calculated NOx (SCR upstream)
: Within range (≥ 0.5 and ≤ 1.4)
• Average Actual NOx (from NOx sensor 2 (SCR downstream)) / Average actual NOx (from NOx sensor 1 (SCR
upstream))
: Out of range (< 0.5 or > 1.4)
When any of the following conditions is satisfied, and has continued for 5 seconds.
• Average actual NOx (from NOx sensor 1 (SCR upstream)) is above 40 ppm
• Average actual NOx (from NOx sensor 1 (SCR upstream)) is below -40 ppm
3. Reset condition

• MIL: ON
• SVS Light: OFF
Symptoms on the vehicle due to backup control (fail safe function)

Symptoms on the vehicle due to malfunction

• –
• After starting the DPR automatic regeneration, form the DTC detection condition.

• Failure of NOx sensor 1 (SCR upstream)
• NOx sensor 2 (SCR downstream) failure
- Sensor internal circuit failure
- NOx sensor controller failure
• Failure of sensor used in calculating model value:
- Air flow sensor
- Boost pressure sensor
- Intake manifold temperature sensor
- Engine coolant temperature sensor
- EGR failure

Refer to the "ENGINE CONTROL SYSTEM (J08E)" in the chapter "ENGINE CONTROL SYSTEM".
DTC: P2202
EN01H16F02040F03001060
DTC: P2202 NOx sensor (SCR upstream) and Heater - Circuit

INFORMATION
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
LES (IGSW) DCU FUSE NOx2 A99 #PH #PH
(3GLD)
FUSE NOx1 A8V #PG #PG
%NL
(6BLD)
#AQ
#AR
%NL
(CANL)
#AQ
#AR
NOx
Twist
Twist
(CANH) %JU
%JZ
Twist
Twist sensor 1
#GV
%JR LE9 LE6

H (VCC)
(CANH) (CANH) LGU
(GND)
%JW LE8 L LE7
(GND)
Common rail_ (CANL) (CANL)
#GV
H L
CAN_J/C3 %JS LED H LEA
(CANH) (CANH) (VCC)
%NM
%NN
%JQ (CANH)
%JX LEC L LEB

#GX
(CANL) (CANL) (GND)
Twist
%NM
%NN
NOx
(CANL)
%JV
PM
sensor sensor 2
L0N
#GX
(CANH) Twist
H L L0K
(CANH)
(CANL)
(CANL)
%KF
%KE
(49LD)
Twist
A7R
Twist %KR
%KP
%KQ
H L %KN
Common rail_ Twist
#AW #AW
#AV #AV
CAN J/C1
%NQ
%NP
(CANH)
(CANL)
%KM
%KL
FUSE
DCU(M)
#CP #CP
#CQ #CQ
%NP
%NQ
Twist
Twist
Twist
Twist
#SD #SD
#SF #SF
#S5 #S5
#S7 #S7
#AU #AU
LEK H(VCC) LEL
(CANH) LEM
%NH
LEJ L(GND)
Twist Twist
(CANL)
H L H L DEF
sensor
(CA1H) LCM
&1D
(CANL) K6W
(CA1L) LCN
(CANH) K6V
(G4-A)
%NH
Z30
(G4C)
ECU
Battery
ground
SAPH16F020400225
• NOx sensor 1 (SCR upstream) is controlled by the NOx sensor controller.
• The NOx sensor controller is connected via the engine ECU and DCU through CAN communication, and it sends
and receives data.
• Failure of circuit inside NOx sensor 1 (SCR upstream) is received from CAN data.

Starter switch ON.
Failure of NOx sensor 1 (SCR upstream) internal circuit (Low failure flag) is received from CAN data.
3. Reset condition

• MIL: ON


• –

- Failure of circuit inside sensor
- Failure of NOx sensor controller
3. Select [DCU] and check if a CAN communication system malfunc-

tion (U029D) has been detected.
SAPH16F020400226
Has DTC U029D been detected?
YES NO
Go to the diagnostic procedure of a related Replace the NOx sensor 1 (SCR upstream).
MATION section.
DTC: P2203
EN01H16F02040F03001061
DTC: P2203 SCR inlet NOx sensor failure (High)

INFORMATION LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
(3GLD)
%NL
(6BLD)
#AQ
#AR
%NL
(CANL)
#AQ
#AR
NOx
Twist
Twist
(CANH) %JU
%JZ
Twist
Twist sensor 1
#GV
%JR LE9 LE6

H (VCC)
(CANH) (CANH) LGU
(GND)
%JW LE8 L LE7
(GND)
#GV
H L
(CANH) (CANH) (VCC)
%NM
%NN
%JQ (CANH)
%JX LEC L LEB

#GX
(CANL) (CANL) (GND)
Twist
%NM
%NN
NOx
(CANL)
%JV
PM
sensor sensor 2
L0N
#GX
(CANH) Twist
H L L0K
(CANH)
(CANL)
(CANL)
%KF
%KE
(49LD)
Twist
A7R
Twist %KR
%KP
%KQ
H L %KN
Common rail_ Twist
#AW #AW
#AV #AV
CAN J/C1
%NQ
%NP
(CANH)
(CANL)
%KM
%KL
FUSE
DCU(M)
#CP #CP
#CQ #CQ
%NP
%NQ
Twist
Twist
Twist
Twist
#SD #SD
#SF #SF
#S5 #S5
#S7 #S7
#AU #AU
LEK H(VCC) LEL
(CANH) LEM
%NH
LEJ L(GND)
Twist Twist
(CANL)
H L H L DEF
sensor
(CA1H) LCM
&1D
(CANL) K6W
(CA1L) LCN
(CANH) K6V
(G4-A)
%NH
Z30
(G4C)
ECU
Battery
ground
SAPH16F020400227
and receives data.
• Failure of NOx sensor 1 (SCR upstream) is received from CAN data.

Starter switch ON.
Failure of NOx sensor 1 (SCR upstream) internal circuit (High failure flag) is received from CAN data.
3. Reset condition

• MIL: ON


• –


tion (U029D) has been detected.
SAPH16F020400228
YES NO
Go to the diagnostic procedure of a related Replace the NOx sensor 1 (SCR upstream).
MATION section.
DTC: P2204
EN01H16F02040F03001062
DTC: P2204 SCR inlet NOx sensor abnormal

INFORMATION
FUSE NOx2
A99
FUSE NOx1 (3GLD)
A8V
(6BLD)
#PG
#PH
#GV #GV %NL %NL LES
(IGSW)
LF5 (CAH1)
DCU
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
#AQ #PG
#AR #PH
#GX
Twist
Boost pressure
sensor
#GX
(CANL)
K2C (GND)
NOx
K2A (VCC)
#AQ
#AR
K2B (SIG)
(CANH) %JU
%JZ
sensor 1
Twist
%JR LE9 LE6
(49LD)
H (VCC)
(CANH) (CANH)
A7R
LGU
(GND)
Twist
%JW LE8 L LE7
(GND)
H L (CANL) (CANL)
H L
%JS LED H LEA
%JQ (CANH)
FUSE coolant Common rail_ %JX LEC L LEB
DCU(M) temperature (CANL) (CANL) (GND)
CAN_J/C3
Twist
sensor 1
Intake NOx
(CANL)
Twist
manifold %JV sensor 2
%NM %NM
%NN %NN
temperature Fuel temperature

sensor sensor
Twist
(THF+)
(THG)
(THF-)
(CANH)
(CANL)
Air flow sensor

(E2)
Twist
%KF
%KE
(WTM-) E24
(WTM+) E23
Twist
Twist Twist
L0N
KTT
KTU
KTS
KTR
KTQ
LB7
LB8
K8Q
(CANH) (CANH) (CANH)

#AW #AW
LEL
#AV #AV
H
PM L0K %KP LEK
sensor (CANL)
H
L
(AFT+)
(AFT-)
(AFVB)
(AFGD)
(AFSG)
(CANL) (CANL) LEM

L
%KN LEJ
Common rail_
%NH %NH
Twist
(CANH)
(CANL)
DEF sensor
%KM
%KL
CAN_J/C1
(DEF tank
#AU #AU
KTT K0W
KTU KTD
KTQ LCH
KTR L2P
KTS L75

sensor)
E23 K0U
#CQ #CQ
#S5 #S5
#S7 #S7
#SD #SD
#SF #SF
H L
Twist Twist
(CA1H) LCM
K0W
K6W
(ATI+) KQY
(CA1L) LCN
LUG
H L
LUH
LCH
(PIM) K6G
(AV3) LSR
(THW+) K0U
&1D
LUF
K6V
(AG6) LUJ
L75
(G4-A)
(THA+)
(AG5)
(AFVB)
(AG4)
(AFSI)
(AG3)
(CANH)
(CANL)
Z30
(G4C)
ECU BATTERY GND
SAPH16F020400229
• The NOx sensor controller is connected via the DCU and a harness, and it sends and receives data.
• Failure of NOx sensor 1 (SCR upstream) is detected.

Starter switch ON.
NOx sensor 1 (SCR upstream) is operating (after heat-up is completed).
Variation of fuel injection quantity (Engine) < 40 mg/cylinder.
The NOx sensor status signal sent from the NOx sensor is invalid for at least 90 sec. in a 180 sec. interval.
3. Reset condition

• MIL: ON


• –

• NOx sensor 1 (SCR upstream) malfunction
4. Select [DCU] and check if any DTC other than P2204 (for example,
P2202, P2203, P2209, U029D) has been detected.
SAPH16F020400230
Has a DTC other than P2204 been detected?
YES NO
2 Inspect the NOx sensor 1 (SCR upstream) [HINO DX Ⅱ ]
2. Disconnect the NOx sensor 1 (SCR upstream) and NOx sensor 2

(SCR downstream).
3. Install NOx sensors 1 and 2 in the vehicle, in their opposite loca-

tion.

SAPH16F020400231
6. Perform the DPR forced regeneration.
YES NO
Go to step 3. Replace the NOx sensor 1 (SCR upstream).

MATION section.

perature sensor.
YES NO

MATION section.
4 Check the engine coolant temperature sensor output signal [HINO DX Ⅱ ]
2. Select [Engine].
3. Select [Engine coolant temperature] from [Data monitor Setting]

on the menu.
4. When the engine coolant temperature (actual measured value) is

50 C {122 F}, check if the temperature output by the engine cool-
ant temperature sensor is 50 C {122 F}.
Standard values
SAPH16F020400232
Coolant temperature sensor output value: 50 C {122 F}
YES NO

sor.
MATION section.
5 Inspect the air flow sensor
1. Check the installation of the air flow sensor.
2. Make sure there is no dirt or damage to the air flow sensor.
YES NO
If dirt, clogging or damage in the sensing Go to step 6.

unit was found, replace the air flow sensor.
MATION section.
6 Inspect the boost pressure sensor
1. Check the installation of the boost pressure sensor.
2. Make sure there is no dirt or damage to the boost pressure sensor.
YES NO

unit was found, replace the boost pressure
sensor.
MATION section.
7 Inspect the boost pressure sensor output signal [HINO DX Ⅱ ]
2. Select [Engine] on the HINO DX Ⅱ .
3. Select [Actual boost pressure] from [Data monitor Setting] on the

menu.
4. Race the engine from idle to No-Load Maximum and check if the
boost pressure output signal varies.
Standard values
SAPH16F020400233 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)

YES NO
Go to step 8. Replace the boost pressure sensor.

MATION section.
8 Inspect the Intake manifold temperature sensor
1. Check the installation of the intake manifold temperature sensor.
2. Make sure there is no dirt or damage to the intake manifold tem-

perature sensor.
YES NO
Clean the Intake manifold temperature sen- Go to step 9.

sor and install it properly. If damaged,
replace the Intake manifold temperature sen-
sor.
MATION section.
9 Inspect the Intake manifold temperature sensor unit
THG E2
2. Disconnect the intake manifold temperature sensor connector.

terminals of the intake manifold temperature sensor.
Measurement Tester
Standard values
Intake manifold 20 C {68 F}:

SAPH16F020400234 LOCK sor 50 C {122 F}:
THG – E2 2.435 – 1.994 k
YES NO
Go to step 10. Replace the intake manifold temperature

sensor.
MATION section.
10 Inspection of the NOx sensor 1 [HINO DX Ⅱ ]
1. Replace NOx sensor 1 with a new sensor.
SAPH16F020400235
YES NO
Replace the DCU. NOx sensor 1 failure. Install a new NOx sen-
Perform "After-inspection work" of INFOR- sor 1.
MATION section.
DTC: P2209
EN01H16F02040F03001063
DTC: P2209 NOx sensor (SCR upstream) Heater Sense Circuit Range/Performance
INFORMATION
FUSE NOx2
A99
FUSE NOx1 (3GLD)
A8V
(6BLD)
#PG
#PH
LES
(IGSW) DCU
(EXT+)
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
(EXT-)
#AQ #PG
#AR #PH
%NL
Twist
LFG
LFH
%NL
(CANL)
NOx
#AQ
#AR
(CANH) %JU
%JZ
sensor 1
Twist
LE4
LE5
LE6
#GV
%JR LE9
H (VCC)
(FAT-)
(CANH) (CANH)
(FAT+)
LGU
(GND)
Twist
%JW LE8 L LE7
(GND)
H L (CANL) (CANL)
H L
#GV
Exhaust gas %JS LED H LEA

temperature (CANH) (CANH) (VCC)
%JQ (CANH)
#GX
sensor Common rail_ %JX LEC L LEB

(SCR inlet) (CANL) (CANL) (GND)
CAN_J/C3
Twist
NOx
(CANL)
Twist
%JV
#GX
Engine coolant sensor 2

temperature
sensor 1 Twist
(49LD)
(CANH)
(CANL)
PM
Twist
%KF
%KE
A7R
(WTM+) E23
(WTM-) E24
%NM %NM
%NN %NN
Twist
Twist
sensor L0N %KR
(CANH) (CANH) (CANH) LEL
H
L0K %KQ %KP LEK
(CANL)
H
L
Twist (CANL) (CANL) LEM

FUSE
L
%KN LEJ
#AW #AW
DCU(M)
#AV #AV
%NH %NH
Common rail_
(CANH)
(CANL)
DEF sensor
%KM
%KL
CAN_J/C1 (DEF tank
#AU #AU
Twist
sensor)
KTU KTD
E23 K0U
#CQ #CQ
#S5 #S5
#S7 #S7
#SD #SD
#SF #SF
H L
Twist Twist
(CA1H) LCM
K6W
(CA1L) LCN
L
(AG5) LUH
(THW+) K0U
&1D
K6V
(G4-A)
(CANH)
(CANL)
Z30
ECU (G4C)
BATTERY GND
SAPH16F020400236
• The NOx sensors are controlled by the NOx sensor controller.
• The NOx sensor controller is connected to the DCU via the harness for reception and transmission of information.
• Failure of NOx sensor 1 (SCR upstream) is detected.

Starter switch ON.
SCR catalyst downstream temperature (from exhaust gas temperature (SCR outlet)) ≥ 200 C {392 F}
Engine coolant temperature ≥ 70 C {158 F}
A valid NOx reading cannot be taken by the NOx sensor when 180 sec. elapses after start of NOx sensor heater
activation.
3. Reset condition

• MIL: ON


• Malfunction of NOx sensor 1 (SCR upstream)
- Malfunction of circuit in the sensor
- Malfunction of NOx sensor controller
1 Inspect the NOx sensor 1 (SCR upstream) connector
1. Check the connection of the NOx sensor (SCR upstream) connec-

tor (Looseness and poor contact).
YES NO

MATION section.
2 Inspect the NOx sensor 1 harness (CAN communication line)

CANL
CANH
2. Disconnect the NOx sensor 1 connector.
4. Use the oscilloscope to measure the voltage between the termi-

nals of the NOx sensor 1 vehicle-side connector.
Measurement Tester
Standard values
SAPH16F020400237 NOx sensor 1
vehicle-side con- Pulse waveform
Starter switch: ON
nector 0 V to 5 V
CANH – CANL
YES NO

MATION section.
3 Inspect the NOx sensor 1 harness (GND line)

GND
GND
terminals of the NOx sensor 1 vehicle-side connector.
Measurement Tester
Standard values
NOx sensor 1
Continuity
LOCK nector
GND – GND
SAPH16F020400238
YES NO

MATION section.
4 Inspect the NOx sensor 1 harness (power supply line)

VCC
GND
Measurement Tester
Standard values
NOx sensor 1
vehicle-side con-
Starter switch: ON 9 V to 16 V
nector
VCC – GND
SAPH16F020400239
YES NO

MATION section.

YES NO

MATION section.

(SCR inlet).

YES NO

(SCR inlet).
MATION section.
FAT- FAT+
nector.

Measurement Tester
Standard values
Exhaust gas tem-

FAT+ – FAT-
YES NO

(SCR inlet).
MATION section.
1. Check the connection of engine coolant temperature sensor con-

YES NO

MATION section.

perature sensor.
YES NO

MATION section.
WTM- WTM+
Measurement Tester
Standard values

LOCK sor 80 C {176 F}:
WTM+ – WTM- 0.310 – 0.326 k
SAPH16F020400241
YES NO

sor.
MATION section.
11 Inspect the NOx sensor 1 [HINO DX Ⅱ ]
2. Replace a new NOx sensor 1.
5. Erase the malfunction history and perform a DPR forced regenera-

tion.

SAPH16F020400242
Has DTC other than P2209 been detected?
YES NO

DTC: P2212
EN01H16F02040F03001064
DTC: P2212 SCR outlet NOx sensor abnormal

INFORMATION
FUSE NOx2
A99
FUSE NOx1 (3GLD)
A8V
(6BLD)
#PG
#PH
#GV #GV %NL %NL LES
(IGSW)
DCU
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
#AQ #PG
#AR #PH
#GX
Twist
Boost pressure
sensor
#GX
(CANL)
K2C (GND)
NOx
K2A (VCC)
#AQ
#AR
K2B (SIG)
(CANH) %JU
%JZ
sensor 1
Twist
%JR LE9 LE6
(49LD)
H (VCC)
(CANH) (CANH)
A7R
LGU
(GND)
Twist
%JW LE8 L LE7
(GND)
H L (CANL) (CANL)
H L
%JS LED H LEA
%JQ (CANH)
FUSE coolant Common rail_ %JX LEC L LEB
DCU(M) temperature (CANL) (CANL) (GND)
CAN_J/C3
Twist
sensor 1
Intake NOx
(CANL)
Twist
manifold %JV sensor 2
%NM %NM
%NN %NN
temperature Fuel temperature

sensor sensor
Twist
(THF+)
(THG)
(THF-)
(CANH)
(CANL)
Air flow sensor

(E2)
Twist
%KF
%KE
(WTM-) E24
(WTM+) E23
Twist
Twist
L0N Twist
KTT
KTU
KTS
KTR
KTQ
LB7
LB8
K8Q

#AW #AW
LEL
#AV #AV
H
PM L0K %KP LEK
sensor (CANL)
H
L
(AFT+)
(AFT-)
(AFVB)
(AFGD)
(AFSG)
(CANL) (CANL) LEM

L
%KN LEJ
Common rail_
%NH %NH
Twist
(CANH)
(CANL)
DEF sensor
%KM
%KL
CAN_J/C1
(DEF tank
#AU #AU
KTT K0W
KTU KTD
KTQ LCH
KTR L2P
KTS L75

sensor)
E23 K0U
#CQ #CQ
#S5 #S5
#S7 #S7
#SD #SD
#SF #SF
H L
Twist Twist
(CA1H) LCM
K0W
K6W
(ATI+) KQY
(CA1L) LCN
LUG
H L
LUH
LCH
(PIM) K6G
(AV3) LSR
(THW+) K0U
&1D
LUF
K6V
(AG6) LUJ
L75
(G4-A)
(THA+)
(AG5)
(AFVB)
(AG4)
(AFSI)
(AG3)
(CANH)
(CANL)
Z30
(G4C)
ECU BATTERY GND
SAPH16F020400243
• NOx is detected by a NOx sensor status signal sent from NOx sensor 2 (SCR downstream).
• Failure of NOx sensor 2 (SCR downstream) is detected.

NOx sensor is activated
|∆Fuel injection quantity (from ECM) |< 40 mg/cyl/sec.
The NOx sensor status signal sent from NOx sensor 2 is invalid for at least 90 sec. in a 180 sec. interval.
3. Reset condition

• MIL: ON


• –

• NOx sensor 2 (SCR downstream) malfunction
P2215, P2216, P2222, U029E) has been detected.
SAPH16F020400244
YES NO
2 Inspect the NOx sensor 2 (SCR downstream) [HINO DX Ⅱ ]
2. Disconnect the NOx sensor 1 (SCR upstream) and NOx sensor 2

(SCR downstream).
3. Install NOx sensors 1 and 2 in the vehicle, in their opposite loca-

tion.

SAPH16F020400245
6. Perform a DPR forced regeneration.
YES NO
Go to step 3. Replace the NOx sensor 2 (SCR down-

stream).
MATION section.
1. Check the installation of the engine coolant temperature sensor is

properly installed.

perature sensor.

SAPH16F020400246
YES NO

MATION section.
4 Check the engine coolant temperature sensor output signal [HINO DX Ⅱ ]
2. Select [Engine].
3. Select [Engine coolant temperature] from [Data monitor Setting]

on the menu.
4. When the engine coolant temperature (actual measured value) is

50 C {122 F}, check if the temperature output by the coolant tem-
perature sensor is 50 C {122 F}.
Standard values
SAPH16F020400247
Engine coolant temperature sensor output value:

50 C {122 F}

YES NO

sor.
MATION section.
Air flow sensor 2. Make sure there is no dirt or damage to the air flow sensor.
SAPH16F020400248
YES NO

MATION section.
6 Inspect the boost pressure sensor
1. Check the installation of the boost pressure sensor.
Engine left side view 2. Make sure there is no dirt or damage to the boost pressure sensor.
Vehicle front
Boost pressure
sensor
SAPH16F020400249
YES NO

unit was found, replace the boost pressure
sensor.
MATION section.
7 Check the boost pressure sensor output signal [HINO DX Ⅱ ]
2. Select [Engine] on the HINO DX Ⅱ .
3. Select [Actual boost pressure] from [Data monitor Setting] on the

menu.
4. Race the engine from idle to No-Load Maximum and check if the
boost pressure output signal varies.
Standard values
SAPH16F020400250 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)
YES NO
Go to step 8. Replace the boost pressure sensor.

MATION section.
8 Inspect the intake manifold temperature sensor
1. Check the installation of the intake manifold temperature sensor.
2. Make sure there is no dirt or damage to the intake manifold tem-

perature sensor.
YES NO
Clean the intake manifold temperature sen- Go to step 9.

sor and install it properly. If damaged,
replace the intake manifold temperature sen-
sor.
MATION section.
9 Inspect the Intake manifold temperature sensor unit
THG E2
2. Disconnect the intake manifold temperature sensor connector.

terminals of the intake manifold temperature sensor.
Measurement Tester
Standard values
Intake manifold 20 C {68 F}:

SAPH16F020400251 LOCK sor 50 C {122 F}:
THG – E2 2.435 – 1.994 k

YES NO
Go to step 10. Replace the Intake manifold temperature

sensor.
MATION section.
10 Inspection of the NOx sensor 2 [HINO DX Ⅱ ]
1. Replace NOx sensor 2 with a new sensor.
SAPH16F020400252
YES NO
Replace the DCU. NOx sensor 2 is faulty. Install a new NOx sen-
Perform "After-inspection work" of INFOR- sor 2.
MATION section.
DTC: P2214
P2214: NOx sensor (SCR downstream) - Performance and Monitoring capability
INFORMATION
(ATSS) LNM LGJ (HH1+) FUSE NOx2

A99
LE4 LFG
(FAT+) (EXT+) (3GLD)
FUSE NOx1
DCU (ATS-) LNN LGK (HH1-)
A8V
LE5 LFH (6BLD)
(FAT-) (EXT-)
LQV
LQU
Ambient air
#PG
#PH
(ER-)
(ER+)
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
temperature sensor
#AQ #PG
#AR #PH
Twist
sensor
(SCR inlet) External
resistance
(CANL)
NOx
(CANH) %JU
%JZ
#AQ
#AR
sensor 1
Twist
%JR LE9 LE6
H (VCC)
(CANH) (CANH)
Twist (GND) LGU
%JW LE8 L
(GND) LE7
H L (CANL) (CANL)
H L
%JS LED H LEA
coolant Common rail_ %JX LEC L LEB
%JQ (12)
temperature (CANL) (CANL) (GND)

CAN_J/C3
Twist
sensor 1
NOx
(CANL)
Exhaust gas Twist

%JV
sensor 4 Twist
(GND2)
(CANH)
(CANL)
Air flow sensor

(TEX2)
PM
%KF
%KE
E24
E23
Twist
Twist
sensor LQN
Twist
KTT
KTU
KTS
KTR
KTQ
KSG
KSH

H
LQK %KP LEK
(CANL)
H
L
(AFT+)
(AFT-)
(AFVB)
(AFGD)
(AFSG)
(CANL) (CANL) LEM

(WTM-)
(WTM+)
#AW #AW
#AV #AV
Common rail_ %KN LEJ

CAN_J/C1
%NH %NH
(CANH)
(CANL)
DEF sensor
%KM
%KL
(DEF tank
#AU #AU
KTT K0W
KTR LUG
KTU LUH
KTQ LCH
KTS L75

sensor)
E23 K0U
#CQ #CQ
#SD #SD
#SF #SF
(CA1H) LCM #S5 #S5
(CA1L) LCN #S7 #S7
H L
Twist
H L
LCG
KRB
K0W
K6W
LUG
LUH
LCH
(THW+) K0U
&1D
K6V
L75
(G4-A)
(ET4+)
(AGD3)
(THA+)
(AG5)
(AFVB)
(AG4)
(AFSI)
(CANH)
(CANL)
Z30
ECU (G4C)
BATTERY GND
SAPH16F020400253
• NOx sensor 2 (SCR downstream) confirms correct value by comparing with the actual NOx sensor 1 (SCR
upstream) value, the NOx sensor 2 (SCR downstream) value and the NOx model value calculated by the ECU.
• NOx model value is calculated according to the engine's state and properties.
• At low NOx concentration, NOx sensor 2 (SCR downstream) confirms correct value by comparing with the Judge-
ment criteria.
• Characteristics failure of NOx sensor 2 (SCR downstream) is detected.

• DPR active regeneration in process
• SCR catalyst temperature (from DCU) ≥ 440 C {824 F} for 100 sec
• DPR upstream temperature ≥ 400 C {752 F}
• 75 kPa ≤ Barometric pressure ≤ 112 kPa
• -7 C {19.4 F} ≤ Intake air temperature (build-in air flow sensor) ≤ 49 C {120 F}
• 55 C {131 F} ≤ Engine coolant temperature ≤ 100 C {212 F}
• NOx sensor (SCR downstream) is valid.
After above conditions are met, DEF dosing is stopped.
Cumulative NOx mass flow (calculated NOx) from DEF dosing stop ≥ 10 g
• 100 ppm ≤ Calculated NOx (SCR upstream) ≤ 1,500 ppm
• |∆ Calculated NOx (SCR upstream)| ≤ 1,172 ppm/sec
• 300 kg/h ≤ Exhaust gas mass flow < 1,000 kg/h
• Fuel injection quantity ≥ 5 mm3/st
• 120 C {248 F} < SCR catalyst temperature < 170 C {338 F}
• DPR active regeneration in not process
• Estimated current NH3 load in SCR – Normal value of NH3 load in SCR ≤ 0 g
• -0.5 C {31 F}/sec ≤ SCR catalyst temperature gradient ≤ 0.25 C {32 F}/sec
• 1,000 r/min ≤ Engine speed ≤ 3,000 r/min
Cumulative Exhaust gas mass flow > 3,000 g from Fuel injection quantity ≤ 0 mm3/st.
(2) Judgment criteria
All of the three conditions described below are formed. (judgment time : 10 sec)
• Average actual NOx (from NOx sensor 1 (SCR upstream)) / Average calculated NOx (SCR upstream)
: Within range (≥ 0.4 and ≤ 4)
• Average Actual NOx (from NOx sensor 2 (SCR downstream)) / Average calculated NOx (SCR upstream)
: Out of range (< 0.5 or > 1.4)
• Average Actual NOx (from NOx sensor 2 (SCR downstream)) / Average actual NOx (from NOx sensor 1 (SCR
upstream))
: Out of range (< 0.5 or > 1.4)
When any of the following conditions is satisfied, and has continued for 5 seconds.
• Average actual NOx (from NOx sensor 2 (SCR downstream)) is above 40 ppm
• Average actual NOx (from NOx sensor 2 (SCR downstream)) is below -40 ppm
3. Reset condition
• After normal operation is restored.

• MIL: ON
• SVS light: OFF
• NOx purification function is stopped.

• Exhaust gas purification function has deteriorated.

• –
• Check that the battery voltage is in the normal range.
• After starting the DPR automatic regeneration, form the DTC detection condition.
• Check that no DTC is detected after test drive.

• NOx sensor 2 (SCR downstream) failure
- Sensor internal circuit failure
- NOx sensor controller failure
• Failure of sensor used in calculating model value:
- Air flow sensor
- Boost pressure sensor
- Intake manifold temperature sensor
- Engine coolant temperature sensor
- EGR failure

Refer to the "ENGINE CONTROL SYSTEM (J08E)" in the chapter "ENGINE CONTROL SYSTEM".
DTC: P2215
EN01H16F02040F03001065
DTC: P2215 NOx sensor (SCR downstream) and Heater - Circuit

INFORMATION
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
(3GLD)
%NL
(6BLD)
#AQ
#AR
%NL
(CANL)
#AQ
#AR
NOx
Twist
Twist
(CANH) %JU
%JZ
Twist
Twist sensor 1
#GV
%JR LE9 LE6

H (VCC)
(CANH) (CANH) LGU
(GND)
%JW LE8 L LE7
(GND)
#GV
H L
(CANH) (CANH) (VCC)
%NM
%NN
%JQ (CANH)
%JX LEC L LEB

#GX
(CANL) (CANL) (GND)
Twist
%NM
%NN
NOx
(CANL)
%JV
PM
sensor sensor 2
L0N
#GX
(CANH) Twist
H L L0K
(CANH)
(CANL)
(CANL)
%KF
%KE
(49LD)
Twist
A7R
Twist %KR
%KP
%KQ
H L %KN
Common rail_ Twist
#AW #AW
#AV #AV
CAN J/C1
%NQ
%NP
(CANH)
(CANL)
%KM
%KL
FUSE
DCU(M)
#CP #CP
#CQ #CQ
%NP
%NQ
Twist
Twist
Twist
Twist
#SD #SD
#SF #SF
#S5 #S5
#S7 #S7
#AU #AU
LEK H(VCC) LEL
(CANH) LEM
%NH
LEJ L(GND)
Twist Twist
(CANL)
H L H L DEF
sensor
(CA1H) LCM
&1D
(CANL) K6W
(CA1L) LCN
(CANH) K6V
(G4-A)
%NH
Z30
(G4C)
ECU
Battery
ground
SAPH16F020400254
• The NOx sensor 2 (SCR downstream) is controlled by the NOx sensor controller.
and receives data.
• Failure of NOx sensor 2 (SCR downstream) is received from CAN data.

Starter switch ON.
Failure of NOx sensor 2 (SCR downstream) internal circuit (Low failure flag) is received from CAN data.
3. Reset condition

• MIL: ON


• –

• Failure of NOx sensor 2 (SCR downstream)

tion (U029E) has been detected.
SAPH16F020400255
Has DTC U029E been detected?
YES NO
Go to the diagnostic procedure of a related Replace the NOx sensor 2 (SCR down-
DTC. stream).
MATION section.
DTC: P2216
EN01H16F02040F03001066
DTC: P2216 SCR outlet NOx sensor failure (High)

INFORMATION LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
(3GLD)
%NL
(6BLD)
#AQ
#AR
%NL
(CANL)
#AQ
#AR
NOx
Twist
Twist
(CANH) %JU
%JZ
Twist
Twist sensor 1
#GV
%JR LE9 LE6

H (VCC)
(CANH) (CANH) LGU
(GND)
%JW LE8 L LE7
(GND)
#GV
H L
(CANH) (CANH) (VCC)
%NM
%NN
%JQ (CANH)
%JX LEC L LEB

#GX
(CANL) (CANL) (GND)
Twist
%NM
%NN
NOx
(CANL)
%JV
PM
sensor sensor 2
L0N
#GX
(CANH) Twist
H L L0K
(CANH)
(CANL)
(CANL)
%KF
%KE
(49LD)
Twist
A7R
Twist %KR
%KP
%KQ
H L %KN
Common rail_ Twist
#AW #AW
#AV #AV
CAN J/C1
%NQ
%NP
(CANH)
(CANL)
%KM
%KL
FUSE
DCU(M)
#CP #CP
#CQ #CQ
%NP
%NQ
Twist
Twist
Twist
Twist
#SD #SD
#SF #SF
#S5 #S5
#S7 #S7
#AU #AU
LEK H(VCC) LEL
(CANH) LEM
%NH
LEJ L(GND)
Twist Twist
(CANL)
H L H L DEF
sensor
(CA1H) LCM
&1D
(CANL) K6W
(CA1L) LCN
(CANH) K6V
(G4-A)
%NH
Z30
(G4C)
ECU
Battery
ground
SAPH16F020400256
• The NOx sensor 2 (SCR downstream) is controlled by the NOx sensor controller.
and receives data.
• Failure of NOx sensor 2 (SCR downstream) is received from CAN data.

Starter switch ON.
Failure of NOx sensor 2 (SCR downstream) (High failure flag) is received from CAN data.
3. Reset condition

• MIL: ON


• –


tion (U029E) has been detected.
SAPH16F020400257
YES NO
Go to the diagnostic procedure of a related Replace the NOx sensor 2 (SCR down-
DTC. stream).
MATION section.
DTC: P2222
EN01H16F02040F03001067
DTC: P2222 NOx sensor (SCR downstream) Heater Sense Circuit Range/Performance
INFORMATION
FUSE NOx2
A99
FUSE NOx1 (3GLD)
A8V
(6BLD)
#PG
#PH
LES
(IGSW) DCU
(EXT+)
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
(EXT-)
#AQ #PG
#AR #PH
%NL
Twist
LFG
LFH
%NL
(CANL)
NOx
#AQ
#AR
(CANH) %JU
%JZ
sensor 1
Twist
LE4
LE5
LE6
#GV
%JR LE9
H (VCC)
(FAT-)
(CANH) (CANH)
(FAT+)
LGU
(GND)
Twist
%JW LE8 L LE7
(GND)
H L (CANL) (CANL)
H L
#GV
Exhaust gas %JS LED H LEA

temperature (CANH) (CANH) (VCC)
%JQ (CANH)
#GX
sensor Common rail_ %JX LEC L LEB

(SCR inlet) (CANL) (CANL) (GND)
CAN_J/C3
Twist
Twist (CANL)
%JV NOx
#GX
Engine coolant sensor 2

temperature
sensor 1 Twist
(49LD)
(CANH)
(CANL)
PM
Twist
%KF
%KE
A7R
(WTM+) E23
(WTM-) E24
%NM %NM
%NN %NN
Twist
Twist
sensor L0N %KR
(CANH) (CANH) (CANH) LEL
H
L0K %KQ %KP LEK
(CANL)
H
L
Twist (CANL) (CANL) LEM

FUSE
L
%KN LEJ
#AW #AW
DCU(M)
#AV #AV
%NH %NH
Common rail_
(CANH)
(CANL)
DEF sensor
%KM
%KL
CAN_J/C1 (DEF tank

#AU #AU
Twist
sensor)
KTU KTD
E23 K0U
#CQ #CQ
#S5 #S5
#S7 #S7
#SD #SD
#SF #SF
H L
Twist Twist
(CA1H) LCM
K6W
(CA1L) LCN
L
(AG5) LUH
(THW+) K0U
&1D
K6V
(G4-A)
(CANH)
(CANL)
Z30
ECU (G4C)
BATTERY GND
SAPH16F020400258
• The NOx sensors (SCR downstream) are controlled by the NOx sensor controller.
• The NOx sensor controller is connected to the DCU via the harness for reception and transmission of information.
• NOx sensor 2 (SCR downstream) heater malfunction is detected.

Starter switch ON.
SCR catalyst upstream temperature (exhaust gas temperature (SCR downstream)) ≥ 200 C {392 F}
Engine coolant temperature ≥ 70 C {158 F}
NOx sensor 2 does not detect appropriate NOx value even after 180 sec. after the NOx sensor 2 (SCR outlet)
heater has started to operate.
3. Reset condition

• MIL: ON


• –

• NOx sensor 2 (SCR downstream) malfunction
- Sensor internal circuit malfunction
- NOx sensor controller malfunction
1 Inspect the NOx sensor 2 (SCR downstream) connector
1. Check the connection of the NOx sensor 2 (SCR downstream)

YES NO

MATION section.
2 Inspect the NOx sensor 2 harness (CAN communication line)

CANL
CANH
4. Use the oscilloscope to measure the voltage between the termi-

Measurement Tester
Standard values
SAPH16F020400259 NOx sensor 2
vehicle-side con- Pulse waves in the
Starter switch: ON
nector range of 0 V to 5 V.
CANH – CANL
YES NO

MATION section.

GND
GND terminal in the NOx sensor 2 vehicle-side connector and the
ground.
Measurement Tester
Standard values
NOx sensor 2
1  or less
LOCK nector
SAPH16F020400260 GND – Ground
YES NO

MATION section.
4 Inspect the NOx sensor 2 harness (Power supply line)

GND
VCC 2. Use the electrical tester to measure the voltage between the termi-
Measurement Tester
Standard values
NOx sensor 2
vehicle-side con-
Starter switch: ON 9 –16 V
nector
VCC – GND
SAPH16F020400261
YES NO

MATION section.
5 Inspect exhaust gas temperature sensor (SCR inlet) connector

YES NO

MATION section.

(SCR inlet).

YES NO

(SCR inlet).
MATION section.
FAT- FAT+
nector.

Measurement Tester
Standard values
Exhaust gas tem-

LOCK (SCR upstream) 220 
FAT+ – FAT-
YES NO

(SCR inlet).
MATION section.


SAPH16F020400263
YES NO

MATION section.

perature sensor.
YES NO

MATION section.
WTM- WTM+
Measurement Tester
Standard values

LOCK sor 80 C {176 F}:
WTM+ – WTM- 0.310 – 0.326 k
SAPH16F020400264
YES NO

sor.
MATION section.
11 Check the NOx sensor 2 [HINO DX Ⅱ ]
2. Replace with a new NOx sensor 2.
5. Erase the malfunction history and perform a DPR forced regenera-

tion.

SAPH16F020400265
YES NO
Replace the DCU. (After replacing, operate Procedure completed.

DPR forced regeneration.) Perform "After-inspection work" of INFOR-
MATION section.
DTC: P2481
EN01H16F02040F03001068
DTC: P2481 Exhaust gas temperature sensor (SCR inlet) - out of range (Out of range low)
INFORMATION
Exhaust gas
LE4 LFG
temperature (FAT+) (EXT+)
sensor (FAT-)
LE5 LFH DCU
(EXT-)
(SCR inlet)
SAPH16F020400266
• Exhaust gas temperature sensor (SCR inlet) monitors the temperature at the SCR upstream.
• Exhaust gas temperature sensor (SCR inlet) detects disconnection and short-circuit based on the circuit voltage
and signals in DCU.
• Failure of exhaust gas temperature sensor (SCR inlet) is detected.

Starter switch ON.
Exhaust gas temperature sensor voltage: Less than 0.7 V
3. Reset condition

• MIL: ON


• –

• Exhaust gas temperature sensor (SCR inlet)
- Sensor disconnection
- Abnormal resistance of sensor

YES NO

MATION section.

(SCR inlet).

YES NO

(SCR inlet).
MATION section.
FAT- FAT+
nector.

Measurement Tester
Standard values
Exhaust gas tem-

SAPH16F020400267 perature sensor
LOCK 220 
FAT+ – FAT-
YES NO

(SCR inlet).
MATION section.
4 Inspect for short-circuit in the exhaust gas temperature sensor (SCR inlet) harness

EXT+ EXT-
SAPH16F020400268
Measurement Tester
Standard values
DCU 86P vehicle-


LOCK EXT+ – Ground
EXT- – Ground
YES NO

MATION section.
5 Inspect disconnection of the exhaust gas temperature sensor (SCR inlet) harness
1. Connect the exhaust gas temperature sensor (SCR inlet) connec-

tor.
EXT+ EXT-
SAPH16F020400269
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 220 
EXT+ – EXT-
YES NO

MATION section.
1. Perform an engine warm-up. (Coolant temperature: 60 C {140 F}

or more)
SAPH16F020400270
YES NO

MATION section.
DTC: P2482
EN01H16F02040F03001069
DTC:P2482 Exhaust gas temperature sensor (SCR inlet) - out of range (Out of range high)
INFORMATION
Exhaust gas
LE4 LFG
temperature (FAT+) (EXT+)
sensor (FAT-)
LE5 LFH DCU
(EXT-)
(SCR inlet)
SAPH16F020400271
• Exhaust gas temperature sensor (SCR inlet) monitors the temperature at the SCR upstream.
• DCU detects disconnection and short-circuit based on the circuit voltage of the exhaust gas temperature sensor
(SCR inlet).

Starter switch ON.
Exhaust gas temperature sensor voltage: More than 2.2 V
3. Reset condition

• MIL: ON


• –

• Exhaust gas temperature sensor (SCR inlet)
- Sensor disconnection
- Abnormal resistance of sensor

YES NO

MATION section.

(SCR inlet).

YES NO

(SCR inlet).
MATION section.
FAT- FAT+
nector.

Measurement Tester
Standard values
Exhaust gas tem-

FAT+ – FAT-
YES NO

(SCR inlet).
MATION section.
4 Inspect for short-circuit in the exhaust gas temperature sensor (SCR inlet) harness
EXT+ EXT-
SAPH16F020400273
Measurement Tester
Standard values
DCU 86P vehicle-


LOCK EXT+ – Ground
EXT- – Ground
YES NO

MATION section.
5 Inspect disconnection of the exhaust gas temperature sensor (SCR inlet) harness
1. Connect the exhaust gas temperature sensor (SCR inlet) connec-

tor.
EXT+ EXT-
SAPH16F020400274
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 220 
EXT+ – EXT-
YES NO

MATION section.

or more)
SAPH16F020400275
YES NO

DTC: P2483
EN01H16F02040F03001070
DTC: P2483 Exhaust gas temperature sensor (SCR inlet) - rationality

INFORMATION (at engine start)
Exhaust gas (ATSS) LNM LGJ (HH1+)

LE4 LFG
(FAT+) (EXT+)
temperature (ATS-) LNN LGK (HH1-)
LE5 LFH DCU
sensor 4 (FAT-) (EXT-)
LQV
LQU
Ambient air
(DPR outlet) temperature
Exhaust gas
(ER-)
(ER+)
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
KSG sensor
(TEX2) temperature
Twist
KSH sensor
(GND2)
resistance
(CANL)
NOx
Differential
(CNNH) %JU
%JZ
sensor 1
Twist
pressure %JR LE9
H (VCC)
sensor (CANH) (CANH)
(GND)
Twist
(VCC) %JW LE8 L
(GND)
H L (CANL) (CANL)
(VOUT) H L
%JS LED H
KSL
(GND) Engine (CANH) (CANH)
%JQ (CANH)
coolant Common rail_ %JX LEC L
temperature (CANL) (CANL)
CAN_J/C3
Twist
sensor 1
NOx
(CANL)
Twist
%JV
EGR gas sensor 2
LCG
LCT
temperature
sensor Twist
%NM %NM
%NN %NN
(CANH)
(CANL)
Air flow sensor
KSG
KSL
(THG)
%KF
%KE
PM
(E2)
(WTM-) E24
(WTM+) E23
Twist
Twist
sensor L0N
Twist
%KR
(AFT+) KTT
(AFT-) KTU
(AFVB) KTS
(AFGD) KTR
(AFSG) KTQ
LHN
LHM
(CANH) (CANH) (CANH) (CANH)
H
L0K %KQ %KP LEK
Twist (CANL) (CANL)
H
L
(CANL) (CANL)
#AW #AW
#AV #AV
L
CAN_J/C1
LCG
KRB
(CANH)
(CANL)
DEF sensor
%KM
%KL
(DEF tank
KTT K0W
KTU KTD
KTQ LCH
KTR L2P
KTS L75
Twist Twist #CP #CP Twist temperature

KSG
KSL
sensor)
E23 K0U
#CQ #CQ
#S5 #S5
#S7 #S7
#SD #SD
#SF #SF
H L
Twist
H L Twist
(CA1H) LCM
LCG
KRB
K0W
K6W
(CA1L) LCN
LUG
LUH
LCH
(THW+) K0U
K6V
LS0
LL8
L75
(ET4+)
(ADG3)
(ETH2)
(AGD7)
(THA+)
(AG5)
(AFVB)
(AG4)
(AFSI)
(CANH)
(CANL)
ECU
SAPH16F020400276
• Exhaust gas temperature sensor (SCR inlet) rationality is checked by temperature model calculated from exhaust
gas temperature sensor 4 (DPR outlet).
• Failure of exhaust gas temperature sensor (SCR inlet) is detected.7

• Difference of Ambient air temperature between engine coolant temperature (from Engine ECU): ≤ 8 C {46.4
F}
• Difference of DEF tank temperature between Ambient air temperature: ≤ 8 C {46.4 F}
• Difference of engine coolant temperature (from Engine ECU) between DEF tank temperature: ≤ 8 C {46.4 F}
• At least 10 seconds has elapsed since engine startup
• Max engine coolant temperature (from Engine ECU) at previous driving cycle > 70 C {158 F}
Difference between exhaust gas temperature sensor (SCR inlet) and ambient air temperature: > 100 C {212 F}
for 1sec.
3. Reset condition

• MIL: ON
• DEF injection is restricted.


• –

• Failure of exhaust gas temperature sensor 4 (DPR outlet)
DTC: P2483 Exhaust gas temperature sensor (SCR inlet) - rationality

INFORMATION (at engine running)
Exhaust gas (ATSS) LNM LGJ (HH1+)

LE4 LFG
(FAT+) (EXT+)
temperature (ATS-) LNN LGK (HH1-)
LE5 LFH DCU
sensor 4 (FAT-) (EXT-)
LQV
LQU
Ambient air
(DPR outlet) temperature
Exhaust gas
(ER-)
(ER+)
LF5 (CAH1)
LEY (CAH0)
LF6 (CAL1)
LF2 (TE1B)
LF1 (TE1A)
LF4 (TE2B)
LF3 (TE2A)
LEZ (CAL0)
KSG sensor
(TEX2) temperature
Twist
KSH sensor
(GND2)
resistance
(CANL)
NOx
Differential
(CNNH) %JU
%JZ
sensor 1
Twist
pressure %JR LE9
H (VCC)
sensor (CANH) (CANH)
(GND)
Twist
(VCC) %JW LE8 L
(GND)
H L (CANL) (CANL)
(VOUT) H L
%JS LED H
KSL
(GND) Engine (CANH) (CANH)
%JQ (CANH)
coolant Common rail_ %JX LEC L
temperature (CANL) (CANL)
CAN_J/C3
Twist
sensor 1
NOx
(CANL)
Twist
%JV
EGR gas sensor 2
LCG
LCT
temperature
sensor Twist
%NM %NM
%NN %NN
(CANH)
(CANL)
Air flow sensor
KSG
KSL
(THG)
%KF
%KE
PM
(E2)
(WTM-) E24
(WTM+) E23
Twist
Twist
sensor L0N
Twist
%KR
(AFT+) KTT
(AFT-) KTU
(AFVB) KTS
(AFGD) KTR
(AFSG) KTQ
LHN
LHM
(CANH) (CANH) (CANH) (CANH)
H
L0K %KQ %KP LEK
Twist (CANL) (CANL)
H
L (CANL) (CANL)
#AW #AW
#AV #AV
L
CAN_J/C1
LCG
KRB
(CANH)
(CANL)
DEF sensor
%KM
%KL
(DEF tank
KTT K0W
KTU KTD
KTQ LCH
KTR L2P
KTS L75
Twist Twist #CP #CP Twist temperature

KSG
KSL
sensor)
E23 K0U
#CQ #CQ
#S5 #S5
#S7 #S7
#SD #SD
#SF #SF
H L
Twist
H L Twist
(CA1H) LCM
LCG
KRB
K0W
K6W
(CA1L) LCN
LUG
LUH
LCH
(THW+) K0U
K6V
LS0
LL8
L75
(ET4+)
(ADG3)
(ETH2)
(AGD7)
(THA+)
(AG5)
(AFVB)
(AG4)
(AFSI)
(CANH)
(CANL)
ECU
SAPH16F020400277
• Exhaust gas temperature sensor (SCR inlet) rationality is checked by temperature model calculated from exhaust
gas temperature sensor 4 (DPR outlet).

• Engine speed ≥ 1000 rpm, and
• Time elapsed since engine start > 10sec
• Fuel injection quantity (from Engine ECU) ≥ 10 mg/cyl/sec
• MAF (from Engine ECU) ≥ 300 kg/h
1. Calculated exhaust gas temperature sensor (SCR inlet): > 210 C {410 F} more than 10 sec.
2. Actual exhaust gas temperature sensor (SCR inlet): < 160 C {320 F} for 7 sec.
or
1. Calculated exhaust gas temperature sensor (SCR inlet): < 210 C {410 F} more than 10 sec.
2. Actual exhaust gas temperature sensor (SCR inlet): < 260 C {320 F} for 7 sec.
3. Reset condition

• MIL: ON


• –

• Failure of exhaust gas temperature sensor 4 (DPR outlet)

YES NO

MATION section.

(SCR inlet).

YES NO

(SCR inlet).
MATION section.
FAT- FAT+
nector.

Measurement Tester
Standard values
Exhaust gas tem-

FAT+ – FAT-
YES NO

(SCR inlet).
MATION section.

Ambient air
temperature
sensor
Bumper
SAPH16F020400279
YES NO

MATION section.

ture sensor.
YES NO

connector and install it properly. If damaged,
replace the ambient air temperature sensor.
MATION section.

HH1- HH1+
HH1- HH1+
LGK LJK
Measurement Tester
Standard values
Ambient air tem-

perature sensor
LOCK 1.7 k
HH1+ – HH1-
SAPH16F020400280
YES NO

MATION section.

poor contact).
YES NO

MATION section.
8 Inspect the ambient air temperature sensor harness
ATS- ATSS
SAPH16F020400281
Measurement Tester
Standard values
DCU 86P vehicle-

side connector
LOCK 3.7 k
ATSS – ATS-
YES NO

YES NO

MATION section.

ER- ER+
Measurement Tester
Standard values

2 k
LOCK ER+ – ER-
SAPH16F020400282
YES NO
Repair or replace the harness. Replace the external resistor.

11 Inspect the exhaust gas temperature sensor 4 (DPR outlet) connector
1. Check the connection of the exhaust gas temperature sensor 4

(DPR outlet) connector (Looseness and poor contact).
YES NO

MATION section.
12 Inspect the exhaust gas temperature sensor 4 (DPR outlet)
1. Check the installation of the exhaust gas temperature sensor 4

(DPR outlet).

ture sensor 4 (DPR outlet).

YES NO
Clean the exhaust gas temperature sensor 4 Go to step 13.

(DPR outlet) and install it properly. If dam-
aged, replace the exhaust gas temperature
sensor 4 (DPR outlet).
MATION section.
13 Inspect the exhaust gas temperature sensor 4 (DPR outlet) unit
1. Disconnect the exhaust gas temperature sensor 4 (DPR outlet)

connector.
TEX2 GND2

terminals of the exhaust gas temperature sensor 4 (DPR outlet).
Measurement Tester
Standard values
20 C {68 F}:
Exhaust gas tem- 13.7 – 29.8 k
Starter switch: perature sensor 4 50 C {122F}:
SAPH16F020400283 LOCK (DPR outlet) 7.13 – 13.7 k
TEX2 – GND2 80 C {176 F}:
4.1 – 7.13 k
YES NO

4 (DPR outlet).
MATION section.

YES NO

MATION section.

perature sensor.
YES NO

MATION section.
WTM- WTM+
Measurement Tester
Standard values

LOCK sor 80 C {176 F}:
WTM+ – WTM- 0.310 – 0.326 k
SAPH16F020400284
YES NO

sor.
MATION section.
Air flow sensor 2. Make sure there is no dirt or damage to the air flow sensor.
SAPH16F020400285
YES NO

MATION section.

or more)
2. Stop the engine.
SAPH16F020400286
YES NO

DTC: P2510
EN01H16F02040F03001071
DTC: P2510 DeNOx Power Relay Sense Circuit Range/Performance

INFORMATION
DCU
FUSE DCU(B)
#GT #GT #GU #GU %NK %NK LEN (+B1)
MAIN FR
W/H W/H
LEP (+B2)
LEQ (+B3)
LER (+B4)
Main
relay
control
DEF pump
power supply
SAPH16F020400287
• After turning off starter switch, DCU stays active for few minutes to evacuation DEF from lines to tank, then writes
the data to the DCU ROM before shut-down.
• After completion of data writing to the ROM, the DCU switches the main relay (built-in in the DCU) off.
• The DCU confirms the ROM and checks that the preceding ROM data writing as being completed correctly.
• Failure detected in the main relay.

Engine operating.
When the ROM data writing status was incomplete before the preceding DCU shut-down.
3. Reset condition
• Detects that the DCU was successfully finished during the previous operation.

• MIL: ON


• –

• Battery
- Too high or low voltage
- Battery replaced before the complete shut-down of the DCU was performed
- When the battery voltage was cut before the complete DCU shut-down
• DCU malfunction
P0562) has been detected.
HINT
If the battery switch is turned OFF or the battery terminal is
removed when the DCU is shut down, the present fault code
(P2510) may be detected.
SAPH16F020400288
YES NO
2 Inspect the DCU power supply circuit

+B2 GND4 GND1
LEP LEW LET
+B2 GND4 GND1
LEP LEW LET
+B3 GND5 GND2

+B3 GND5 GND2
LEQ LEX LEU
LEQ LEX LEU
+B4
LER
+B1
LEN
GND3
LEV measure the voltage between the each terminal of DCU 53P vehi-
+B4 +B1 GND3
LER LEN LEV cle-side connector and the battery minus (BAT-).
CAH1
LF5
Measurement Tester
CAL1
Standard values
TE1B
LF6
LF2
TE1A CAH0
LF1
TE2B
LEY
CAL0
DCU 53P vehicle-
side connector –
LF4 LEZ
TE2A
LF3
BAT-
Starter switch: ON +B1 – BAT- 9 V – 16 V
IGSW
LES +B2 – BAT-
+B3 – BAT-
Battery +B4 – BAT-
SAPH16F020400289
YES NO
Go to step 3. Inspect or repair the power supply circuit

(harness).
MATION section.
3 Inspect the DCU harness

2. Disconnect the connector between the cab main harness and
+B2 GND4 GND1
LEP LEW LET chassis front harness.
+B2 GND4 GND1
LEP LEW LET
+B3 GND5 GND2

+B3
LEQ
GND5
LEX
GND2
LEU LEQ LEX LEU 3. Connect the signal check harness and use the electrical tester to
+B4
LER
+B1
LEN
GND3
LEV
measure the resistance between the DCU 53P vehicle-side con-
+B4
LER
+B1
LEN
GND3
LEV
nector and each terminal of the chassis front harness connector
(chassis side) of the cab main harness.
CAH1
LF5
CAL1
LF6 Measurement Tester
Standard values
TE1B
LF2 conditions connections
TE1A CAH0
LF1 LEY
TE2B
LF4
CAL0
LEZ DCU 53P vehicle-
TE2A
LF3
side connector –
chassis side con-
Starter switch: nector
IGSW +B 1
1  or less
+B1 – #GT
LES #GS #J7
6
#96
IG 14 16 9 5 2
3
#93 LOCK
+B
#GX #FE #MG #M9 #JB #J8
4 +B2 – #GT
#GR 5 22 13 12 10 6 3 #94
+B
#F5 #FN #MD #MC #MA #JC #J9
5
+B3 – #GT
+B4 – #GT
21 14 15 11 4
#GT #FM #ME #MF #MB #JA #95
Cab main harness to

chassis front harness
connector (chassis side)
SAPH16F020400290
YES NO
Go to step 4. Inspect or repair the power supply circuit

(harness).
MATION section.
2. Select [DCU].
4. Start up the engine.
5. Keep the vehicle connecting to HINO DX Ⅱ and set the starter

switch to the "LOCK" position.
When communicat-
ion with the engine 6. After checking that communication between HINO DX Ⅱ and the
ECU is interrupted DCU has been disconnected, set the starter switch to the "ON"
while the engine position again.
ECU is connected
to the HINO DXⅡ,
the connection
symbol at the left
bottom of the HINO
DXⅡ screen
becomes
disconnected.
SAPH16F020400291
Has DTC P2510 detected?
YES NO

DTC: P2BAE
EN01H16F02040F03001072
DTC: P2BAE Feedback control

INFORMATION
Air flow sensor

LCH KTQ LCH KTQ (AFSG)
(AFSI)
LUG KTR L2P KTR (AFGD)
(AG4)
L75 KTS L75 KTS (AFVB)
(AFVB)
LUH KTU KTD KTU (AFT-)
(AG5)
K0W KTT K0W KTT (AFT+) DCU
(THA+)
#S5 #S5 #AW #AW %NM %NM LF5 (CAH1)

(CA1H) LCM
H H Exhaust gas
#S7 #S7 #AV #AV %NN %NN LF6 (CAL1) temperature
(CA1L) LCN
L L sensor
Twist
Twist
Twist
Twist
(SCR inlet)
Engine
ECU
(CANH) K6V #SD #SD #CP #CP (EXT-) LFH LE5 (FAT-)
LEY
(CANL) K6W #SF #SF #CQ #CQ (CAH0)
LEZ
(CAL0)
Twist
Twist
Twist
Common rail_
CAN_J/C1
(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
Twist
(CANH)
(CANH)
%JS
%JW
(CANL)
(CANL)
%JX
%JR
(CANL)
(CANH)
%KN
%KP
Twist Twist Twist
Twist
(CANH)
(CANL)
(CANH)
(CANH)
(CANL)
(CANL)
LEJ
LEK
LEC
LED
LE9
LE8
L H H H
L L
DEF sensor NOx NOx

SAPH16F020400292
• The DEF injection control feeds back DEF dose if a measured NOx purification quantity deviates from an estimated
NOx purification rate.
• The NOx sensor measures NOx level and also counts NH3 as NOx.
• Failure of DEF injection control is detected.
• Feedback is reset when the target purification quantity during feedback implementation is stuck at the maximum
value. If reset is repeated, this DTC is detected.

The engine is ON.
Dosing feedback is reset 3 times at an interval of 180 sec. or shorter.
3. Reset condition

• MIL: ON


• –

• It is likely that a NOx purification quantity has dropped or NH3 slip has occurred.
(When the amount of NOx to be purified is small compared with the amount of DEF solution, NH3-slip will occur. In
the NOx sensor, NH3 is functionally counted as NOx; when NH3-slip occurs, therefore, the NOx sensor reading will
be higher than the actual value.)
• NOx sensor 1 (SCR upstream)
- If the NOx sensor 1 (SCR upstream) reads low or high NOx due to malfunction, the NOx sensor 2 (SCR down-
stream) reading may be high due to NH3 slip.
• NOx sensor 2 (SCR downstream)
- It is likely that the NOx sensor 2 (SCR downstream) reads high NOx.
• DEF: Low concentration
• DEF dose: Excessively low level of DEF dose
• SCR catalyst: When purification performance is degraded by deterioration of the catalyst, feedback control will be
activated.
NOTICE
If no trouble causes are found, it can be suspected that the respective DTC was issued because of a temporary
fault condition caused by the freezing of the DEF.
INSPECTION PROCEDURE: P2BAE

Refer to the "INSPECTION PROCEDURE: P207F" in the chapter "ENGINE CONTROL SYSTEM (J08E)".
DTC: U0029
EN01H16F02040F03001073
DTC: U0029 Vehicle Communication Bus A Performance

INFORMATION
Common rail J/C1 Common rail CAN J/C3

KRH %JC %JZ
Twist (CA2L) %JV(CANL) (CANL)0.50 W - %NS
L (EJ1L) L %NS
0.50 W -
KGR %JD #SF %JQ(CANH) H %JU 0.50 B - %NR %NR

Twist
(CA2H) H (EJ1H) (LEZ) #SF (CANH)
0.50 R -
0.50 W -
(CANH)
(CANL)
(CANH)
(CANL)
%JW
%JR
%JX
%JS
Twist
(L4R) %J8
(L4S) %J5
(KV8) %J3
(KV9) %J2
#SD #SD
0.50 W -
Twist Common (LEY)
Twist
rail J/C2
#CQ 0.50 W -
#CP 0.50 R -
0.50 R -
%JA %J6
LE8 0.75 W -
LEC 0.75 W -
LE9 0.75 V -
LED 0.75 V -
0.50 R -
(EJ2L) (LEZ) Twist

L Twist
%JB %J7
(CANH)
(CANL)
0.50 W -
0.50 B -
(CANH)
(CANH)
(CANL)
(CANL)
(EJ2H)
F2E
F2F
H (LEY)
Twist
0.50 W -
(K6V) %J4
(K6W) %J1
0.50 B -
Twist Twist
0.50 B - #CP
0.50 W - #CQ
(CAH0)
(CAL0)
LEY
NOx NOx
LEZ
sensor 1 sensor 2
CAN TMN
Twist
Twist
Common rail CAN J/C1
%KL %KE
(CANL)
%KM
L (CANL)
%KF
DCU
0.50 W -
0.50 W -
0.50 W -
0.50 R -
0.50 R -
0.50 R -
(CANH) H (CANH)
%KR
%KQ
%KP
(CANH)
%KN
(CANL)
(CANH)
(CANL)
Twist
-
B-
0.50 W -
B-
0.50 W
(EGRH)
(CANH)
(EGRL)
(VNTH)
(CANL)
(VNTL)
0.50
LEK 0.50
K6W
KV8
KV9
K6V
L4R
L4S
(CANH)
(CANH)
(CANL)
(CANL)
L0N
LEJ
L0K
EGR VNT Engine

DEF PM
Controller Controller ECU Sensor Sensor
SAPH16F020400293
• Vehicle communication bus (CAN) A (ENGINE CAN LINE) is connected to CAN terminator, Engine ECU, EGR,
VNT, NOx sensor 1 (SCR upstream), NOx sensor 2 (SCR downstream), DEF sensor and DCU.
• Interruption in CAN communication is detected.

Starter switch ON.
DCU cannot receive all message from CAN A (ENGINE CAN LINE).
3. Reset condition



• –

• DCU malfunction
INSPECTION PROCEDURE: U0029

Refer to the "ENGINE CAN COMMUNICATION LINE" in the chapter "CAN COMMUNICATION".
DTC: U0038
EN01H16F02040F03001074
DTC: U0038 Vehicle Communication Bus B Performance

INFORMATION
Diagnosis
Connector Vehicle Control ECU
(16P)
Meter
(CDGH)
(ECAH)
L83
L84
L8Y
L8Z
(CDGL)
(ECAL)
(CAN+)
(CAN-)
KS4
KS3
(MC5-)
ER0
(MC5+)
ER1
Twist
Twist
Twist
Twist
Twist
(METL)
(CANL)
%L6
%JG
CAN_J/C2_Low CAN_J/C3_Low
Twist Twist Twist

%JF %JH %L5 %L4
(CANL) (CANL) (METL) (METL) Telematics
%K1 Unit
(DLC3)
(METH)
%F5
(CANH)
(DLC3)
Twist
%F4
(CANH)
%L3
ESU
%JC
(ENCH)
ESV
(ENCL)
Twist
%K2
%L2 %L1 (CANL)
%JB %JD
(CANH) (CANH) (METH) (METH)
#S1
#S3
CAN_J/C3_High
CAN_J/C2_High
(500L)
(500H)
(500H)
#S1
#S3
#S5 #S5
#S7
Twist
#S7
Twist
(CA1L)
(CA1H)
(500L)
#AW
%JP
%JL
#AV
Twist
Twist
%JM
#AW
#AV
(CA1H) H L
No.30_J/C
%JK
(CA1L)
(CA1L)
(CA1H)
%JN
%JJ
Twist
Twist
(CAH1)
(CA1H)
(CAL1)
(CA1L)
LF6
LCM
LF5
LCN
DCU ECU
SAPH16F020400294
• Vehicle communication bus B (Diagnosis CAN line) is connected to diagnosis connector for HINO DX Ⅱ .
• Interruption in CAN communication is detected.

Starter switch ON.
DCU cannot receive all massage from CAN B (Diagnosis CAN line).
3. Reset condition

• –

• –

• –

• Disconnection of CAN line.

Refer to the "DIAGNOSIS CAN COMMUNICATION LINE" in the chapter "CAN COMMUNICATION".
DTC: U0100
EN01H16F02040F03001075
DTC: U0100 DeNOx ECU CAN communication (ECM)

INFORMATION
DCU
#S5 #S5 #AW #AW %NM %NM LF5 (CAH1)

(CA1H) LCM
H H
#S7 #S7 #AV #AV %NN %NN LF6 (CAL1)
(CA1L) LCN
L L
Twist Twist Twist
CAN B (500 k)
Engine
ECU CAN A (250 k)
LEY
(CAH0)
(CAL0)
(CANL) K6W #SF #SF #CQ #CQ Twist

Twist
Twist
Common rail_
CAN_J/C1
(CANH) H (CANH)
%KL %KE %JV L %JZ
Twist
Twist
Twist
%JX
(CANL)
%JS
(CANH)
%JW
(CANL)
%JR
(CANH)
%KN
(CANL)
%KP
(CANH)
Twist Twist Twist
Twist
(CANH)
(CANL)
(CANH)
(CANH)
(CANL)
(CANL)
LEJ
LEK
LEC
LED
LE9
LE8
L H H H
L L
DEF sensor NOx NOx

SAPH16F020400295
• The DCU carries out CAN communication with the engine ECU via CAN circuit A (ENGINE CAN LINE/250 k) and
CAN circuit B (DIAGNOSIS CAN LINE/500 k).
• CAN communication signal reception error is detected.

Starter switch ON.
CAN communication signal from the engine ECU cannot be received.
3. Reset condition


• Exhaust gas purification function decline.

• –

• Looseness or poor contact of the connector
• DCU malfunction
• Engine ECU malfunction
1 Check the DTC detected (Engine)
3. Select [Engine] and check if the following CAN communication

system DTCs have been detected.
CAN A LINE (ENGINE CAN LINE/250k)

U010A, U010C, U029D, U029E, U0073, U010E, U02A2
CAN B LINE (DIAGNOSIS CAN LINE/500k)

U1001, U110A
SAPH16F020400296
Were the multiple CAN communication system DTCs detected?
YES NO
Considered failure of the main CAN commu- Go to step 2.

nication line. Refer to "ENGINE CAN COM-
MINICATION LINE / CAN COMMUNICATION
LINE MALFANCTION PART DETERMINATION
TABLE" and "DIAGNOSIS CAN COMMINICA-
TION LINE / CAN COMMUNICATION LINE
MALFANCTION PART DETERMINATION
TABLE" of CAN chapter, and inspect the
diagnosed item of the detected DTC.
2 Inspect the connector
1. Check the connection of the joint connector No.30_J/C, Common

rail_CAN_J/C3 and DCU connector (Looseness and poor contact).
YES NO
Repair or replace the faulty part, and go to Connect securely, and go to step 3.
step 3.
2. Select [DCU] and check if U0100 has been detected.
SAPH16F020400297
Has DTC U0100 been detected?
YES NO

DTC: U029D
EN01H16F02040F03001076
DTC: U029D DeNOx ECU CAN communication (NOx sensor (SCR upstream))
INFORMATION

KRH %JC %JZ
L (EJ1L) L %NS
0.50 W -

Twist
0.50 R -
0.50 W -
(CANH)
(CANL)
(CANH)
(CANL)
%JW
%JR
%JX
%JS
Twist
(L4R) %J8
(L4S) %J5
(KV8) %J3
(KV9) %J2
#SD #SD
0.50 W -
Twist Common (LEY)
Twist
rail J/C2
#CQ 0.50 W -
#CP 0.50 R -
0.50 R -
%JA %J6
LE8 0.75 W -
LEC 0.75 W -
LE9 0.75 V -
LED 0.75 V -
0.50 R -
(EJ2L) (LEZ) Twist

L Twist
%JB %J7
(CANH)
(CANL)
0.50 W -
0.50 B -
(CANH)
(CANH)
(CANL)
(CANL)
(EJ2H)
F2E
F2F
H (LEY)
Twist
0.50 W -
(K6V) %J4
(K6W) %J1
0.50 B -
Twist Twist
0.50 B - #CP
0.50 W - #CQ
(CAH0)
(CAL0)
LEY
NOx NOx
LEZ
sensor 1 sensor 2
CAN TMN
Twist
Twist
%KL %KE
(CANL)
%KM
L (CANL)
%KF
DCU
0.50 W -
0.50 W -
0.50 W -
0.50 R -
0.50 R -
0.50 R -
(CANH) H (CANH)
%KR
%KQ
%KP
(CANH)
%KN
(CANL)
(CANH)
(CANL)
Twist
-
B-
0.50 W -
B-
0.50 W
(EGRH)
(CANH)
(EGRL)
(VNTH)
(CANL)
(VNTL)
0.50
LEK 0.50
K6W
KV8
KV9
K6V
L4R
L4S
(CANH)
(CANH)
(CANL)
(CANL)
L0N
LEJ
L0K
EGR VNT Engine

DEF PM
SAPH16F020400298
• NOx sensor communicates with DCU via CAN.
• CAN message from NOx sensor 1 (SCR upstream) cannot be received.

Starter switch ON.
Continuously checked in the configured raster: [0] – 10
CAN data from NOx sensor 1 (SCR upstream) is interrupted for 0.25 seconds
3. Reset condition

• MIL: 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.


• –

• CAN line disconnection
• Crossed lines
• Abnormal external noise
INSPECTION PROCEDURE: U029D

DTC: U029E
EN01H16F02040F03001077
DTC: U029E DeNOx ECU CAN communication (NOx sensor (SCR downstream))
INFORMATION

KRH %JC %JZ
L (EJ1L) L %NS
0.50 W -
Twist
0.50 R -
0.50 W -
(CANH)
(CANL)
(CANH)
(CANL)
%JW
%JR
%JX
%JS
Twist
(L4R) %J8
(L4S) %J5
(KV8) %J3
(KV9) %J2
#SD #SD
0.50 W -
Twist Common (LEY)
Twist
rail J/C2
#CQ 0.50 W -
#CP 0.50 R -
0.50 R -
%JA %J6
LE8 0.75 W -
LEC 0.75 W -
LE9 0.75 V -
LED 0.75 V -
0.50 R -
(EJ2L) (LEZ) Twist

L Twist
%JB %J7
(CANH)
(CANL)
0.50 W -
0.50 B -
(CANH)
(CANH)
(CANL)
(CANL)
(EJ2H)
F2E
F2F
H (LEY)
Twist
0.50 W -
(K6V) %J4
(K6W) %J1
0.50 B -
Twist Twist
0.50 B - #CP
0.50 W - #CQ
(CAH0)
(CAL0)
LEY
NOx NOx
LEZ
sensor 1 sensor 2
CAN TMN
Twist
Twist
%KL %KE
(CANL)
%KM
L (CANL)
%KF
DCU
0.50 W -
0.50 W -
0.50 W -
0.50 R -
0.50 R -
0.50 R -
(CANH) H (CANH)
%KR
%KQ
%KP
(CANH)
%KN
(CANL)
(CANH)
(CANL)
Twist
-
B-
0.50 W -
B-
0.50 W
(EGRH)
(CANH)
(EGRL)
(VNTH)
(CANL)
(VNTL)
0.50
LEK 0.50
K6W
KV8
KV9
K6V
L4R
L4S
(CANH)
(CANH)
(CANL)
(CANL)
L0N
LEJ
L0K
EGR VNT Engine
DEF PM
SAPH16F020400299
• NOx sensor communicates with DCU via CAN.
• CAN message from NOx sensor 2 (SCR downstream) cannot be received.

Starter switch ON.
CAN data from NOx sensor 2 (SCR downstream) is interrupted for 0.25 seconds
3. Reset condition

• MIL: ON


• –

• CAN line disconnection
• Abnormal external noise
• Crossed lines
INSPECTION PROCEDURE: U029E

DTC: U02A2
EN01H16F02040F03001078
DTC: U02A2 Communication disrupt (DEF tank sensor)

INFORMATION

KRH %JC %JZ
L (EJ1L) L %NS
0.50 W -

Twist
0.50 R -
0.50 W -
(CANH)
(CANL)
(CANH)
(CANL)
%JW
%JR
%JX
%JS
Twist
(L4R) %J8
(L4S) %J5
(KV8) %J3
(KV9) %J2
#SD #SD
0.50 W -
Twist Common (LEY)
Twist
rail J/C2
#CQ 0.50 W -
#CP 0.50 R -
0.50 R -
%JA %J6
LE8 0.75 W -
LEC 0.75 W -
LE9 0.75 V -
LED 0.75 V -
0.50 R -
(EJ2L) (LEZ) Twist

L Twist
%JB %J7
(CANH)
(CANL)
0.50 W -
0.50 B -
(CANH)
(CANH)
(CANL)
(CANL)
(EJ2H)
F2E
F2F
H (LEY)
Twist
0.50 W -
(K6V) %J4
(K6W) %J1
0.50 B -
Twist Twist
0.50 B - #CP
0.50 W - #CQ
(CAH0)
(CAL0)
LEY
NOx NOx
LEZ
sensor 1 sensor 2
CAN TMN
Twist
Twist
%KL %KE
(CANL)
%KM
L (CANL)
%KF
DCU
0.50 W -
0.50 W -
0.50 W -
0.50 R -
0.50 R -
0.50 R -
(CANH) H (CANH)
%KR
%KQ
%KP
(CANH)
%KN
(CANL)
(CANH)
(CANL)
Twist
-
B-
0.50 W -
B-
0.50 W
(EGRH)
(CANH)
(EGRL)
(VNTH)
(CANL)
(VNTL)
0.50
LEK 0.50
K6W
KV8
KV9
K6V
L4R
L4S
(CANH)
(CANH)
(CANL)
(CANL)
L0N
LEJ
L0K
EGR VNT Engine

DEF PM
SAPH16F020400300
• DEF tank sensor communicates with DCU via CAN.
• CAN communication with DEF sensor is interrupted.

Starter switch ON.
DCU power supply voltage is 11 V – 16 V.
CAN data from DEF sensor are not received for at least 30 seconds.
3. Reset condition
• After normal operation is restored and the starter switch is turned OFF.

• MIL: ON


• –

• CAN circuit failure (engine CAN)
• DEF sensor failure
• DEF sensor power supply/GND harness disconnection or short-circuit
INSPECTION PROCEDURE: U02A2

DTC: U0597
EN01H16F02040F03001079
DTC: U0597 Invalid Data Received From AC to DC Converter (DeNOx ECU)

INFORMATION
• The AC/DC converter inside the DCU is checked inside the DCU.
• Failure of AC/DC converter inside DCU is detected.

Starter switch ON.
Failure of AC/DC converter inside DCU is detected.
3. Reset condition

• MIL: ON

• –


• DCU malfunction
3. Select [DCU] in the HINO DX Ⅱ menu and check the communica-

tion between the HINO DX Ⅱ and the DCU.

When communicat-
ion with the engine
ECU is interrupted 6. Check if the DCU main relay is OFF in the HINO DX Ⅱ menu. (This
while the engine cuts off the communication between HINO DX Ⅱ and the DCU.)
ECU is connected
HINT
to the HINO DXⅡ,
the connection
symbol at the left ture (SCR inlet) drops below 200 C {392 F}.
bottom of the HINO
DXⅡ screen 7. Set the starter switch to the "ON" position.
becomes
disconnected.
SAPH16F020400301
YES NO

MATION section.
BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION)) 9–1

(ABS:HYDRAULIC (E VERSION))
9 9-001
ABS .............................................................................. 9-2

TROUBLESHOTTING............................................. 9-2
9–2 BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION))
ABS
TROUBLESHOTTING
EN01H16F06080F03001001
BEFORE YOU BEGIN

This manual provides maintenance and service instructions for Meritor
WABCO's hydraulic ABS for medium-duty trucks, buses and motor
home chassis. Before you begin procedures:
1. Read and understand all instructions and procedures before you

begin to service components.
2. Read and observe all Caution and Warning safety alerts that pre-
cede instructions or procedures you will perform. These alerts help
to avoid damage to components, serious personal injury, or both.
3. Follow your company's maintenance and service, installation, and
diagnostics guidelines.
4. Use special tools when required to help avoid serious personal injury
and damage to components.
1. SAFETY ALERTS, TORQUE SYMBOL AND NOTES
! WARNING A Warning alerts you to an instruc-

tion or procedure that you must fol-
low exactly to avoid serious
personal injury and damage to
components.
! CAUTION A Caution alerts you to an instruc-

tion or procedure that you must fol-
low exactly to avoid damage to
components and possible serious
injury.
NOTICE A Note provides information or

suggestions that help you correctly
service a component.
2. ACCESS INFORMATION ON ARVINMERITOR'S WEB SITE

Additional maintenance and service information for ArvinMeritor's com-
mercial vehicle systems component lineup is also available at
www.arvinmeritor.com.
To access information, click on Products & Services/Tech Library Icon/

HVS Publications. The screen will display an index of publications by
type.
SAPH16F060800001
SYSTEM LAYOUT
A typical Meritor WABCO Hydraulic ABS is illustrated below.
BRAKE HOSE
BRAKE PIPE
BRAKE WIRING
HYDRO-
MAX
M
WHEEL
FRONT WHEEL REAR
SENSOR CAB SIDE
BRAKE SENSOR BRAKE
CHASSIS SIDE
(RH) (RH)
ABS
MODULATOR
ABS ECU
WHEEL FRONT ABS WHEEL REAR

SENSOR BRAKE WARNING SENSOR BRAKE
(LH) LIGHT (LH)
SAPH16F060800002
SYSTEM COMPONENTS
The following components make up the Meritor WABCO Hydraulic
ABS.
ELECTRONIC CONTROL UNIT (ECU)

• Processes sensor signals and generates solenoid valve commands
to reduce, maintain or reapply brake pressure.
• This ECU is integrated with the ABS modulator.
SAPH16F060800003
MODULATOR ASSEMBLY
• Houses the ABS solenoid control valves (one inlet valve and one out-
let valve per wheel), a pump motor and two accumulators.
• Contains brake fluid and must be handled with appropriate care. It
should not be exposed to impact loads, excessive vibrations or com-
pressed air blown into the hydraulic ports.
SAPH16F060800004
SENSOR WITH MOLDED SOCKET

• Measures the speed of a tooth wheel rotating with the vehicle wheel.
• Produces an output voltage proportional to wheel speed.
SAPH16F060800005
SENSOR SPRING CLIP

• Holds the wheel speed sensor in close proximity to the tooth wheel.
SAPH16F060800006
TOOTH WHEEL
• A machined or stamped ring mounted to a machined surface on the
hub of each ABS-monitored wheel.
SAPH16F060800007
SENSOR EXTENSION CABLES

• Two-wire cable with molded-on connector.
• Connects the wheel speed sensor to the ECU.
SAPH16F060800008
ABS INDICATOR LIGHT

• Located on vehicle dash.
• Alerts drivers to a possible system fault.
• ABS indicator light is not provided by Meritor WABCO.
SAPH16F060800009
GENERAL INFORMATION
There is no regularly scheduled maintenance required for Meritor
WABCO E Version Hydraulic ABS. However, ABS does not change cur-
rent vehicle maintenance requirements. For example, it is important
that the vehicle brake fluid level be correctly maintained.
SYSTEM WIRING INFORMATION

NOTICE
Wiring may vary, according to the vehicle. Refer to the vehicle
specifications for specific wiring diagrams. A typical Meritor
WABCO 4S/4M Hydraulic ABS wiring diagram.
1. PIN NUMBERS AND LOCATIONS

(1) PIN IDENTIFICATION FOR WIRE HARNESS CONNEC-
TORS TO THE ECU
27 31
16
26
1 15
(9511)
Count from the pin number at the end of each row, identify pin assembly to measure. Connector
view shows the back of the connector.
Pin # Circuit Label Pin # Circuit Label

1 Ignition 12v 16 Pump Motor Supply 12v+
2 3rd Brake Relay (optional) 17 Solenoid Valve Supply 12v+
3 Not Used 18 Pump Motor Ground -Gnd
4 Not Used 19 Solenoid Valve Ground -Gnd
5 Not Used 20 Not used
6 Reference Ground 21 ABS Warning Light Relay
7 Not Used 22 Rear Right Wheel Speed Sensor
8 Not Used 23 Rear Left Wheel Speed Sensor
9 Not Used 24 Front Left Wheel Speed Sensor
10 Not Used 25 Front Right Wheel Speed Sensor
11 Not Used 26 J1587 Diag. B + LOW
12 Not Used 27 Rear Right Wheel Speed Sensor
13 Not Used 28 Rear Left Wheel Speed Sensor
14 J1939 + High - (optional) 29 Front Left Wheel Speed Sensor
15 J1939 - Low - (optional) 30 Front Right Wheel Speed Sensor
31 J1587 Diag. A + High
SAPH16F060800010
S7-UNAE13A_3 print.book
GROUND
SBX A2W
16 MOTOR(+)
(MT+ ) (LD )
9 ページ
18 MOTOR(-) SBY
(MT- )
S1V AE0
17 VALVE(+) (91LD)
(VV1 )
VALVE(-) SC0
19
(GND2 )
S1Q AA9
1 IGN (IGN ) (1CLD)
POWER SUPPLY CIRCUIT
S2B S08 S07

5 GND (S+ )
(GND ) (S- )
S09 E0K
LIGHT
S1S SE7 (B ) (MABS)

21 INDICATOR LIGHT (NC )
(WL )
KDX
(BRX)
AUTO
WARNING
2.
CIRCUIT
N1P
LIGHT RELAY
(ABS)
２０１５年１１月６日　金曜日　午後７時４３分
S0C S0B
(S- ) (S+ )
S0D ADN
S0E (B ) (LD )
S1P (NC )
8 EXH RELAY
(EXHR)
(ABS )
K4V
ECU CIRCUIT
J2L
VEHICLE
(RTC1)
CONTROL
WARNING TRANSMISSION VEHICLE CONTROL
ECU CIRCUIT
S2P K2E
31 J1708 (+) (5AE+) (+ )
26 J1708 (-) S24 K2F
(DST-) (- )
S2E S1L
(FLS+) 24 FL SENSOR
(SFL+)
LEFT
S2F S1K FL SENSOR
29
CIRCUIT
(SFLE) (FLS-)
BRAKE CONTROL SYSTEM (ABS:HYDRAULIC (E VERSION))
RELAY
S2G S1X
25 FR SENSOR
DIAGNOSTICS
EXHAUST
(SFR+) (FRS+)
S1Y
BRAKE CUT
S2H FR SENSOR
RIGHT
30
(SFRE) (FRS-)
S2J S2C
23 RL SENSOR
(SRL+) (RLS+)
E VERSION HYDRAULIC ABS WIRING DIAGRAM
LEFT
S2K S2D RL SENSOR
FRONT FRONT REAR

28
(SRLE) (RLS-)
ECU
S2L S2O
(SRR+) (RRS+) 22 RR SENSOR
S2M S1Z RR SENSOR
27
REAR
(SRRE) (RRS-)
RIGHT
SAPH16F060800011
SENSOR SENSOR SENSOR SENSOR
9–9
SYSTEM DIAGNOSTICS
Use Meritor WABCO's PC-based diagnostic program, TOOLBOX Soft-
ware.
1. TOOLBOX SOFTWARE
NOTICE
For complete instructions for using this program, refer to the
User's Manual, TP-99102. Contact Meritor WABCO at 800-535-5560
for information about TOOLBOX Software.
If you have TOOLBOX Software installed on your computer, use it
to identify system faults. Then, follow the on-screen repair infor-
mation to make the necessary repairs or replacements.
SAPH16F060800012
To display Hydraulic ABS faults, use the pull-down menu or the

HABS (Hydraulic ABS) icon to select HABS from the Main Menu.
The HABS Main Menu will appear.
SAPH16F060800013
Select the View ECU Faults icon or select Display Faults to use the pull-
down menu.
SAPH16F060800014
This will display the Fault Information screen.
SAPH16F060800015
The Fault Information Screen contains a description of the fault.

Repair instructions for each fault appear at the bottom of the screen.
Faults that occur after the screen is displayed will not appear until a
screen update is requested. Use the UPDATE button to refresh the fault
information table.
After making the necessary repairs, use the CLEAR FAULTS button to
clear the fault. Use the update button to refresh the fault information
table and display the new list of faults.
2. TESTING THE SYSTEM

This section of the manual contains information for testing the
hydraulic ABS with TOOLBOX Software, as well as procedures for
conducting standard air and electrical tests.
! WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Exhaust gas contains poison. When testing a vehicle with the

engine running, test in a well-ventilated area or route the exhaust
hose outside.
To avoid serious personal injury, keep away, and keep test equip-
ment away, from all moving or hot engine parts.
Refer to, and follow, the vehicle manufacturer's Warnings, Cau-
tions and Service Procedures.
When testing, set the parking brake and place the gear selector in
NEUTRAL (manual transmission) or PARK (automatic transmis-
sion) unless otherwise directed.
(1) Meritor WABCO TOOLBOXTM Software
Use TOOLBOXTM Software to verify the activation of various
system components:
• Turn valves, pump and retarder relay on and off (Valve
Activation Menu).
• Turn ABS warning light on and off (Miscellaneous Output
Activation Menu).
NOTICE
• TOOLBOXTM Software must be connected to the vehicle and the
vehicle ignition must be ON in order to display information.
• For complete instructions for using this program, refer to the
User's Manual, TP-99102. Contact Meritor WABCO at 800-535-
5560 for information about TOOLBOXTM Software.
(2) E Version Hydraulic ABS Menus and Toolbars

Select Hydraulic ABS from the TOOLBOXTM Main Menu.
TOOLBOXTM senses the type of ECU being used and dis-
plays the HABS Main Screen.
(3) Main Screen
This screen provides icons and pull-down menu task selec-
tions. It also provides information about the current status of
Meritor WABCO HABS.
ECU information is read once from the ECU and does not
change. All other information (e.g., wheel sensors, voltages
and fault information) is read and updated continuously.
SAPH16F060800016
(4) Display
Select Display from the HABS Main Screen. A pull-down
menu will appear.
SAPH16F060800017
(5) Faults
Select Faults to display the Fault Information screen.
The Fault Information screen contains a description of each
fault, including the type of fault (Active or Stored), number of
occurrences, SID and FMI number. Repair instructions for
the fault appear at the bottom of the screen.
Faults that occur after the screen is displayed will not appear
until a screen update is requested. Use the Update button at
the bottom of the screen to refresh the fault information table
and display a new list of faults.
SAPH16F060800018 After making any required repairs, use the Clear Faults but-
ton to clear the fault. Clear each fault as it is repaired. Cycle
the ignition after clearing the faults.
Use the Save or Print button to save or print the fault infor-
mation data. Select Exit to close this section.
(6) Wheel Speed

Select Wheel Speed to display the Wheel Speed screen.
Use the Wheel Speed screen to verify that sensors are con-
nected at each wheel. Speed at a sensed wheel (FL, FR, RL,
RR) indicates sensors are installed, but does not verify cor-
rect sensor installation.
SAPH16F060800019
(7) Counters
Select Counters to display the Counters screen.
The Counters screen provides an overview of HABS compo-
nent performance (pump hours, brake events, etc.) as well as
general vehicle activity such as ignition cycles. Occurrences
displayed on this screen accumulate until the Clear button is
selected.
SAPH16F060800020
(8) Component Tests

Select Component Tests from the HABS Main Screen. A
pull-down menu will appear.
SAPH16F060800021
(9) Miscellaneous Outputs
Select Miscellaneous Outputs to display the Actuate Mis-
cellaneous Outputs test screen.
NOTICE
Use TOOLBOXTM Software to test the following components:
Retarder Relay, Brake Light Relay, Supply Valve, Cut-Off Valve,
ABS Light, Traction Light, Brake Warning, Pump Front, Pump
Rear, Buzzer.
This screen provides a check of several HABS components,
as well as a way to check either inlet or outlet activity of the
valves, pump or retarder relay.
Highlight the component you wish to test, then select the

Send button to actuate the component. Component activa-
tion status appears in the Status Box field. Select Close to
SAPH16F060800022 exit this screen.
(10) Valves
Select Valves to display the Valve Activation test screen.
The Valve Activation test screen lets you activate the HABS
valves to check for correct activation and to verify correct
brake line installation.
Click on the valve you wish to test, then click the Send button
to actuate the component. Component activation status
appears in the Status box field. Select Close to exit this
screen.
SAPH16F060800023
(11) Lamps
Select Lamps to display the Light Test screen.
As each light is tested, check the actual light to verify correct
operation. Select Close to exit this screen.
SAPH16F060800024
(12) Relay
Select Relay to display the Activate Relay test screen.
This screen allows you to turn the retarder relay on or off.
This is helpful in verifying correct operation, installation and
wiring of the unit under test. Select Close to exit this screen.
SAPH16F060800025
(13) Engine Data Link

Select Engine Data Link to display the Data Link test
screen.
This screen allows you to send a "limit engine torque" com-
mand to the engine or a "disable retarder" command to the
retarder.
Select the data link destination (engine or retarder), then

select Send to test. Use the Stop button to end testing.
Select Close to exit this screen.
SAPH16F060800026
(14) Reset Memorized

This is an automatic default and cannot be de-selected. It
indicates the ECU has memorized the installed retarder relay.
Once the ECU has seen a retarder, it expects to see it every
time the vehicle is powered up.
Because there are times when an ECU is moved to another

vehicle - or during diagnostic testing - you may want the ECU
to disregard this learned component. Use the Reset Memo-
rized command for this purpose.
SAPH16F060800027
Select Component Tests from the Hydraulic ABS Main

Menu. Then, select Reset Memorized from the pull-down
menu to reset the Learned Component screen.
SAPH16F060800028
(15) Standard Testing

a. Test Equipment: Volt-Ohm Meter (VOM)
Use of a VOM with automatic polarity sensing is recom-
mended. This eliminates the concern of the polarity of the
meter leads during voltage measurements.
(16) System Requirements and Component Tests
a. Tire Size Range
For correct hydraulic ABS operation, front and rear tire
sizes must be within 16% of each other.
Contact the Meritor WABCO Customer Support Center at

800-535-5560 if you plan a tire size difference greater than
8%.
Calculate the tire size with the following equation:

% Difference = (RPM Steer/RPM Drive)-1 x 100
RPM = tire revolutions per mile
! CAUTION
When troubleshooting or testing the ABS system, do not damage
the connector terminals. Damaged connector terminals may
cause system malfunction.
b. Voltage Check
Voltage must be between 9.5 and 14 volts for the 12-volt
hydraulic ABS to function correctly.
Check voltage as follows.

• Turn ignition ON.
• Check for the correct voltage.
• Pins 16 to 18
• Pins 17 to 19
• Pins 1 to 6
(17) Standard Component Testing
a. ABS Warning Light
If the ABS warning light does not come on after the ignition
is turned on, or it comes on but does not go out after three
seconds, check all ABS fuses or circuit breakers and
replace if necessary.
Check the wiring to the warning light and repair or replace
the wiring as required. When checking the warning light,
follow these steps:
b. Check voltage potential at the light socket.
c. Check continuity of the wires to the socket.
d. Replace the bulb.
(18) Sensor Adjustment

On steering axles, the sensor is typically accessible on the
in-board side of the steering knuckle.
On drive axles, the sensor is typically accessible on the in-
board side of the rear axle spindle.
To adjust the sensor, push the sensor in until it contacts the
tooth wheel.
• Do not pry or push sensors with sharp objects.
• Sensors will self-adjust during wheel rotation.
NOTICE
No gap is allowable at installation. During normal operation, a gap
not to exceed 0.04 inch is allowable.
(19) Sensor Output Voltage Test
Sensor output voltage must be at least 0.2 volt AC at 30rpm.
Test the sensor output voltage as follows:
a. Turn ignition OFF.
b. Disconnect the ECU to measure voltage at the pins on the
ECU connector. Refer to Table D.
! WARNING
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Support the vehicle with safety stands.
Do not work under a vehicle supported only by jacks. Jacks can
slip and fall over. Serious personal injury and damage to compo-
nents can result.
c. Place blocks under the front and rear tires to stop the vehi-
cle from moving.
d. Raise the vehicle off the ground. Place safety stands under
the axle.
e. Rotate the wheel by hand at 30 rpm (1/2 revolution per
second).
f. Measure the voltage at the pins indicated in Table D. Volt-
age tolerance is ≥0.2 volts alternating current (VAC).
Table D: Sensor Check Pins
Sensor HABS E Version ECU
31-Pin Harness
Left Front 24 and 29
Right Front 25 and 30
Left Rear 23 and 28
Right Rear 22 and 27
(20) Sensor Resistance

The sensor circuit resistance must be between 900 and 2000
. Measure resistance at the sensor connector, or at the pins
on the ECU connector, as follows.
b. To measure resistance at the pins on ECU connector, dis-
connect the ECU connector from the ECU.
To measure resistance at the sensor connector, disconnect
the sensor from the sensor extension cable.
c. Measure output at the pins indicated in Table D.
If measurement is not between 900 and 2000 , replace
the sensor.
COMPONENT REMOVAL AND INSTALLATION
1. SENSORS: WHEEL SPEED SENSOR REPLACEMENT —

FRONT AXLE
Meritor WABCO specifications call for a sensor lubricant with the
following characteristics:
Lube must be mineral oil-based and contain molydisulfide. It

should have excellent anti-corrosion and adhesion characteristics
and be capable of continuous function in a temperature range of -
40C to 300F (-40 to 150C).
(1) Removal
! WARNING
Block the wheels to prevent the vehicle from moving. Support the
vehicle with safety stands. Do not work under a vehicle supported
only by jacks. Jacks can slip and fall over. Serious personal injury
can result.
To avoid damage to the electrical system or ABS components,

when welding on an ABS-equipped vehicle disconnect the power
connector from the ECU.
a. Apply the parking brakes. Chock the rear tires to prevent
vehicle movement.
If necessary, raise the front tires off the ground. Put safety
stands under the axle.
b. Disconnect the fasteners that hold the sensor cable to

other components.
c. Disconnect the sensor cable from the chassis harness.
d. Remove the sensor from the sensor holder. Twist and pull
the sensor to remove it from the sensor bracket. Do not
KNUCKLE-MOUNTED pull on the cable.
SENSOR
1004706a
SAPH16F060800029
(2) Installation
a. Connect the sensor cable to the chassis harness.
b. Install the fasteners used to hold the sensor cable in place.
c. Apply a Meritor WABCO-recommended lubricant to the
sensor spring clip and sensor.
d. Install the sensor spring clip. Make sure the spring clip tabs
are on the inboard side of the vehicle.
e. With the tabs on the inboard side, push the sensor spring
clip into the bushing in the steering knuckle until the clip
stops.
f. Push the sensor completely into the sensor spring clip until
it contacts the tooth wheel.
g. Fasten the sensor cable with tie wraps every 12 inches.
Properly bundle and store excess cable in the sub frame.
h. Remove the blocks and safety stands.
i. Perform a voltage output check to ensure proper installa-
tion. Refer to "Voltage Check" in page 9-16.
2. WHEEL SPEED SENSOR REPLACEMENT REAR AXLE

(1) Removal
a. Apply the parking brake. Chock the front tires to prevent
vehicle movement.
b. Raise the rear tires off of the ground. Put safety stands
under the axle.
c. If the rear tire must be removed to gain access to the sen-
sor, release the parking brake to release the brake shoe.
Remove the wheel and tire assembly from the axle.
Remove the sensor from the mounting block in the axle

housing. Use a twisting motion if necessary. Do not pull
on the cable.
d. Disconnect the sensor cable from the chassis harness.
e. Remove the sensor cable from any cable clamps or clips.
f. Remove the sensor spring clip from the sensor bracket.
(2) Installation
a. Connect the new sensor cable to the chassis harness.
b. Press the sensor spring clip into the sensor bracket,
located on the rear axle, until it stops. Make sure the tabs
are on the inboard side.
c. Apply a Meritor WABCO-recommended lubricant to the
sensor.
d. Push the sensor completely into the spring clip until it con-
tacts the tooth wheel.
e. Reattach the sensor cable to the cable clamps or clips.
f. Replace the tire, remove the safety stands, lower the vehi-
cle and remove the chocks from the front tires.
g. Perform a voltage output check to ensure proper installa-
tion.
3. MODULATOR ASSEMBLY
(1) Modulator Assembly Removal
! CAUTION
The modulator assembly contains hydraulic brake fluid, a caustic
substance. Remove the valve carefully so that fluid does not leak
and cause skin irritation or damage to components.
a. Apply the parking brakes. Chock the front and rear tires to
prevent vehicle movement.
b. Place a container under the modulator assembly to catch
leaking brake fluid.
c. Disconnect the electrical harness connectors from the
modulator assembly.
d. Mark the six brake lines for ease of installation. Disconnect
the lines from the modulator assembly.
e. Remove the three mounting capscrews, washers and nuts
that attach the modulator assembly and bracket assembly
to vehicle.
NOTICE
Whenever any hydraulic system fitting is loosened or discon-
nected, the entire system must be bled to remove any air that may
have entered.
f. Remove the modulator assembly and bracket.
(2) Modulator Assembly Installation
a. Position the modulator assembly and bracket in place on
the vehicle.
b. Tighten the three mounting nuts.
Tightening torque
27-33 Nm (275-336 kgf.cm, 239-295 lbf-in)
c. Connect and tighten brake line connections as follows:
• Two small (MI0XI) adapters:
12Nm (122kgf.cm,108 lbf-in)
• Four large (MI2XI) adapters:
15Nm (153kgf.cm,132 lbf-in)
d. Bleed the brake system, per the following instructions.
SAPH16F060800030
e. Connect the electrical harnesses to the modulator assem-
bly.
4. BRAKE BLEEDING PROCEDURES

(1) General
The following brake bleeding methods explain how to bleed
the hydraulic ABS modulator assembly during installation, or
in the event of air in the brake system. There are instructions
for both pressure and manual bleeding procedures.
These instructions include the procedure for bleeding both

the master cylinder and the brake system. In some cases, for
example, if you are replacing only the modulator assembly, it
may not be necessary to bleed the master cylinder. If you
have any questions, please contact the Meritor Service Cen-
ter at 800-535-5560.
NOTICE
The modulator assembly must be handled with appropriate care
and should not be exposed to excessive impact or compressed air
at the hydraulic ports prior to assembly.
! WARNING
Failure to bleed the system whenever any hydraulic system fitting
is loosened or disconnected will allow air to remain in the system.
This will prevent the hydraulic pressure in the brake system from
rising enough to apply the brakes properly. This will cause the
stopping distance to increase and can result in serious personal
injury.
Properly discard hydraulic brake fluid that is removed from the

brake system. Hydraulic brake fluid that is removed can be con-
taminated and can cause damage, loss of braking and serious
personal injury.
Use only the type of hydraulic brake fluid specified by the equip-
ment manufacturer. Do not use or mix different types of hydraulic
brake fluid. The wrong hydraulic brake fluid will damage the rub-
ber parts of the brake caliper and can cause damage, loss of brak-
ing and serious personal injury.
NOTICE
Use DOT 3 or DOT 4 hydraulic brake fluid. Refer to the vehicle
specifications to determine which fluid to use.
! CAUTION
Hydraulic brake fluid is a caustic substance. Contact with hydrau-
lic brake fluid can cause skin irritation. Do not let hydraulic brake
fluid touch any painted surfaces, as it will remove the paint.
Hydraulic brake fluid may also damage certain non-metal sur-
faces. Do not let fluid get on brake pads, shoes, rotors or disks.
1004709a
SAPH16F060800031
(2) Pressure Fill and Bleed

Pressure fill and bleeding is the preferred method for
bleeding the service brake system. It requires the use of a
special pressure bleeder kit, consisting of a tank, pressure
pump and valve, gauge, tubing and adapter. These kits are
available from a number of manufacturers and include
instructions for use.
(3) Pressure Fill and Bleed Procedure:
a. Apply the parking brake and chock the tires. Turn the igni-
tion OFF and disconnect the battery terminals.
NOTICE
The ignition must remain off for the entire bleeding procedure;
energizing the unit during bleeding must be impossible.
b. Fill the pressure bleeder with new DOT 3 or DOT 4 hydrau-
lic brake fluid. Refer to the vehicle specifications to deter-
mine which fluid to use.
c. Follow the manufacturer's instructions to connect the pres-
sure bleeder to the brake master cylinder reservoir.
d. Set filling pressure to 20 to 30 psi (1.5 to 2.0 bar).
e. Turn on bleeding equipment until fluid level in reservoir
reaches approximately 0.875-inches (20 mm).
f. Release pressure for 3 to 5 seconds. Apply pressure for 5
to 10 seconds.
g. Repeat Steps 5 and 6 approximately 10 times. After
releasing the pressure, air bubbles should rise up into the
reservoir.
! WARNING
Do not let the brake master cylinder fluid get below the minimum
level during the bleeding operation. Keep the master cylinder res-
ervoir filled with new DOT-approved brake fluid, as specified by
the original equipment manufacturer. Failure to keep the brake
reservoir level above minimum could result in more air entering
system, making it impossible to effectively bleed the system.
h. Bleed the brake system:
• Set filling pressure to 20 to 30 psi (1.5 to 2.0 bar).
• Put a wrench on the brake actuator bleeder fitting. Start
with the farthest from the modulator, (typically the right
rear), then attach a length of clear plastic tubing to the
bleeder fitting. Make sure the tube fits snugly.
i. Submerge the tubing in a container of clean hydraulic
brake fluid.
NOTICE
Both the tubing and container must be able to withstand the
1004710a
effects of hydraulic brake fluid.
SAPH16F060800032
Loosen the bleeder fitting until the fluid begins to flow
(about 3/4 turn). Let the hydraulic fluid flow out of the fitting
until it is free of air bubbles.
j. Tighten firmly to secure the fitting.
k. Repeat Steps 5 through 8 to bleed the remaining three
brake actuators. Bleed in sequence of the longest to short-
est circuit from the modulator assembly.
l. Turn off bleeding equipment and remove pressure.
Remove bleeding device and check fluid level in reservoir.
Fill if required. Replace reservoir cap and dispose of used
brake fluid.
m. Remove wheel chocks.
(4) Manual Bleeding Procedure:

a. Apply the parking brake and chock the tires. Turn the igni-
tion OFF and disconnect the battery terminals.
NOTICE
The ignition must remain off for the entire bleeding procedure;
energizing the unit during bleeding must be impossible.
b. Fill the reservoir with DOT 3 or DOT 4 hydraulic brake fluid.
Refer to the vehicle specifications to determine which fluid
to use.
c. Depress the brake pedal five times using the stroke
between 1/3 travel and maximum travel in 5 seconds.
d. Release the pedal for 5 to 10 seconds. Air bubbles will rise
into the reservoir while depressing and releasing pedal.
e. Repeat Steps 3 and 4 another three times, or until suffi-
cient pedal resistance is felt.
! WARNING
Do not let the brake master cylinder fluid get below the minimum
level during the bleeding operation. Keep the master cylinder res-
ervoir filled with new DOT-approved brake fluid as specified by the
original equipment manufacturer. Failure to keep the brake reser-
voir level above minimum could result in more air entering sys-
tem, making it impossible to effectively bleed the system.
f. Bleed the brake system. Put a wrench on the brake actua-
tor bleeder fitting. Start with the farthest from the modula-
tor, (typically the right rear), then attach a length of clear
plastic tubing to the bleeder fitting. Make sure the tube fits
snugly.
g. Submerge the tubing in a container of clean brake fluid.
NOTICE
Both the tubing and container must be able to withstand the
effects of brake fluid.
h. Depress the brake pedal 10 to 15 times, using the maxi-
mum available stroke.
i. Loosen the bleeder fitting until the fluid begins to flow,
(about 3/4 turn), while depressing the brake pedal through
its maximum available stroke.
j. Tighten the fitting firmly prior to releasing the brake pedal.
k. Repeat Steps 6 through 8 several times until the dis-
charged fluid is free of air bubbles.
l. Repeat Steps 3 through 9 to bleed the remaining three
brake actuators. Bleed in sequence of the longest to the
shortest circuit from the modulator.
m. Check the travel of the brake pedal. If a firm resistance is
felt the manual bleeding procedure is complete.
n. Check the fluid level in reservoir and fill if required.
Replace reservoir cap and dispose of used brake fluid.
o. Remove wheel chocks.
BRAKE CONTROL SYSTEM (ABS:FULL AIR) 9–1
BRAKE CONTROL SYSTEM (ABS:FULL AIR)

9
9-002
ABS .............................................................................. 9-2

TROUBLESHOTTING............................................. 9-2
9–2 BRAKE CONTROL SYSTEM (ABS:FULL AIR)
ABS
TROUBLESHOTTING
EN01H16F07080F03001001
BEFORE YOU BEGIN

This manual provides instructions for Meritor WABCO's anti-lock brak-
ing system for trucks, tractors and buses. Before you begin procedures:
1. Read and understand all instructions and procedures before you
begin to service components.
2. Read and observe all Caution and Warning safety alerts that pre-
cede instructions or procedures you will perform. These alerts help
to avoid damage to components, serious personal injury, or both.
3. Follow your company's maintenance and service, installation, and
diagnostics guidelines.
4. Use special tools when required to help avoid serious personal injury
and damage to components.
1. SAFETY ALERTS, TORQUE SYMBOL AND NOTES
! WARNING A Warning alerts you to an instruction or pro-

cedure that you must follow exactly to avoid
serious personal injury and damage to com-
ponents.
! CAUTION A Caution alerts you to an instruction or pro-

cedure that you must follow exactly to avoid
damage to components and possible serious
injury.
NOTICE A Note provides information or suggestions

that help you correctly service a component.
2. ACCESS INFORMATION ON ARVINMERITOR'S WEB SITE

Additional maintenance and service information for ArvinMeritor's
commercial vehicle systems component lineup is also available at
www.arvinmeritor.com.
To access information, click on Products & Services/Tech Library

Icon/HVS Publications. The screen will display an index of publica-
tions by type.
3. ADDITIONAL INFORMATION
Call ArvinMeritor's Customer Service Center at 800-535-5560 to
order the following item.
• Drivetrain PlusTM by ArvinMeritor Technical Electronic Library
on CD. Features product and service information on most Meri-
tor, ZF Meritor and Meritor WABCO products. $20. Order TP-
9853.
SAPH16F070800001
ABS CONFIGURATION
SAPH16F070800002
1 Wheel sensors 3 Relay valve

2 ABS control valve 4 ABS ECU
SYSTEM COMPONENTS
The ECU is the brain of the ABS system. It receives information from
the sensors and sends signals to the ABS valves. The ECU is cab-
mounted.
NOTICE
Do not open the ECU. Opening the ECU to gain access to the inter-
nal components will void the warranty.
SAPH16F070800003
A tooth wheel (A) is mounted at, or cast in, the hub of each sensed
wheel, with a sensor (B) installed so that its end is against the tooth
wheel. A sensor clip (C) holds the sensor in place at the tooth wheel.
NOTICE
The sensor and clip must be greased with Meritor WABCO-recom-
mended lubricant. Refer to "Sensor Lube Specification" page 9-23
for lube specification.
1002009b
SAPH16F070800004
An ABS modulator valve controls air pressure to each affected brake

during an ABS event. The modulator valve is usually located on a frame
Also available with rail or cross member near the brake chamber. The modulator valve is
2
open-style connector .
available in bayonet-style or open-style connector.
1
BAYONET-STYLE
CONNECTOR
1. Air In (Port 1)
2. Air Out (Port 2)
SAPH16F070800005
TOOLBOX Software is a PC-based diagnostics program that can dis-

play wheel speed data, test individual components, verify installation
wiring and more. Runs in Windows 95, 98 and NT. An RS232 to
J1708 convertor box is required. Versions 3.2 and higher support E ver-
sion ABS.
Available from SPX (Kent-Moore), 800-328-6657

SAPH16F070800006
The MPSI Pro-Link 9000 with a multiple protocol cartridge (MPC)

and Meritor WABCO applications card, version 2.0 or higher, provides
diagnostic and testing capabilities for the E version ABS.
NOTICE
The Power Line Carrier Communication (PLC) functions of E ver-
sion ABS cannot be tested with the Pro-Link.
1002014a System Diagnostics

Use any of the following methods to diagnose E version ABS:
Available from SPX (Kent-Moore), 800-328-6657
• TOOLBOX Software, version 3.2 or higher, a PC-based ABS diag-
SAPH16F070800007 nostic and testing program that runs in Windows 95, 98 or NT
• Blink Codes — Tractor ABS only
• MPSI Pro-Link with MPC and Meritor WABCO applications card, ver-
sion 2.0 or higher
• OEM Diagnostic Displays (Refer to the Vehicle Operator's Manual)
Information about TOOLBOX Software, MPSI Pro-Link and Blink Codes
follows. If you have any questions about system diagnostics, please
contact ArvinMeritor's Customer Service Center at 800-535-5560.
1. TOOLBOX SOFTWARE
NOTICE
For complete instructions for using TOOLBOX Software, refer to
the User's Manual.
If you have TOOLBOX Software installed on your computer, use it
to identify system faults. Then, follow the on-screen repair informa-
tion to make the necessary repairs or replacements.
To display E version ABS faults:

(1) Connect the computer to the vehicle:
SERIAL • Attach the cable from your computer to the J1708 to
CABLE RS232 converter box.
• Attach the diagnostic cable (Deutsch) to the vehicle.
TO VEHICLE
J1587 J1708-TO-RS232
CONNECTOR CONNECTOR
SAPH16F070800008
(2) Select TOOLBOX Software from Desktop or from the Win-

dows Start Menu to display the TOOLBOX Main Menu.
SAPH16F070800009
(3) From the Main Menu, select Tractor ABS Diagnostics, or

use the pull down menu to make your selection. The ABS
Main Screen will appear.
SAPH16F070800010
SAPH16F070800011
(4) From the ABS Main Screen, select the Faults icon, or use
the pull down menu to display the faults from the ECU.
NOTICE
If there are Faults in the system (YES in existing or stores fields)
double-click on the YES to display Fault Information.
SAPH16F070800012
(5) The Fault Information Screen contains a description of the

fault. Repair instructions for each fault appear at the bottom
of the screen.
NOTICE
Faults that occur after the screen is displayed will not appear until
a screen update is requested. Use the Update button at the bottom
of the screen to refresh the fault information table.
(6) After making the necessary repairs, use the Clear Faults
button at the bottom of the screen to clear the fault. Use the
Update button to refresh the fault information table and dis-
play the new list of faults.
SAPH16F070800013
2. BLINK CODE DIAGNOSTICS (TRACTOR ABS ONLY)

(1) Definitions
Before using blink code diagnostics, you should be familiar
with a few basic terms. If you used previous versions of Meri-
tor WABCO's blink code diagnostics, review these definitions
to identify major changes.
ABS Indicator Light: This light serves two purposes: it

alerts drivers to an ABS tractor fault and it is used during
diagnostics to display the blink code.
Blink Code: A series of blinks or flashes that describe a par-

ticular ABS system fault or condition.
Blink Code Cycle: Two sets of flashes with each set sepa-
rated by a one-and-one-half second pause. Blink codes are
defined in Blink Code Identification in this section.
Blink Code Switch: A momentary switch that activates blink

code diagnostic capabilities. Switch types and locations vary,
depending on the make and model of the vehicle.
Clear: The process of erasing faults from the ECU.
Diagnostics: The process of using blink codes to determine

ABS system faults.
Fault: An ABS malfunction detected and stored in memory

by the Meritor WABCO ECU. System faults may be Active or
Stored.
Active Fault: A condition that currently exists in the ABS sys-

tem; for example, a sensor circuit malfunction on the left front
steering axle. An active fault must be repaired before it can
be cleared from memory — and before you can display addi-
tional blink code faults.
Stored Fault: There are two types of stored faults:
a. A repaired active fault that has not been cleared from the
ECU.
b. A fault that occurred but no longer exists. For example, a
loose wire that makes intermittent contact. Because stored
faults are not currently active they do not have to be
repaired before they can be cleared from memory.
Meritor WABCO recommends you keep a record of these

faults for future reference.
1 2
System Configuration Code: One digit code displayed
during the clear mode. Blink codes for common ABS sys-
tem configurations are shown in figure.
4S/4M
1. Number of Flashes
2. ABS Configuration
1002020c
SAPH16F070800014
3. DIAGNOSTIC MODE
To enter the diagnostic mode, press and hold the blink code switch
for one second, then release.
4. CLEAR MODE
To erase faults from the ECU, you must be in the clear mode. To
enter the clear mode, press and hold the blink code switch for at
least three seconds, then release.
If the system displays eight quick flashes followed by a system

configuration code, the clear was successful. Stored ABS faults
have been cleared from memory.
If you do not receive eight flashes, there are still active faults that
must be repaired before they can be cleared.
5. BLINK CODE DIAGNOSTICS
Troubleshooting with Blink Code Diagnostics

Mode Procedure System Response Action
Step I. Possible responses:
Turn Ignition ON A. ABS indicator light comes on No recognizable active faults in the
momentarily then goes out, ABS. No action required.
indicating System O.K.
B. ABS indicator light does not light, Inspect wiring. Inspect bulb. Make
indicating possible wiring fault or necessary repairs.
burned-out bulb.
C. ABS indicator light stays on,

indicating:
• Fault, or faults, in the system. Continue with blink code diagnostics.

(Go to Step II.)
• Sensor fault during last Continue with blink code diagnostics.

operation. (Go to Step II.)
• Faults cleared from ECU, but Drive vehicle light will go out when
DIAGNOSTICS
vehicle not driven. vehicle reaches 4 mph (6 km/h).
• ECU disconnected. Connect ECU.
Step II. ABS indicator light begins flashing Determine if fault is active or stored:
Press and hold Blink Code Switch two-digit blink code(s). Active Fault: Light will repeatedly
for one second, then release. display one code.
Stored Fault: Light will display code
for each stored fault then stop
blinking. Faults will be displayed one
time only.
Step III. First Digit: 1 - 8 flashes, Pause Find definition for blink code on blink
(1-1/2 seconds). code chart.
Count the flashes to determine
the blink code. Second Digit: 1 - 6 flashes, Pause
(4 seconds).
Step IV. Active Fault. Make the necessary repairs. Repeat

Turn Ignition OFF . Steps I, II, and III until System O.K.
code (1-1) received.
Repair and Record faults. Stored Faults. Record for future reference.
NOTE: Last fault stored is first fault
displayed.
Step V. ABS Indicator Light flashes eight All stored faults successfully cleared.
times. Turn ignition OFF.
CLEAR
Turn Ignition ON.
Clear Faults from memory: Press Eight ßashes not received. Active faults still exist, repeat Steps I
and hold blink code switch for at through V.
least three seconds, then release.
SAPH16F070800015
6. BLINK CODES ILLUSTRATED
1 Second Active Fault

Hold
1-8 Flashes 1-6 Flashes
Pause Pause Pause Pause
Continues until
1.5 s 1.5 s 4s 1.5 s ignition is turned off
Light ON 1st Digit 2nd Digit Repeat of Blink Code
(2) (3) (2) (3)
Example:
Blink Code 2-3: Fault in ABS modulator
valve, right rear drive axle.
1 Second Stored Faults

Hold Displays all stored
Off
Pause Pause Pause Pause
faults once − last fault
1.5 s 1.5 s 4s 1.5 s stored is displayed first
Light ON 1st Digit 2nd Digit 1st Digit 2nd Digit
1st Stored Fault 2nd Stored Fault
(5) (2) (3) (4)
Example:
Blink Code 5-2: Sensor signal erratic,
left front steer axle.
3-4: Too much sensor gap,
left rear drive axle.
1 Second System O.K.

Hold
Pause Pause
Blink Code 1-1: System OK
1.5 s 1.5 s
Light ON (1) (1)
S = Seconds 1002021b
SAPH16F070800016
Note: After faults are cleared and

3 Second vehicle is started, ABS light will stay
Faults Cleared on until vehicle is driven over 4 mph (6 km/h).
Hold
Continues until
Pause Pause Pause Pause Pause ignition is
1.5 s 4s 4s 4s 4s turned off
Light ON 8 Quick Blinks = Faults Cleared System ID System ID System ID System ID
(2) (2) (2) (2)
System Configuration Code 2: 4S/4M System
3 Second
Faults Not Cleared (Active Faults Still Exist)
Hold
Pause Pause Pause Pause Continues until ignition
4s 4s 4s 4s is turned off
Light ON System ID System ID System ID System ID
(2) (2) (2) (2)
S = Seconds
1002022
SAPH16F070800017
WORKING WITH BLINK CODES
1. BLINK CODE CONDITIONS

When using blink code diagnostics, the following conditions could
occur:
Blink Code Conditions
Condition Reason Action
ABS indicator light does not come on at Loose or burned-out bulb. Check bulb.
ignition. Check connections.
Make necessary repairs.
Voltage not within acceptable range Check connections.

(9.5-14.0 volts). Measure voltage.
Make necessary repairs.
Can't use blink code diagnostics; ABS Switch not held for proper length of Repeat procedure, hold switch for
indicator light will not go off when blink time: proper length of time.
code is activated. 1 Second — Diagnostics Mode
3 Seconds — Clear All Mode
Improper or faulty wiring. Inspect and repair wiring.
Eight Flashes not received after blink code Active Faults still exist. Identify active faults, then make nec-
switch pressed for at least three seconds, essary repairs. Turn ignition OFF,
then released. then repeat Blink Code Diagnostics.
2. BLINK CODE IDENTIFICATION

Use the following information to identify the blink code:
Blink Code Identification
First Digit (Type of Fault) Second Digit — Specific Location of Fault

1 No faults 1 No faults
2 ABS modulator valve 1 Right front steer axle (curb side)

3 Too much sensor gap 2 Left front steer axle (driver's side)
4 Sensor short or open 3 Right rear drive axle (curb side)
5 Sensor signal erratic/tire size 4 Left rear drive axle (driver's side)
6 Tooth wheel
7 System function** 1 J1939 datalink

2 ATC valve
3 Retarder relay (third brake)
4 ABS indicator light
5 ATC configuration
6 ATC prop./dif lock/stop valve
8 ECU 1 Low power supply

2 High power supply
3 Internal fault
4 System configuration error
5 Ground
* Tandem, lift, tag or pusher axle depending upon the type of

suspension.
** If this code continues after all repairs have been made — or

if you receive a code for a component that is not installed on
the vehicle — it may be necessary to reconfigure the ECU.
Refer to the Reconfiguration Procedure described in page 9-
28. TOOLBOX Software may also be used to reconfigure the
ECU (refer to page 9-28). Contact ArvinMeritor's Customer
Service Center at 800-535-5560 for reconfiguration informa-
tion.
3. BLINK CODE TROUBLESHOOTING AND REPAIR
Blink
Action Required Reference
Code
2-1 2-4 Check ABS modulator valve, valve cable, and connectors. Refer to "Valve Tests," page 9-23.
2-2 2-5 Verify 4.0-9.0 ohms resistance (ABS modulator valve).
2-3 2-6
3-1 3-4 Adjust wheel sensor to touch tooth wheel. Refer to "Sensor Adjustment," page 9-22, "Sen-
3-2 3-5 Check sensor gap. sor Output Voltage Test," page 9-22, and "Com-
3-3 3-6 Check for loose wheel bearings or excessive hub runout. ponent Tests and Functions," page 9-17.
Verify minimum 0.2 volts AC output @ 30 rpm.
4-1 4-4 Check sensor, sensor cable, and connectors. Repair or replace as needed.
4-2 4-5 Verify 900-2000 ohms resistance.
4-3 4-6
5-1 5-5 Check for tire size mismatch or tooth wheel difference. Refer to "Tire Size Range," page 9-21.
5-2 5-6 Check sensor, sensor cable, and connector for intermittent
5-3 5-7 contact.
6-1 6-4 Check for damaged tooth wheel. Repair or replace as needed.
6-2 6-5
6-3 6-6
7-1* Check for proper J1939 data link connection. Refer to wiring diagram in page 9-27.
Verify wheel spin on each axle.
7-2* Check ATC Valve, valve cables, and connectors. Refer to "Valve Tests," page 9-23.
Verify 7.0-14.0 ohms resistance.
7-3* Check retarder (third brake) connections. Refer to wiring diagram in page 9-27.
7-4* Check ABS indicator light connections.

Verify blink code switch was activated longer than 16 sec-
onds.
7-5* Verify proper ATC set-up.
7-6* Verify accuracy of blink code and clear from ECU memory. Refer to "Blink Code Diagnostics (Tractor ABS
only)," page 9-9.
8-1 Check for low voltage. Refer to wiring diagram in page 9-27 and "Volt-
Check vehicle voltage, fuse, and supply to ECU (9.5-14.0 age Check," page 9-21.
volts).
8-2 Check for high voltage. Refer to "Voltage Check," page 9-21, and "Blink
Check vehicle voltage (9.5-14.0 volts). Code Diagnostics (Tractor ABS only)," page 9-
Verify accuracy of blink code and clear from ECU memory. 9.
8-3 Verify accuracy of blink code and clear from ECU memory. Refer to "Blink Code Diagnostics (Tractor ABS
only)" and "Clear Mode," page 9-9.
8-4 Verify all ECU connectors are in place. Contact ArvinMeritor's Customer Service Cen-
Verify accuracy of blink code and clear from ECU memory. ter at 800-535-5560.
If code does not clear, it may be necessary to replace the
ECU.
8-5 Check all ABS, ECU and ATC valve grounds. Refer to wiring diagram in page 9-27.
* If this code continues after all repairs have been made — or

if you receive a code for a component that is not installed on
the vehicle — it may be necessary to reconfigure the ECU.
Refer to the Reconfiguration Procedure described in page 9-
28. TOOLBOX Software may also be used to reconfigure the
ECU (refer to page 9-28). Contact ArvinMeritor's Customer
Service Center at 800-535-5560 for reconfiguration informa-
tion.
PRO-LINK DIAGNOSTICS
NOTICE
You must use Multiple Protocol Cartridge (MPC) and Meritor
WABCO application card, version 2.0 or higher, with E version
ECUs. The PLC functions of E version ABS cannot be tested with
the Pro-Link.
The Pro-Link 9000 may be used in place of blink code diagnostic pro-
cedures.
The following Pro-Link information applies to E version ECUs. Refer to

Maintenance Manual 28 if you are using the Pro-Link with C version
ECUs or Maintenance Manual 30 if you are using the Pro-Link with D
version ABS.
1. DIAGNOSTIC PROCEDURE
(1) Slide the MPC into the Pro-Link keypad until the connection
is tight. Then, insert the Meritor WABCO applications card
into the cartridge.
(2) Chock the wheels, apply the parking brake, and make sure
ignition power is off.
(3) Locate the 6-pin diagnostic receptacle in the vehicle cab.
Insert the 6-pin connector from the Pro-Link into the recepta-
cle.
(4) Turn the ignition to the ON/RUN position. The Pro-Link
screen should power up. If the Pro-Link does not power up,
or if the screen indicates NO DATA RECEIVED:
• Check connections.
• Make sure the cartridge is properly connected to the Pro-
Link keypad.
• Verify 9.5-14.0 volts DC power and ground at the connec-
tor and ABS ECU.
• Check the fuse panel for a blown fuse.
• Check for proper wiring in the diagnostic connector.
(5) Refer to the Pro-Link manual for complete diagnostic instruc-
tions.
The Pro-Link 9000 is available from Kent-

Moore, 800-328-6657.
2. PRO-LINK SCREENS
This information provides basic screen explanations for the Pro-
Link 9000 with an MPC and Meritor WABCO application card.
For complete operating instructions and test information, refer to
the Pro-Link manual.
(1) Fault Information Screens:
Existing Faults: Use these screens to identify existing faults.
The Pro-Link screen displays a written description of the
fault, including the location on the vehicle where each exists.
As long as there is an active (existing) fault in the system, the
Pro-Link will not let you clear faults.
Stored Faults: Use these screens to identify faults stored in

the ECU memory. Stored faults may be existing faults that
have been repaired, or faults that existed for a short time,
then corrected themselves. After displaying the stored faults,
the Pro-Link lets you erase them from memory. All stored
faults are cleared at one time.
J1939 DATALINK VERIFICATION — PRO-LINK 9000

The Pro-Link diagnostic tool may be used to verify J1939 datalink con-
nection. If you do not have a Pro-Link, you can use the blink code
switch to verify this connection.
1. Turn ignition ON. Press blink code switch 1.

IGNITION ON
hold for 3 seconds. OFF ON
3 Second Hold
A. ATC indicator light will come on and stay A.

on for the entire test. ATC
If vehicle is not equipped with ATC, the

ATC indicator light will not come on.
B. ABS indicator light will come on and blink B.
8 times.
If the light does not blink 8 times, there 8 Quick Blinks = Faults Cleared
are faults that must be cleared before you
continue with this test.
Pause Pause
Continues
C. The eight quick flashes will be followed by C. 4s 4s During Test
the system configuration code. A 4S/4M
(2 blinks) system is identified here. System ID System ID System ID
(2) (2) (2)
The system configuration code will
continue during the entire test.
2. Activate the J1939 engine torque reduction 2.
code, as follows:
1000
A. Step on the accelerator. Bring the engine A.

IDLE
to 1000 rpm. RPM
Leave your foot on the accelerator during

the entire test.
B. While engine is at 1000 rpm, press the B.
blink code switch twice, as follows:
Press for one second
1 Second 1 Second Pause
Pause
Release for one second Hold Hold
Press for one second

Release for one second
C. The engine will go to idle for C. 1000 1000
approximately 10 seconds and then return IDLE IDLE
to 1000 rpm. RPM RPM
3. Turn ignition OFF . 3.

OFF ON
Test complete, engine torque reduction
command verified.
SAPH16F070800018
1. COMPONENT TEST SCREENS

These screens help you test ABS components. Select this function
from the Tractor ABS/ATC menu.
ABS VALVES
ATC
ABS INDICATOR LIGHT
ABS TRAILER INDICATOR LIGHT
ATC INDICATOR LIGHT
ABS/ATC SWITCHES
SENSORS
ENGINE DATALINK
RETARDER RELAY
RETARDER DATALINK
VEHICLE VOLTAGES
Select the appropriate function. Each screen has instructions

to guide you through the test. Refer to the Pro-Link Manual for
complete instructions.
2. PRO-LINK 9000 DISPLAY

With some ECUs, the Pro-Link will display system information —
components or options supported by the ECU. Access these
screens through System Setup (main ABS menu).
The following screens illustrate:

• A 4S/4M ABS/ATC system
• Where the ECU has not recognized a retarder relay
• Where the ECU has recognized a J1939 datalink
• The ECU is capable of supporting ABS and ATC switches.
NOTICE
Yes indicates the ECU is capable of supporting these options.
These may or may not be installed on the vehicle.
TRACTOR ABS/ATC
SYSTEM INFORMATION
SENSORS 4
MODULATORS 4
ATC VALVE YES

RETARDER RELAY NO
J1939 YES
DIFF LOCK NO
ABS SWITCH YES
ATC SWITCH YES
3. SYSTEM INFORMATION
(1) TOOLBOX Software Display
NOTICE
Refer to page 15 of this manual for instructions for running TOOL-
BOX Software, or refer to the Software Owner's Manual, TP-99102,
for complete instructions.
The quickest method of verifying system information is the TOOLBOX

Software ABS Main Screen.
This screen provides information about the current state of Meritor

WABCO ABS. ECU information is read once from the ECU and does
not change. All other information (e.g., wheel sensors, control status,
SAPH16F070800019
voltages, faults and road speed) is read and updated continuously.
The status of ABS switches and lights, as well as other data, may also
be observed from this screen.
4. COMPONENT TESTS AND FUNCTIONS

(1) TOOLBOX Software
NOTICE
Refer to page 15 of this manual for instructions for running TOOL-
BOX Software, or refer to the Software Owner's Manual, TP-99102,
Use TOOLBOX Software to display wheel speeds, cycle ABS

SAPH16F070800020
valves, activate ABS and ATC lights, including the trailer ABS
light, and turn the retarder relay on or off. In addition, the
J1939 engine datalink connection may be quickly verified by
using TOOLBOX Software.
(2) Wheel Speed
Select the wheel speed icon or use the pull down menu from
the ABS Main Screen to display wheel speed data in both
numeric and graphical form. This data may be shown in RPM
or MPH format and in vertical or horizontal graphs. Select the
appearance and style from the options menu.
SAPH16F070800021
(3) Valve Activation

Select the valve icon or use the pull down menu to select and
cycle individual ABS valves. Then listen to ensure the correct
valve is cycling. This is helpful when verifying proper opera-
tion, installation and wiring.
SAPH16F070800022
(4) Light Activation

Select the light icon or use the pull down menu to turn the
tractor and trailer ABS and/or the ATC (wheel spin) lights on
or off. This is helpful when verifying proper operation, instal-
lation and wiring of the lights to the ECU.
SAPH16F070800023
(5) Data Link Activation

Select the Engine Data Link icon from the Main ABS Screen
or use the pull down menu to send a "limit engine torque"
command to the engine or a "disable retarder" command to
the retarder.
SAPH16F070800024
(6) Component Tests and Functions (Pro-Link)

These screens help you test ABS components. Select this
function from the Tractor ABS/ATC menu.
TRACTOR COMP TESTS

— SELECTIONS —
 VEHICLE VOLTAGES 
Select the appropriate function. Each screen has instructions

to guide you through the test. Refer to the Pro-Link Manual
The following definitions explain the function of each test.
Component Test Function
Vehicle Voltages Monitors the voltage signals powering the ECU.
ABS Valves Cycles the valves, one at a time. With brake pedal applied, you should
hear four short air exhausts, then one long air pressure hold. A menu
selection lets you choose from four or six valves. This test is used to ver-
ify valve locations and proper wiring.
NOTICE
The treadle must be applied to pressurize the brake chambers.
ATC Checks the ATC valve. You will hear a click as the valve cycles.
NOTICE
TOOLBOX Software or the Pro-Link may be used to shut off ATC for
dynamometer testing.
ABS Tractor Light Monitors the commanded (on/off) states of the ABS tractor light. Follow
the screen prompts (1 On, 2 Off) to change the status of the light on the
instrument panel.
ABS Trailer Light Monitors the commanded (on/off) states of the ABS trailer light. Follow
instrument panel.
ATC Tractor Light Monitors the commanded (on/off) states of the ATC tractor light. Follow
instrument panel.
ABS/ATC Switches Checks the status of ABS and ATC/Deep Snow and Mud switches on the
instrument panel.
Sensors Monitors the input to the ECU from the wheel. Vehicle must be stationary
and wheels must be rotated during this test.
Engine Datalink Checks wiring connections and response between the engine and the
ECU.
Retarder Relay Activates the relay to verify function (a click will be heard). This test also
checks wiring connections.
Retarder Datalink Checks wiring connections and retarder response between the retarder
and the ECU.
a. Tire Size Range

For proper ABS/ATC operation with the standard ECU,
front and rear tire sizes must be within  14% of each
other. When this tire size range is exceeded without elec-
tronically modifying the ECU, the system performance can
be affected and the indicator light can illuminate.
Call Meritor WABCO at 800-535-5560 if you plan a tire size

difference greater than 14%.
Calculate the tire size with the following equation:
5. TESTING COMPONENTS
! CAUTION
When troubleshooting and testing the ABS system, do not dam-
age the connector terminals.
(1) Voltage Check
Measure voltage at the pins indicated in Table C.
• Voltage must be between 9.5 and 14.0 volts.
• The ignition must be turned ON for this test.
Table C: Voltage check pins
ECU Connector Pins
Universal 14-Pin 4 and 9

9 and 4
Basic 14-Pin 7 and 4

8 and 9
Frame-mounted X1-Grey 1 and 12

2 and 11
NOTICE
Pin locations are illustrated in figure (Frame) and figure (Basic
and Universal).
VIEW INTO ECU CONNECTOR
BASIC
1 4 7 10 13 16 1 4 7 10 13
2 5 8 11 14 17 2 5 8 11 14
3 6 9 12 15 18 3 6 9 15
18 14
SAPH16F070800026
(2) Location of Sensors

On steering axles, the sensor is accessible on the in-board
side of the steering knuckle.
On drive axles, the drum assembly may have to be pulled to

gain access to the sensor.
(3) Sensor Adjustment
• Push the sensor in until it contacts the tooth wheel.
• Do not pry or push sensors with sharp objects.
• Sensors will self-adjust during wheel rotation.
(4) Sensor Output Voltage Test
Voltage must be at least 0.2 volts AC at 30 rpm.
b. Disconnect the appropriate connector from the ECU (refer
to wiring diagram).
c. Rotate wheel by hand at 30 rpm (1/2 revolution per sec-
ond).
d. Measure voltage at the pins indicated in Table D.
• If the minimum output voltage is less than 0.2, push the
corresponding sensor toward the tooth wheel, then
repeat the measurement.
Table D: Sensor Check Pins
ECU Sensor Connector Pins
Basic LF 18-Pin 12 and 15

RF 18-Pin 10 and 13
LR 18-Pin 11 and 14
RR 18-Pin 17 and 18
(5) Sensor Resistance

The sensor circuit resistance must be between 900 and 2000
ohms. Resistance can be measured at the sensor connector,
or at the pins on the ECU connector. To measure resistance:
b. To measure resistance at the sensor connector, disconnect
the ECU connector from the ECU. To measure resistance
at the sensor connector, disconnect the sensor from the
sensor extension cable.
c. Measure output at the pins indicated in Table D.
VALVE TESTS
1. ABS MODULATOR VALVE

Bayonet-Style Connector Measure resistance across each valve solenoid coil terminal and
ground on the ABS valve to ensure 4.0 to 9.0 ohms.
• If the resistance is greater than 9.0 ohms, clean the electrical
contacts in the solenoid. Check the resistance again.
1
• To check the cable and the ABS valve as one unit, measure
resistance across the pins on the ECU connector of the har-
ness. Check the diagram of the system you are testing for pin
2 numbers. (Refer to page 9-27.)
1. Exhaust Solenoid (blue wire)

2. Inlet Solenoid (brown wire)
3. Ground Terminal
SAPH16F070800027
COMPONENT REMOVAL AND INSTALLATION
1. VALVES
• ABS Modulator Valves
2. SENSOR LUBE SPECIFICATION

Meritor WABCO specifications call for a sensor lubricant with the
following characteristics:
Lube must be mineral oil-based and contain molydisulfide. It

should have excellent anti-corrosion and adhesion characteristics,
and be capable of continuous function in a temperature range of -
40 to 300F (-40 to 150C).
! WARNING
Release all air from the air systems before you remove any com-
ponents. Pressurized air can cause serious personal injury.
! CAUTION
Use the following procedures to avoid damage to the electrical
system and ABS/ATC components.
When welding on an ABS- or ABS/ATC-equipped

vehicle is necessary, disconnect the power con-
nector from the ECU.
3. WHEEL SPEED SENSOR REMOVAL — FRONT AXLE

To remove the sensor from the front axle:
! WARNING
slip and fall over. Serious personal injury can result.
(1) Put blocks under the rear tires to stop the vehicle from mov-
ing. Apply the parking brake.
(2) If necessary, raise the front tires off the ground. Put safety
(3) Disconnect the fasteners that hold the sensor cable to other
components.
(4) Disconnect the sensor cable from the chassis harness.
(5) Remove the sensor from the sensor holder. Use a twisting
motion if necessary. Do not pull on the cable.
1002036a
Knuckle-Mounted Sensor
SAPH16F070800028
4. WHEEL SPEED SENSOR INSTALLATION — FRONT AXLE

To replace the sensor in the front axle:
(1) Connect the sensor cable to the chassis harness.
(2) Install the fasteners used to hold the sensor cable in place.
(3) Apply a Meritor WABCO recommended lubricant to the sen-
sor spring clip and sensor.
(4) Install the sensor spring clip. Make sure the spring clip tabs
(5) Push the sensor spring clip into the bushing in the steering
knuckle until the clip stops.
(6) Push the sensor completely into the sensor spring clip until it
contacts the tooth wheel.
NOTICE
After installation, there should be no gap between the sensor and
the tooth wheel. During normal operation, a gap of up to 0.04-inch
is allowable.
(7) Remove the blocks and safety stands.
5. WHEEL SPEED SENSOR REMOVAL— REAR AXLE

To remove the sensor in the rear axle:
! WARNING
(1) Put blocks under the front tires to stop the vehicle from mov-
ing.
(2) Raise the rear tire off the ground. Put safety stands under the
axle.
(3) Release the parking brake and back off the slack adjuster to
release the brake shoes.
(4) Remove the wheel and tire assembly from the axle.
(5) Remove the brake drum.
(6) Remove the sensor from the mounting block in the axle hous-
ing. Use a twisting motion if necessary. Do not pull on the
cable.
(7) Remove the sensor spring clip from the mounting block.
(8) Disconnect the fasteners that hold the sensor cable and the
hose clamp to other components.
(9) Disconnect the sensor cable from the chassis harness.
6. WHEEL SPEED SENSOR INSTALLATION—REAR AXLE

(1) Apply a Meritor WABCO recommended lubricant to the sen-
1
2 sor spring clip and sensor.
(2) Install the sensor spring clip. Make sure the spring clip tabs
(3) Push the sensor spring clip into the mounting block until it
stops.
4 3
NOTICE
After installation, there should be no gap between the sensor and
the tooth wheel. During normal operation, a gap of up to 0.04-inch
is allowable.
(4) Push the sensor completely into the sensor spring clip until it
contacts the tooth wheel.
(5) Insert the sensor cable through the hole in the spider and
axle housing flange. Route the cable to the frame rail. Be
sure to route the cable in a way that will prevent pinching or
chafing and will allow sufficient movement for suspension
travel.
(6) Connect the sensor cable to the chassis harness.
1002037a (7) Install the fasteners that hold the sensor cable in place.
(8) Install the brake drum on the wheel hub.
1. Spring Clip
2. Sensor Holder
(9) Complete the installation per vehicle manufacturer's manual.
3. Spring Clip Tab
4. Sensor
SAPH16F070800029
7. ABS MODULATOR VALVE

(1) Removal
a. Turn ignition switch to the OFF position, apply parking
brake.
! WARNING
b. Put blocks under the front and rear tires to stop the vehicle
2 1 from moving.
c. If necessary, raise the vehicle off the ground and put safety
d. Disconnect the wiring connector from the ABS valve.
e. Disconnect the air lines from Ports 1 (air supply) and 2 (air
discharge) of the ABS valve.
f. Remove the two mounting capscrews and nuts.
g. Remove the ABS valve.
1002038a
1. Port 1 (Air In)
2. Port 2 (Air Out)
SAPH16F070800030
(2) Installation
! CAUTION
Moisture can affect the performance of all ABS/ATC systems, as
well as the standard braking system. Moisture in air lines can
cause air lines to freeze in cold weather.
To install the ABS modulator valve:

a. Install the ABS valve with two mounting capscrews and
nuts. Tighten the capscrews per the manufacturer's recom-
mendation.
b. Connect the line to the brake chambers to Port 2 of the
ABS valve. Connect the air supply line to Port 1 of the ABS
valve.
c. Connect the wiring connector to the ABS valve. Hand
tighten only.
d. Remove the blocks and stands.
e. Test the installation. (Refer to below.)
f. Checking the installation
To test the modulator valve:

a. Apply the brakes. Listen for leaks at the modulator valve.
b. Turn the ignition on and listen to the modulator valve cycle.
If the valve fails to cycle, check the electrical cable connec-
tion. Make repairs as needed.
c. Drive the vehicle. Verify that the ABS indicator light oper-
ates properly.
WIRING DIAGRAM
1. BASIC ECU (CAB-MOUNTED)
BASIC
1 4 7 10 13 16 1 4 7 10 13
2 5 8 11 14 17 2 5 8 11 14
3 6 9 12 15 18 3 6 9 15
18 14
SAPH16F070800031
TP
J1587 B 10 10 J1587 B
J1587 A 11 11 J1587 A
SAE SAE TP
J1939 3 TR-WL 2 J1939 1 J1939 L 1 1 J1939 L
H L J1939 H 3 3 J1939 H
BATTERY 8 14 AWG 15A AMP 8 BAT
ECU+ 7 5A AMP 7 IGN
ATC 6 ABS 5 ECU- 4 86 30
14 PIN CONNECTOR
TO 3RD BRAKE
3RD BRAKE 14
TRAILER 2 85 87 87A
GND 9 BAT 8 ECU+ 7 WARNING 14
LIGHT
ATC LIGHT 13
TRACTOR WARNING LIGHT
SAE SAE TRACTOR 15 15
JUMPER 12 J1587 11 J1587 10 WARNING
A B BLINK CODE
LIGHT SWITCH
ATC
SWITCH
ATC SWITCH 6
ABS OFF ROAD SWITCH
ABS 3RD ATC ABS OFF 5
LIGHT 15 BRK
14 LIGHT
13 ROAD
ECU- 4 4
GND 9 9
BACK VIEW OF HARNESS CONNECTOR

GND*
INLET 1 1 IV
INLET INLET INLET VALVE 16 AWG GND RIGHT FRONT
VALVE 3 VALVE 2 VALVE
1 ABS VALVE
OUTLET 4 4 OV
VALVE
INLET 3 3 IV
LEFT FRONT
VALVE 16 AWG GND
ABS VALVE
OUTLET OUTLET OUTLET OUTLET 6 6 OV
VALVE 6 VALVE 5 VALVE 4
VALVE
INLET 2 2 IV
VALVE LEFT REAR
16 AWG GND
18 PIN CONNECTOR
ABS VALVE
OUTLET 5 5 OV
OUTLET INLET VALVE
VALVE 9 VALVE 8 DIF- 7
DIF- 7
INLET 8 8 IV
VALVE 16 AWG GND RIGHT REAR
ABS VALVE
OUTLET 9 9 OV
SENSOR 11
VALVE
SENSOR 12 SENSOR 10 TP
SENSOR 10 10 RIGHT FRONT
SENSOR
SENSOR 13 13
TP
SENSOR 11 11 LEFT REAR
SENSOR
SENSOR 15
SENSOR 14 14
SENSOR 14 SENSOR 13 TP
SENSOR 12 12 LEFT FRONT
SENSOR 15 15 SENSOR
DIF+ 16
TP
SENSOR 18 SENSOR 17 DIF+ 16 SENSOR 17 17 RIGHT REAR
SENSOR
SENSOR 18 18
BACK VIEW OF HARNESS CONNECTOR
1. Momentary Switch
2. Optional Equipment
3. Twisted Pair = TP
4. All unmarked wires should be 16 or 18 AWG.
5. All fuses should be blade type.
*All connected to a common star ground.
SAPH16F070800032
RECONFIGURATION PROCEDURE
1. HOW TO RECONFIGURE AN ECU (E VERSION)

Before reconfiguring the ECU, contact ArvinMeritor's Cus-
tomer Service Center at 800-535-5560 for additional informa-
tion.
E version ECUs memorize the following components if they are

connected at power-up:
• ATC valve
• Retarder relay
• Datalink SAE J1939
Once these components have been memorized, the ECU will look for
them at each power-up. If memorized component is not present, the
ECU will record a fault. For example, if an ATC valve memorized, but is
not present at the next power-up, the ECU records a fault. This can
occur if an ECU is moved from one truck to another and one or more of
the memorized components are not available on the new truck. If this
occurs, use TOOLBOX Software to reconfigure the ECU. If you do not
have TOOLBOX Software, follow the Manual Reconfiguration instruc-
tions listed on 9-29.
2. TOOLBOX SOFTWARE
NOTICE
For complete instructions for using TOOLBOX Software, refer to
the TOOLBOX User's Manual, TP-99102.
To reconfigure the ECU with TOOLBOX Software, use the Reset Mem-
orized command.
Select Reset Memorized from the pull down menu to tell the ECU to
reset the memorized or "learned" components.
3. MANUAL RECONFIGURATION
Action Result Reason

1. Turn ignition ON. ABS light displays the ABS system Stored faults cleared, no active faults
2. Press and hold blink switch for at configuration code*: present. Continue with reconfiguration.
least three seconds. O Two blinks: 4S/4M NOTE: The reconfiguration procedure
* The ABS light may display eight quick can not be conducted if there are active
NOTE: Do not hold this switch longer faults present. These must be repaired
than seven seconds. flashes before the system configuration
code begins. before proceeding with the
reconfiguration.
Observe the ABS and A TC lights. ATC light comes on and stays on. A complete A TC system including an
ATC light is installed. If not, the A TC
light will not come on.
ABS light will continuously blink the ECU reconfiguring the system.
system configuration code.
The ECU checks the following
components and reprograms itself based
on the new system:
O Retarder relay
AND/OR
While the configuration code is flashing, ABS light displays four quick flashes , Successfully reconfigured.
press the blink code switch three times followed by a continuous display of the
(one second each, with a one second system configuration code.
pause between each).
NOTE: System configuration code
Turn ignition OFF . continues until ignition is turned OFF.
SAPH16F070800033
A system reconfiguration is illustrated below:
IGNITION ON
1s 1s 1s
SWITCH
3 Second 1s 1s
Hold
ATC Reset Continues
Confirmation until
Pause Pause Pause Pause Pause Pause Pause power is
1.5 s 4s 4s 4s 4s 4s 4s turned off
System ID System ID System ID System ID System ID System ID
(2) (2) (2) (2) (2) (2)
ATC
ATC Light - Dyno Function (remains lit for entire test)
Light ON*
*ATC Light will light only if ATC is connected.
SAPH16F070800034
TROUBLESHOOTING GUIDE - MERITOR WABCO

ABS VALVE PACKAGE
This Troubleshooting Guide is a reference tool to help identify possible
malfunctions of the ABS modulator or relay valves. It does not take the
place of diagnostic tests or other service instructions.
ABS Valve Package Troubleshooting Guide
Condition Possible Cause Recommended Action
Air constantly leaks from exhaust port Internal relay valve problem. • Replace the relay valve.
of relay valve.
Air leaks from exhaust port of ABS Parking brake problem. • Service appropriate component.
modulator valve or relay valve when OR - Refer to manufacturer’s service
parking brake is released. Anti-compound 2-way check valve manual for instructions.
problem.
Rear service brakes releasing slowly Kinked air line. • Inspect/repair lines, brakes.
(brakes dragging) Dirt buildup inside relay valve.
If condition is not corrected:
• Replace relay valve.
ABS Valve Package Troubleshooting Guide
Condition Possible Cause Recommended Action
valves don't cycle at power-up. Broken wire. • Check wires and connectors.
OR OR - Make repairs as needed.
Indicator light comes on (blink code or Loose or broken terminal connection.
diagnostic tool indicates electrical Corroded connector pins. If condition is not corrected:
problem with ABS valve). OR
• Measure resistance across each
Problem with solenoid.
valve solenoid coil terminal and
Open-Style Connector ground on the ABS modulator valve
to ensure 4.0 to 8.0 ohms.
- If greater than 8.0 ohms, clean
valve and repeat measurement.
- If cleaning does not solve prob-
lem, replace the ABS modula-
tor valve.
- If less than 4.0 ohms, replace
ABS modulator valve.
1. Ground Terminal
3. Inlet Solenoid (Brown wire)
Bayonet-Style Connector

2. Inlet Solenoid (Brown wire)
3. Ground Terminal
ABS valve package damaged. • Road Hazards. • Replace complete ABS valve pack-
OR age or individual component as
• Vehicle Damage. required.
VEHICLE CONTROL SYSTEM (VCS) 11–1
VEHICLE CONTROL SYSTEM (VCS)

11
11-001
VEHICLE CONTROL SYSTEM..................................11-2

PRECAUTIONS FOR DIAGNOSIS .......................11-2
SYSTEM BLOCK DIAGRAM.................................11-4
SIGNAL CHECK HARNESS .................................11-5
TOOL...................................................................11-13
VEHICLE CONTROL ECU INSPECTION...........11-14
DIAGNOSIS MONITOR CODE AND DIAGNOSIS
TROUBLE CODE TABLE....................................11-20
DTC: P0500 ........................................................11-21
DTC: P0501 ........................................................11-25
DTC: P0562 ........................................................11-29
DTC: P0563 ........................................................11-32
DTC: P0617 ........................................................11-35
DTC: P0704 ........................................................11-38
DTC: P0850 ........................................................11-44
DTC: P1565 ........................................................11-50
DTC: U0101 ........................................................11-56
DTC: U0105 ........................................................11-59
DTC: U0155 ........................................................11-62
NO ACTIVATION OF AUXILIARY BRAKE ..........11-64
NO ACTIVATION/RELEASE OF ENGINE
REVOLUTION CONTROL ..................................11-70
NO ACTIVATION/RELEASE OF
CRUISE FUNCTION ...........................................11-75
NO ACTIVATION/RELEASE OF ECO
MODE .................................................................11-83
11–2 VEHICLE CONTROL SYSTEM (VCS)
VEHICLE CONTROL SYSTEM
PRECAUTIONS FOR DIAGNOSIS

EN01H16F04100F03001001
• Verify that connectors are properly connected before starting opera-

tions.
• Make sure to set the starter switch to the "LOCK" position before dis-
connecting 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 anal-
ysis.
1. ILLUSTRATION OF CONNECTOR AND MEASUREMENT ON

TERMINAL
LOCK
ILLUSTRATION OF CONNECTOR
The illustration of a connector contained in this document
represents an image of a connector with its lock positioned
on top as viewed from the connecting face.
To be connected
Male Female
connector connector
NUMBERING OF CONNECTOR TERMINALS

3 2 1 1 2 3 The terminals are symmetrically numbered (symmetrically
6 5 4 4 5 6 reversed numbering) as viewed on the connecting faces of a
pair of connectors.
The terminal #1 is located at the top right corner of a male
connector and at the top left corner of a female connector
Male Female respectively in this document.
connector connector
PRECAUTIONS FOR TERMINAL MEASUREMENT

Incorrect Unless otherwise specified in this document, the illustration
of a connector represents an image of a connector as viewed
from the connecting face. A test probe must access the back
Correct 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.
Correct
As to a connector that is designed to use the signal check
harness for terminal measurement, do not place a test probe
Incorrect directly onto the front or back face. Use a contact box of the
connected signal check harness to take measurement on
terminals.
Waterproof connector
ILLUSTRATION OF CONNECTOR AND

MEASUREMENT SURFACE
A The illustration of a connector contained in this document
1 2
4 3 represents an image of a connector as viewed from the
5 6 connecting face. For example, the terminal #1 of a female
View A connector is located at the top left corner of a connector as
viewed from the connecting face.
3 2
6 1 In actual measurement on the terminal #1 of a female
5 4 connector, a test probe must be placed onto the top right
corner on the back face of a connector.
View B
B
SAPH16F041000001
SYSTEM BLOCK DIAGRAM

EN01H16F04100F03001002
ENGINE ECU MAIN RLY

(ENGINE CIRCUIT)
40A 30A
BATTERY POWER 1
30A 30A
BATTERY POWER 2
10A
ACT RELAY ACTUATOR POWER SUPPLY 1

A 15A 100A
S
80A B C M ACTUATOR POWER SUPPLY 2
T
C
LOCK ACTUATOR POWER SUPPLY 3
ACC
ON ACTUATOR RELAY DRIVE
ST 10A
STARTER SIGNAL 1
ST
VEHICLE CAN+ 250kCAN
PW3
5A METER
KEY SW SIGNAL 1 VEHICLE CAN
-
TRANS
KEY SW SIGNAL 2 VEHICLE CAN+ (DL)
VEHICLE CAN- (DL)
ENGINE CAN+ 500kCAN(DIAG)

ENGINE
ENGINE CAN - AFTER TREATMENT
DLC CONNECTOR
ENGINE CAN+ (DL)
ENGINE CAN - (DL)
OFF
ON
ECONOMY
RHEOSTAT RUNNING SW
VEHICLE CONTROL ECU
TACHOMETER METER
CRUISE SW 1
SET
CRUISE SW 2
RESUME
FREE
PUSE
BRAKE SW BRAKE SW
CONSTANT-SPEED SW
ABS DRIVE SIGNAL
CLUTCH SW
ABS
EE
B1 COMBINATION SW 1st
OFF
50A 10A
STOP LIGHT SW
ABS ECU ABS MALFUNCTION SIGNAL

ISO9141
MT : NEUTRAL SW
TRANS : NEUTRAL SIGNAL NEUTRAL SIGNAL DATA LOGGER
RS232CTx DLC CONNECTOR
FORM TRANS ECU
DATA LOGGER
RS232CRx
IDLE UP SIGNAL
EQUIPMENT REQUIREMENTS FOR ADDITIONAL
INSTRUMENT
20A G2GND1
PARKING BUZZER
OFF SW G2GND2
G2GND3
G4GND1
METER VEHICLE SPEED SW: SWITCH
G4GND2
ENGINE ECU
SAPH16F041000002
SIGNAL CHECK HARNESS

EN01H16F04100F03001003
1. MENTION OF THE SIGNAL CHECK HARNESS

(1) HINO provides a signal check harness to check the ECU.
! CAUTION
To prevent damage of the ECU connector, connect the signal
check harness and perform measuring by bringing the test probe
into contact with the signal check harness side (Contact box).
HINT
The terminal numbers referred in text or illustrations in this docu-
ment correspond to the numbering in the next section "COM-
PUTER (ECU) PIN ASSIGNMENT" as shown in the figure below.
Computer (ECU) SP2 SP1
terminal signal ISSW CRSW BBSW RANH CSW3 CSW2 CSW1 IDLE CLSW
ISOK AGD4 ASCS APC4
Computer (ECU) 1 2 3 4 5 6 7
Example: A22 terminal terminal No. 8 9 10 11 12 13 14 15 16 17
A 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
A22
A
Signal check
harness
(contact box) 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
SAPH16F041000003
2. CONNECT THE SIGNAL CHECK HARNESS.

(1) Turn the starter switch to the "LOCK" position and disconnect
Harness the connectors from the vehicle control ECU.
ECU
(vehicle side)
(2) Connect a signal check harness to the vehicle harness and
the vehicle control ECU.
SST: Signal check harness (S0904-91080)
Signal check
harness
Test probe
Contact box
SAPH16F041000004
COMPUTER (ECU) PIN ASSIGNMENT
Computer (ECU) terminal signal Computer (ECU) terminal No.
SP2 SP1 A 1 2 3 4 5 6 7
CRSW CSW1 CLSW 8 9 10 11 12 13 14 15 16 17
ISOK 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
B 1 2 3 4 5 6 7
SET RES PRKB KSW2 KSW1 NUSW TBSM STS 8 9 10 11 12 13 14 15 16 17 18 19
AFSW 20 21 22 23 24 25 26 27
VSP1 RNRR 28 29 30 31 32 33 34 35
SG2 SG1 C 1 2 3 4 5 6 7
ABS BSW1 8 9 10 11 12 13 14 15 16 17
BRX 18 19 20 21 22 23 24 25 26 27
ECAL ECAH VCAL VCAH 28 29 30 31 32
AG3 D 1 2 3 4 5 6
TACH 7 8 9 10 11 12 13 14 15 16
ARY1 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
AP3 AP2 AP1 AG2 AG1 E 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17
DAT2 DAT1 18 19 20 21 22 23 24 25
CDGL CDGH HCAL HCAH 26 27 28 29 30 31
Signal check harness (CONTACT BOX) terminal No.
A 1 2 3 4 5 6 7 8 9 10 B 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40 31 32 33 34 35 36 37 38 39 40
C 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
D 1 2 3 4 5 6 7 8 9 10 E 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40 31 32 33 34 35 36 37 38 39 40
SAPH16F041000005
COMPUTER (ECU) PIN CONNECTION

• The terminal number in the table correspond with the contact box of
signal check harness.
CONTACT BOX (A)
No. Signal Connection destination No. Signal Connection destination
1 – 18 –
2 – 19 ISOK Diagnosis connector
3 – 20 –
4 – 21 –
5 – 22 –
6 SP2 Fuse 7B 23 –
7 SP1 Fuse 7B 24 –
8 – 25 –
9 – 26 –
10 CRSW Auto cruising switch 27 –
11 – 28 –
12 – 29 –
13 – 30 –
14 – 31 –
15 CSW1 Combination switch 32 –
16 – 33 –
17 CLSW Clutch switch 34 –

CONTACT BOX (B)
1 – 19 STS Starter switch signal
2 – 20 –
3 – 21 –
4 – 22 –
5 – 23 AFSW Economy running switch
6 – 24 –
7 – 25 –
8 SET Auto cruising switch 1 26 –
9 RES Auto cruising switch 2 27 –
10 – 28 –
11 PRKB Parking buzzer off switch 29 –
12 KSW2 Key switch 2 30 –
13 KSW1 Key switch 1 31 –
14 NUSW Neutral switch 32 –
15 – 33 VSP1 Speed sensor
16 – 34 –
17 TBSW Brake switch 35 RNRR Idle up signal
18 –
CONTACT BOX (C)
1 – 17 BSW1 Stop light switch
2 – 18 –
3 SG2 Ground 19 –
4 SG1 Ground 20 –
5 – 21 –
6 – 22 –
7 – 23 –
8 – 24 –
9 – 25 BRX ABS light
10 – 26 –
11 – 27 –
12 – 28 ECAL Junction CAN
13 – 29 ECAH Junction CAN
14 – 30 –
15 – 31 VCAL Junction CAN
16 ABS ABS cut relay 32 VCAH Junction CAN

CONTACT BOX (D)
1 AG3 Ground 19 –
2 – 20 –
3 – 21 –
4 – 22 –
5 – 23 ARY1 Actuator relay
6 – 24 –
7 – 25 –
8 – 26 –
9 – 27 –
10 TACH Tachometer 28 –
11 – 29 –
12 – 30 –
13 – 31 –
14 – 32 –
15 – 33 –
16 – 34 –
17 – 35 –
18 –
CONTACT BOX (E)
1 AP3 Fuse7B 17 –
2 AP2 Fuse7B 18 –
3 AP1 Fuse7B 19 –
4 AG2 Fuse7B 20 –
5 AG1 Fuse7B 21 –
6 – 22 –
7 – 23 –
8 – 24 DAT2 Data logger RxD
9 – 25 DAT1 Data logger TxD
10 – 26 CDGL Junction CAN
11 – 27 CDGH Junction CAN
12 – 28 HCAL Junction CAN
13 – 29 HCAH Junction CAN
14 – 30 –
15 – 31 –
16 –

TOOL
EN01H16F04100F03001004
1. DIAGNOSIS TOOL
(1) Trouble diagnosis can be performed using the PC diagnosis
tool. By connection to the trouble diagnosis connector, the
trouble location is indicated.
PC:
Laptop computer
Complete function of HINO DX Ⅱ is conformed on "Pana-
sonic CF-D1".
SST:
Computer interface
SAPH16F041000006 (DENSO DST-i set without LCD)
(DENSO DST-i set with LCD)
Diagnosis software: Hino Diagnostic explorer Ⅱ (HINO DX
Ⅱ)
NOTICE
Only ECU reprogramming can be performed by authorized HINO
dealer.
2. CONNECT THE PC DIAGNOSIS TOOL

(1) Turn the starter switch to the "LOCK" position.
(2) Connect the PC diagnosis tool to the trouble diagnosis con-
nector on the left side of steering column.
Trouble diagnosis
connector
SAPH16F041000007
VEHICLE CONTROL ECU INSPECTION

EN01H16F04100F03001005
INFORMATION: VEHICLE CONTROL ECU INSPECTION
FUSE FUSE
VCS ACT A5Z common rail(M)
AA5
(7ALD)
(1ALD)
(U2M)
%GB
FUSE Common rail J/C No.1
VCS MAIN A61 ADM ADN
(B ) (LD ) %GC
(7BLD) (U2M)
ADK ADL
(S+ ) (S- ) %GD
VCS actuator (U2M)
(SP1) L7W
L7Q
relay
L7H
(AP3) L7R
L7K
L7S
(SP2) L7X
L7P
L7T
(ARY1) L96
L90
L91
L7J
(AG3)
(AG2)
(AG1)
(SG2)
(SG1)
(AP2)
(AP1)
(KSW1)
(KSW2)
Vehicle control ECU
J/C G4
&DH &DC #G1 #G1
(G4A) (G45A)
&1D
W/S G4 (G4-A)
Z30
(G4C)
Battery ground
SAPH16F041000008
INSPECTION PROCEDURE: VEHICLE CONTROL ECU INSPECTION
1 Inspect the voltage of power supply [HINO DX Ⅱ ]
4. Select [Vehicle control ECU] on HINO DX Ⅱ .
5. Select following items from the [Data monitor Setting] menu, and
measure them.
Measurement
SAPH16F041000009 Monitoring items Standard values
conditions
Starter switch: ON Voltage 10 – 16 V
YES NO
2 Inspect the ground circuit of the vehicle control ECU

C4 D1 E5
2. Connect the signal check harness to the vehicle control ECU. (Do
not connect the harness to the ECU.)

terminals of the vehicle control ECU (signal check harness) and
the ground.
Measurement Tester
Standard values
SAPH16F041000010 Vehicle control
ECU (signal check
Starter switch: harness)
Below 1 
LOCK SG1(C4) – Ground
AG3(D1) – Ground
AG1(E5) – Ground
YES NO
Go to step 3. Repair or replace the ground circuit.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
3 Inspect the power supply circuit of the vehicle control ECU (Power supply of battery)
nals of the vehicle control ECU (signal check harness).
A6 A7 C4
Measurement Tester
Standard values
Vehicle control
ECU (signal check
Starter switch:
harness) 10 – 16 V
LOCK
SP1(A7) – SG1(C4)
SP2(A6) – SG1(C4)
SAPH16F041000011
YES NO
Replace the vehicle control ECU. Repair or replace the power supply circuit
Perform After-inspection work. (Clear all past between fuse and the vehicle control ECU.
DTC. Check no DTC is stored after test Perform After-inspection work. (Clear all past
drive.) DTC. Check no DTC is stored after test
drive.)
4 Inspect the starter switch [HINO DX Ⅱ ]
measure them.
Measurement
Monitoring items Standard values
conditions
Starter switch: ON Starter switch ON
SAPH16F041000012
YES NO
5 Inspect the power supply circuit of the vehicle control ECU (Power supply of starter switch)
nals of the vehicle control ECU (signal check harness).
B13 C4
B12 Measurement Tester
Standard values
Vehicle control
ECU (signal check
harness)
Starter switch: ON KSW1(B13) – 10 – 16 V
SG1(C4)
KSW2(B12) –
SAPH16F041000013 SG1(C4)
YES NO
Replace the vehicle control ECU. Repair or replace the power supply circuit
Perform After-inspection work. (Clear all past between Common rail J/C No.1 and the vehi-
DTC. Check no DTC is stored after test cle control ECU.
drive.) Perform After-inspection work. (Clear all past
drive.)
6 Inspect the VCS actuator relay [HINO DX Ⅱ ]
1. Select [Vehicle control ECU] and on HINO DX Ⅱ .
measure them.
Measurement
conditions
Starter switch: ON Actuator relay ON
SAPH16F041000014
YES NO

drive.)
7 Inspect the power supply circuit of the vehicle control ECU (Power supply of the VCS actua-
tor relay activation)
E3 nals of the vehicle control ECU (signal check harness).
E2
E1 C4
Measurement Tester
Standard values
Vehicle control
ECU (signal check
harness)
Starter switch: ON 10 – 16 V
AP3(E1) –SG1 (C4)
AP2(E2) –SG1 (C4)
AP2(E2) –SG1 (C4)
SAPH16F041000015
YES NO
Replace the vehicle control ECU. Repair or replace the VCS actuator relay and
Perform After-inspection work. (Clear all past the VCS actuator relay circuit.
DTC. Check no DTC is stored after test Perform After-inspection work. (Clear all past
drive.) DTC. Check no DTC is stored after test
drive.)
DIAGNOSIS MONITOR CODE AND DIAGNOSIS TROUBLE CODE TABLE

EN01H16F04100F03001006
NOTICE
DTC No.: Diagnosis Trouble Code (Using the PC diagnosis tool)
DTC No. DIAGNOSIS ITEM
P0704 Clutch switch malfunction
P1565 Cruise switch malfunction
P0850 Neutral switch malfunction
P0501 Vehicle speed sensor signal error
P0500 Vehicle speed sensor input open/short
P0617 Starter switch battery short
P0563 VBB fail trouble (High range)
P0562 VBB fail trouble (Low range)
U0101 Disconnection of bus line between Automatic transmission controller and vehicle control
U0155 Disconnection of bus line between meter and vehicle control
U0105 Blackout in the engine CAN

DTC: P0500
EN01H16F04100F03001007
DTC: P0500 Vehicle speed sensor input open/short

INFORMATION
METER Common rail J/C No.2

E7F %DF %DG L8F
(PCO4) (VSP1) Vehicle control ECU
(JC) (JC)
%DE
(JC)
K6L %DE K6L

(VS ) Engine ECU
SAPH16F041000016
• The vehicle control ECU consistently measures pulses from the vehicle speed sensor through the combination
meter.
• Abnormal pulses from the vehicle speed sensor through the combination meter cannot.

(1) Check conditions
Starter switch ON. Engine speed is 800 r/min or more. Gears are engaged. The fuel injection quantity meet the
specified value or more. Engine coolant temperature is 50 C {122 F} or higher. Battery voltage is in the range
of 10 V to 16 V.
Vehicle speed that is recognized in the vehicle control ECU remains at a vehicle speed of 0 km/h {0 mile/h} for 1
seconds or longer.
3. Reset condition
• Immediately after normal operation is restored.

• SVS light: ON
<Symptoms on the vehicle due to backup control (fail safe) - Action arising from backup control>
• –

• Economy run is not available.
• Exhaust brake is not available.
• Cruise control is not available.

• Vehicle speed sensor abnormal
• Malfunction of pulse modulator (in combination meter)
• Malfunction of vehicle control ECU
1 Read the DTC [HINO DX Ⅱ ]
4. Select [Engine] and check if the DTC (P0500) has been detected.
SAPH16F041000017
Has DTC (P0500) been detected in the engine ECU?
YES NO
Go to diagnosis procedure of DTCs in the Go to step 2.

engine ECU.
2 Inspect the vehicle control ECU
1. Perform "VEHICLE CONTROL ECU INSPECTION", ensure that

there is no other abnormality.
YES NO
Repair or replace the failure part. Go to step 3.

MATION section.
3 Inspect for open-circuits in the wire harness of the vehicle speed signal circuit
B 33 B PC04
2. Disconnect the combination meter connector.
3. Connect the signal check harness to the engine ECU vehicle-side

harness. (Do not connect the harness to the ECU.)

terminals of the combination meter vehicle-side connector and
vehicle control ECU (signal check harness).
Measurement Tester
SAPH16F041000018 Standard values
Combination
meter vehicle-side
connector – Vehi-
Starter switch:
cle control ECU Less than 1 
LOCK
(signal check har-
ness)
PC04 – VSP1(B33)
YES NO
Replace the vehicle control ECU. Repair or replace the wire harness.
DTC: P0501
EN01H16F04100F03001008
DTC: P0501 Vehicle speed sensor signal error

INFORMATION
METER Common rail J/C No.2

E7F %DF %DG L8F
(PCO4) (VSP1) Vehicle control ECU
(JC) (JC)
%DE
(JC)
K6L %DE K6L

(VS ) Engine ECU
SAPH16F041000019
• The vehicle control ECU consistently measures pulses from the vehicle speed sensor through the combination
meter.
• Abnormal pulses from the vehicle speed sensor through the combination meter.

Starter switch ON.
The fuel injection quantity meet the specified value or more.
Battery voltage is in the range of 10 V to 16 V.
Output of the vehicle speed sensor remains at a vehicle speed of 200 km/h {125 mile/h} for 5 seconds or longer.
3. Reset condition

• SVS light: ON
• –

• Economy run is abnormal.
• Exhaust brake is abnormal.
• Cruise control is abnormal.

• Vehicle speed sensor abnormal
• Malfunction of pulse modulator (in combination meter)
SAPH16F041000020
YES NO

engine ECU.

YES NO

MATION section.
3 Inspect for open-circuits in the wire harness of the vehicle speed signal circuit
B 33 B PC04
2. Disconnect the combination meter connector.

harness. (Do not connect the harness to the ECU.)

terminals of the combination meter vehicle-side connector and
vehicle control ECU (signal check harness).
Measurement Tester
Combination
meter vehicle-side
connector – Vehi-
Starter switch:
cle control ECU Less than 1 
LOCK
(signal check har-
ness)
PC04 – VSP1(B33)
YES NO
Replace the vehicle control ECU. Repair or replace the wire harness.
DTC: P0562
EN01H16F04100F03001009
DTC: P0562 VBB fail trouble (High range)

INFORMATION
DPR REFRESH SW
A1H A1J KSM
(33+) (33LD) (SW+) FUSE common rail ACT
A1G
(32LD)
KBP KBJ
(LD) (B )
KBH KBG FUSE common rail MAIN
(S- ) (S+)
K7N K7M A1E
Common rail
ACT power RLY (E) (B ) (31LD)
K7L K7K
(S- ) (S+)
ADM ADN
Engine ECU
(B ) (LD)
FUSE GCU(M)
MAIN RLY FUSE VCS.ACT

(D5+)
ALW
A5Z ADK ADL

(7ALD) (S+ ) (S- )
VCS actuator relay

(D5LD)
ALX
FUSE VCS
MAIN A61
KU6
LCV
L2H
K08
K07
K56
K57
L2J
(7BLD)
#R3
#R4
%DM
#R2
#R6
%DN
#R1
#R5
KU6
LCV
L2H
K08
K07
K56
K57
L2J
(VB2)
(VB1)
(+BF1)
(VB3)
(MRL1)
(+BF2)
(VB4)
(MRL2)
L7W
L7Q
L7R
(SP2) L7X
L7P
L96
(SP1)
(ARY1)
(AP3)
(AP2)
(AP1)
Engine ECU
Vehicle control ECU
SAPH16F041000022
• Abnormally low battery voltage (vehicle control ECU power supply circuit).

Starter switch ON.
Battery voltage (Vehicle control ECU): 0 V.
3. Reset condition
• After restoration to normal condition

• SVS light: OFF
• –

• Exhaust brake is not available.
• Engine revolution control is not available.

• Battery terminals: Disconnection
• Battery: Discharged
• Harnesses and terminals: Disconnection, short circuit, irregular contact, looseness
• Connectors, harnesses and terminals: Disconnection, irregular contact, looseness
• Vehicle control ECU: Malfunction
SAPH16F041000023
YES NO

engine ECU.

YES NO
Repair or replace the failure part. Replace the vehicle control ECU.
DTC: P0563
EN01H16F04100F03001010
DTC: P0563 VBB fail trouble (High range)

INFORMATION
FUSE common rail (M)

AA5
(1ALD)
(U2M)
%GB
Common rail J/C No.1
%GC
(U2M)
%GD
(U2M)
L90
L91
(KSW1)
(KSW2)
Vehicle control ECU
SAPH16F041000024
• Abnormally high battery voltage (vehicle control ECU power supply circuit).

Starter switch ON.
Vehicle control ECU power supply voltage is 16 V or more.
3. Reset condition
• After restoration to normal condition

• SVS light: OFF
• –

• –

• Fusible Link, FUSE: Fusing, irregular contact, partial engagement
• Alternator failure (abnormal voltage or requires adjustment)
• Vehicle control ECU: Malfunction
4. Select [Engine ECU] and check if the DTC P0563 has been
detected.
SAPH16F041000025
Has DTC (P0563) been detected?
YES NO

engine ECU.

YES NO
Repair or replace the failure part. Replace the vehicle control ECU.
DTC: P0617
EN01H16F04100F03001011
DTC: P0617 Starter switch battery short

INFORMATION
L95
(STS) Vehicle control ECU
(STA)
%H1
Starter relay
A3T #AB #AB %H3 %H2 K03

(SW ) (STA) (STA) (B )
Common rail J/C No.2

Starter cut relay
SAPH16F041000026
• The vehicle control ECU evaluates the starting condition based on the starter signal.
• Detection of a high fixed value for the starter signal.

Starter switch ON. Battery voltage is in the range of 10 V to 16 V. Engine speed is 1,000 r/min or more.
Starter signal (START) "ON" is detected with in the above DTC detection condition.
3. Reset condition
• After normal operation is restored and engine is restarted after engine stall.

• SVS light: OFF
• –

• –

• Malfunction of starter switch.
• Harness disconnection or short-circuit.
• Malfunction of vehicle control ECU.
SAPH16F041000027
YES NO

engine ECU.

YES NO

MATION section.
3 Inspect for starter signal [HINO DX Ⅱ ]
measure them.
Measurement
conditions
Starter switch
Starter switch: [LOCK]: OFF
ST switch
SAPH16F041000028 LOCK/START Starter switch
[START]: ON
YES NO

MATION section.
4 Inspect the starter signal circuit
B19 2. Connect the signal check harness to the vehicle-side connector of

the vehicle control ECU. (Do not connect the harness to the ECU.)
nals of the vehicle control ECU (signal check harness) and the
ground.
Measurement Tester
Standard values
SAPH16F041000029 Vehicle control Starter switch
ECU (signal check [LOCK]: 0 V
Starter switch:
harness) Starter switch
LOCK/START
STS(B19) – [START]: 9 V or
Ground more
YES NO
Replace the vehicle control ECU Repair or replace the starter signal circuit.
DTC: P0704
EN01H16F04100F03001012
DTC: P0704 Clutch switch malfunction

INFORMATION
VCS ECU VCS ACT RLY

L8J ADN
(CSW1) (LD )
#TD #TD
(CLT+)
Clutch switch K2X
K2Y
(CLT-)
#TB #TB
(CLSW)
LN3
Vehicle control ECU
SAPH16F041000030
• The vehicle control ECU recognizes clutch operation based on the clutch switch signal.
• The clutch switch cannot be correctly sensed.

Vehicle with manual transmission.
This will be detected if presence or absence of input of clutch switch signals cannot be sensed after 5 or more
cycles of vehicle stop (vehicle speed = 0 km/h {0 mile/h})  80 km/h {50 mile/h} (run)  stop.
3. Reset condition

• SVS light: OFF
• –


• Improperly adjusted clutch switch (does not turn ON when pedal is released)
• Clutch switch OFF failure, circuit disconnection, faulty contact

YES NO

MATION section.
2 Inspect the clutch switch [HINO DX Ⅱ ]
measure them.
Measurement
conditions
Depress the clutch

Clutch pedal pedal: OFF
Starter switch: ON
switch Release the clutch
pedal: ON
YES NO

MATION section.
3 Inspect the clutch switch signal circuit
A17 2. Connect the signal check harness to the vehicle-side connector of

the vehicle control ECU. (Do not connect the harness to the ECU).
ground.
Measurement Tester
Vehicle control
Depress the clutch
ECU (signal check
pedal: 0 V
Starter switch: ON harness)
Release the clutch
CLSW(A17) –
pedal: 10 – 16 V
Ground
YES NO
Replace the vehicle control ECU Go to step 4.

MATION section.
4 Inspect the clutch switch
1. Check if the clutch switch is properly adjusted.
YES NO
Adjust the clutch switch. Go to step 5.

MATION section.
5 Inspect the clutch switch connector
1. Check the connection of the clutch switch connector (Looseness

and poor contact).
YES NO

MATION section.
6 Inspect the clutch switch unit
CLT+ 2. Disconnect the clutch switch connector.

terminals of the clutch switch.

CLT-
With switch depressed (ON):
Clutch switch <1
CLT+ – CLT- With switch released (OFF):
SAPH16F041000033 
YES NO
Go to step 7. Replace the clutch switch.

MATION section.
7 Inspect the power supply of the clutch switch
CLT+
2. Use the electrical tester to measure the voltage between the CL2+
terminal in the clutch switch vehicle-side connector and the
CLT+ ground.
CLT-
Measurement Tester
Standard values
Clutch switch
vehicle-side con-
nector
SAPH16F041000034 CL2+ – Ground
YES NO
Repair or replace the wire harness between Repair or replace the power supply circuit of
the clutch switch and the vehicle control the clutch switch.
ECU. Perform "After-inspection work" of INFOR-
MATION section.
DTC: P0850
EN01H16F04100F03001013
DTC: P0850 Neutral switch malfunction

INFORMATION
TRANS starter relay
(S+ )
NJX
(NTSW)
%DY
TRANS ECU
N1N #D2 #D2
(NOUT)
%G2
(NSIG) %G1 L98
Neutral switch %DW (NSIG)
(NUSW) Vehicle control ECU
(NTSW)
NRF #LH #LH
(- ) J/C SIGNAL
%DX
(NTSW)
%17
(SIG)
Neutral switch
SAPH16F041000035
• The vehicle control ECU recognizes the gear neutral position based on the neutral switch signal.
• The neutral switch signal cannot be recognized normally.

Vehicle with manual transmission.
Even when the vehicle speed changes from 0 km/h {0 mile/h} (stop)  80 km/h {50 mile/h} (drive)  0 km/h {0
mile/h} (stop), there is no input change (ON/OFF) of the neutral switch signal.
3. Reset condition

• SVS light: OFF
• –

• Economy run is abnormal.
• Engine speed control is abnormal.

• Malfunction of Neutral switch (sticking)
• Open circuit or short circuit of wire harness

YES NO

MATION section.
2 Inspect the neutral switch [HINO DX Ⅱ ]
measure them.
Measurement
conditions
Neutral: ON
Starter switch: ON Neutral switch Without neutral:
OFF
YES NO

MATION section.
Y186_17MY_DIA8.fm 47 ページ２０１５年１１月９日　月曜日　午後６時３０分
3 Inspect the neutral switch signal circuit

ground.
Measurement Tester
Vehicle control
ECU (signal check Neutral: 10 – 16 V
Starter switch: ON harness) Without neutral:
NUSW(B14) – 0V
Ground
YES NO
Replace the vehicle control ECU. Go to step 4.

MATION section.
4 Inspect the neutral switch
1. Check if the neutral switch is properly adjusted.
YES NO
Adjust the neutral switch. Go to step 5.

MATION section.
Y186_17MY_DIA8.fm 48 ページ２０１５年１１月９日　月曜日　午後６時３０分
5 Inspect the neutral switch connector
1. Check the connection of the neutral switch connector (Looseness

and poor contact).
YES NO

MATION section.
6 Inspect the neutral switch unit

NRF(-) NRE(+)
2. Disconnect the neutral switch connector.

terminals of the neutral switch.
Measurement Tester
Standard values
Neutral: < 1 
Starter switch: Neutral switch
Without neutral:
LOCK NRE – NRF

SAPH16F041000038
YES NO
Go to step 7. Replace the neutral switch.

MATION section.
7 Inspect the neutral switch power supply

NRE(+) NRF(-)
2. Use the electrical tester to measure the voltage between the NRE
terminal in the neutral switch vehicle-side connector and the
ground.
Measurement Tester
Standard values
Neutral switch
vehicle-side con-
nector
SAPH16F041000039 NRE – Ground
YES NO
the neutral switch and the vehicle control the neutral switch.
MATION section.
DTC: P1565
EN01H16F04100F03001014
DTC: P1565 Cruise switch malfunction

INFORMATION
ABS EXH VCS ACT RLY

CUT RLY
ADN
(LD )
RHEOSTAT
(LIGHT)
S0D
(B )
EC8
(SRI+) L2W L2X (SRI-)
(COM)
(CIL+)
KCZ
KD2
KD5 (SET)
G5Y
KD4
FREE Cruise main switch
BLOWER SW
(STCM) KD6
PUSH (Auto cruising switch)
(P1)
(RSM)
(FSC) KD0
(CIL-) KD3
Set / resume
switch
W/S EARTH 1
%W4(G2G3)
K4A
K1Z
(RES) K49
Z21
(G2)
(SET)
(CRSW)
Cab ground DR1
Vehicle control ECU
SAPH16F041000040
• The vehicle control ECU recognizes auto cruise operation, based on the cruise main switch signal and the Set/
Resume switch signal.
• Malfunction of the Set/Resume switch (Sticking in the "ON" position) is detected.

Starter switch ON.
ON status (switch operated) of the Set/Resume switch has been recognized when the starter is running.
3. Reset condition
• After the engine stops, the OFF status (switch not operated) of the Set/Resume switch is recognized when perform-
ing an engine restart.

• SVS light: OFF
• –


• Malfunction of Set/Resume switch.
• Harness disconnection or short-circuit.
• Malfunction of ECU.
• Irregular contact (disconnection or poor fit of connector).

YES NO

MATION section.
2 Inspect the set/resume switch 1 [HINO DX Ⅱ ]
measure them.
Measurement
conditions
Cruise control Set position: ON

Starter switch: ON
switch 1 Free position: OFF
YES NO
3 Inspect the set/resume switch 2 [HINO DX Ⅱ ]
measure them.
Measurement
conditions
Resume position:
Cruise control
Starter switch: ON ON
switch 2
Free position: OFF
SAPH16F041000042
YES NO

MATION section.
4 Inspect the set/resume switch signal circuit
B8
2. Connect the signal check harness to the vehicle-side connector of
ground.
Measurement Tester
Standard values
B9 conditions connections
Vehicle control Set switch

ECU (signal check Resume switch
- ON: 10 – 16 V
SET(B8) – Ground
RES(B9) – Ground - OFF: 0 V
SAPH16F041000043
YES NO

MATION section.
5 Inspect the set/resume switch connector
1. Check the connection of the set/resume switch connector (Loose-

YES NO

MATION section.
6 Inspect the set/resume switch unit

SET STCM
2. Disconnect the set/resume switch connector.

terminals of the set/resume switch.
Set switch
Set/resume switch Resume switch
STCM – SET
- ON: < 1 
STCM RSM STCM – RSM
- OFF:  
SAPH16F041000044
YES NO
Go to step 7. Replace the set/resume switch.

MATION section.
7 Inspect the power supply of the set/resume switch

STCM
2. Use the electrical tester to measure the voltage between the
STCM terminal in the set/resume switch vehicle-side connector
STCM
KD4 and the ground.
Measurement Tester
Standard values
Set/resume switch
vehicle-side con-
nector
SAPH16F041000045 STCM – Ground
YES NO
the set/resume switch and the vehicle control the set/resume switch.
MATION section.
DTC: U0101
EN01H16F04100F03001015
DTC: U0101 Disconnection of bus line between Automatic transmission controller and
vehicle control
INFORMATION
Twist
(CANH)
%JT
%CT (CAN+)
CAN J/C %BA E4L
%CU (CAN-) %BF
(CAN+) (CAN+) (MMT+)
Twist METER
(CANL)
%JY
Twist
E4M
%BK (MMT-)
%BR
(CAN-)
(CAN-)
Twist
(CAN-)
%BD
%BN
(CAN-)
(CAN+)
%BL
(CAN+)
%BB
Twist Twist
(CASH)
(CASL)
O9G
O9H
Twist Twist
(HCAH)
(CAN+)
(HCAL)
(CAN-)
ESW
ESX
N6S
Selector
N6T
L81
L82
L8C
(VCAH) L8B
(VCAL)
(VHCL)
(VHCH)
Diagnosis
connector
(9P)
Vehicle control ECU Telematics unit
Twist
Twist
#H3
#H5
#H4
#H2
#H2
#H3
#H5
#H4
Twist
Twist
%K4
(CANL)
(CANH) %K3
Twist
(CAN+)
(CAN-)
NXG
NXF
TRANS ECU
SAPH16F041000046
• –
• The vehicle control ECU detected interruption of CAN communication with the TRANS-ECU.

Starter switch ON.
Vehicle control ECU power supply voltage is in the range of 10 V to 16 V.
CAN data from the TRANS-ECU to the vehicle control ECU is interrupted.
3. Reset condition
• After restoration to normal condition.

• SVS light: OFF
• –

• –

• CAN circuit failure
• TRANS-ECU failure

Refer to the "CONTROL CAN COMMUNICATION LINE" in the chapter "CAN COMMUNICATION".
DTC: U0105
EN01H16F04100F03001016
DTC: U0105 Blackout in the engine CAN

INFORMATION
METER
Vehicle Control ECU

Diagnosis
(MC5+)
Connector
(MC5-)
(16P)
L83
(CDGH)
L84
(CDGL)
L8Y
(ECAH)
L8Z
(ECAL)
KS4
(CAN-)
KS3
(CAN+)
ER0
ER1
Twist Twist
Twist
Twist
(METL)
(CANL)
%L6
%JG
Twist
Twist Twist
Twist
%JF %JH %L5 %L4
(CANL) (CANL) (METL) (METL)
(CANH)
(METH)
CAN J/C3 Low Telematics Unit
%JC
%F5
CAN J/C2 Low
%L3
(DLC3)
%F4
%K1 ESU
(DLC3)
(ENCH)
(CANH)
ESV (ENCL)
%K2 (CANL)
%JB %JD %L2 %L1
(CANH) (CANH) (METH) (METH)
Twist
#S1
#S3
CAN J/C2 High CAN J/C3 High
(500H)
(500L)
#S1
#S3
(500H)
#S5 #S5
(CAN1H)
(CAN1L)
#S7 #S7
%JP
%JL
(500L)
Twist Twist
%NM
%NN
%JM
#AW
#AV
(CA1H)
Twist V J/C
%JK
#AW
#AV
(CA1L)
%NM
%NN
(CAN1L)
(CAN1H)
%JN
%JJ
Twist
Twist
Twist
(CAH1)
(CA1H)
(CAL1)
(CA1L)
LCM
LCN
LF5
LF6
DCU ECU
SAPH16F041000047
• –
• The vehicle control ECU detected interruption of CAN communication with the engine ECU.

Starter switch ON.
CAN data from the engine ECU to the vehicle control ECU is interrupted.
3. Reset condition

• SVS light: OFF
• –

• –

• CAN circuit failure (Engine / diagnosis CAN)
• Vehicle control ECU failure

Refer to the "DIAGNOSIS CAN COMMUNICATION LINE" in the chapter "CAN COMMUNICATION".
DTC: U0155
EN01H16F04100F03001017
DTC: U0155 Disconnection of bus line between meter and vehicle control
INFORMATION
Twist
(CANH)
%JT
%CT (CAN+)
CAN J/C %BA E4L
%CU (CAN-) %BF
(CAN+) (CAN+) (MMT+)
Twist METER
(CANL)
%JY
Twist
E4M
%BK (MMT-)
%BR
(CAN-)
(CAN-)
0.50 W-
0.50 R-
Twist
(CAN-)
%BD
%BN
(CAN-)
(CAN+)
%BL
(CAN+)
%BB
Twist Twist
(CASH)
(CASL)
O9G
O9H
Twist Twist
(HCAH)
(CAN+)
(HCAL)
(CAN-)
ESW
ESX
N6S
Selector
N6T
L81
L82
L8C
(VCAH) L8B
(VCAL)
(VHCL)
(VHCH)
Diagnosis
connector
(9P)
Vehicle control ECU Telematics unit
Twist
Twist
#H3
#H5
#H4
#H2
MAIN W/H
FR W/H
#H2
#H3
#H5
#H4
Twist
%K4
(CANL)
(CANH) %K3
Twist
(CAN+)
(CAN-)
NXG
NXF
TRANS ECU
SAPH16F041000048
• –
• The vehicle control ECU detected interruption of CAN communication with the combination meter.

Starter switch ON.
CAN data (ID) from the combination meter to the vehicle control ECU is interrupted.
3. Reset condition

• SVS light: OFF
• –

• –

• CAN circuit failure
• Combination meter failure
NO ACTIVATION OF AUXILIARY BRAKE

EN01H16F04100F03001018
INSPECTION PROCEDURE

YES NO

drive.)
4. Select [Vehicle control ECU] and check if any of the DTCs have
been detected.
SAPH16F041000049
Has DTC been detected?
YES NO

3 Inspect the exhaust brake switch (Wiper and retarder switch) [HINO DX Ⅱ ]
measure them.
Measurement Tester
Standard values
Starter switch: ON
Exhaust brake
Exhaust brake ON
switch
switch: ON
SAPH16F041000050
YES NO
4 Inspect the exhaust brake switch (Wiper and retarder switch) signal circuit 1

A15
ground
Measurement Tester
Vehicle control Exhaust brake

ECU (signal check switch
- ON: 10 – 16 V
CSW1(A15) –
Ground - OFF: 0 V
YES NO

drive.)
5 Inspect the exhaust brake switch (wiper and retarder switch) signal circuit 2
A15
2. Disconnect the brake switch (wiper and retarder switch) connector.
RTR1

terminals of the vehicle control ECU (signal check harness) and
the exhaust brake switch vehicle-side connector.
Measurement Tester
Standard values
Vehicle control
SAPH16F041000052 ECU (signal check
harness) –
Starter switch: ON Exhaust brake Less than 1 
vehicle-side con-
nector
CSW (A15) – RTR1
YES NO
Go to step 6. Repair or replace the wire harness between

the exhaust brake switch and the vehicle
control ECU.
drive.)
6 Inspect the exhaust brake switch (wiper and retarder switch) connector
1. Check the connection of the brake switch connector (Looseness

and poor contact).
YES NO

drive.)
7 Inspect the exhaust brake switch (Wiper and retarder switch) unit
1. Disconnect the exhaust brake switch (Wiper and retarder switch)

connector.
RTR1 RTC1
terminals of the exhaust brake switch (Wiper and retarder switch)
unit side.
Exhaust brake switch

Exhaust brake switch
- ON: Less than 1 
RTC1 – RTR1
SAPH16F041000053
- OFF:  
YES NO
Go to step 8. Replace the exhaust brake switch (Wiper and

retarder switch).
drive.)
8 Inspect the exhaust brake switch (Wiper and retarder switch) power supply circuit 1
1. Disconnect the ABS exhaust brake cut relay.

ABS exhaust brake cut relay
(Fuse and relay block B)
S0E RTC1
S-
S0C terminals of the exhaust brake switch (Wiper and retarder switch)
B NC
S0D S0E
S+
unit side and the ABS exhaust brake cut relay connector.
S0B
Exhaust brake switch vehicle

-side connector – ABS
exhaust brake cut relay con- Less than 1 
nector
SAPH16F041000054 RTC1 – SOE
YES NO
Go to step 9. Repair or replace the wire harness between

the exhaust brake switch and the ABS
exhaust brake cut relay.
drive.)
9 Inspect the brake switch (wiper and retarder switch) power supply circuit 2

terminal S0D of the ABS exhaust brake cut relay connector and
E3 E ABS exhaust brake cut relay
(Fuse and relay block B) the vehicle control ECU (signal check harness).
S0D
S-
S0C Tester connections Standard values
B NC
S0D S0E
S+
S0B ABS exhaust brake cut relay
connector – Vehicle control
Less than 1 
ECU (signal check harness)
S0D – AP1 (E3)
SAPH16F041000055
YES NO
Replace the ABS exhaust brake cut relay. • Check the fuse VCS_ACT2 (Fusing and
Perform After-inspection work. (Clear all past irregular contact).
DTC. Check no DTC is stored after test • Repair or replace the wire harness
drive.) between the ABS exhaust brake cut relay
and the terminal AP1 of the vehicle control
ECU.
drive.)
10 CHECK THE AUXILIARY BRAKE ACTIVATION CONDITION.
1. Check whether under condition of the auxiliary brake activation.

• Engine retarder activation conditions (Under all of the conditions 1 to
9.)
• One of the requests listed below:
- Driver's request for engine retarder (1st or 2nd lever position)
- Engine retardation by auxiliary brake interlock function
- Engine retardation by cruise interlock
- Engine retardation by external request
• No engine stall
• P.T.O. inactive
• Engine retarder setting selected
• Engine speed predetermined for engine retarder activation (850 r/
min or more)
• Water temperature predetermined for engine retarder activation (40
C {104 F} or more)
• Injection flow predetermined for engine retarder activation
• No cut in engine retarder (clutch pedal not depressed; accelerator
opening of 0%; ABS not activated)
• No auxiliary brake control stop
• Exhaust braking is requested when a vehicle stops.
YES NO
Repair or replace the failure part. Procedure completed.

Perform After-inspection work. (Clear all past Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test DTC. Check no DTC is stored after test
drive.) drive.)
NO ACTIVATION/RELEASE OF ENGINE REVOLUTION CONTROL

EN01H16F04100F03001019

YES NO

drive.)
4. Select [Vehicle control ECU] and check if any DTC has been
detected.
SAPH16F041000056
Has any DTC been detected in the vehicle control ECU?
YES NO

3 Inspect the brake switch [HINO DX Ⅱ ]
measure them.
Measurement
conditions
Depress the brake

pedal: ON
Starter switch: ON Brake switch
SAPH16F041000057 Release the brake
pedal: OFF
YES NO

drive.)
4 Inspect the brake switch signal circuit

ground.
Measurement Tester
Vehicle control
Depress the brake
ECU (signal check
pedal: 0 V
Release the brake
TBSW(B17) –
pedal: 10 – 16 V
Ground

YES NO

drive.)
5 Inspect the brake switch connector

and poor contact).
YES NO

drive.)
6 Inspect the brake switch
1. Check the installation of the brake switch.
2. Check if the brake switch is properly adjusted.
YES NO
Adjust the brake switch so that it is correctly Go to step 7.

installed.
drive.)
7 Inspect the brake switch unit

NC+
NC- 2. Disconnect the brake switch connector.

terminals of the brake switch.
Measurement Tester
Standard values
BRAKE SW (HYD) Depress the brake
Starter switch: Brake switch pedal:  
NC- NC+ LOCK NC+ – NC- Release the brake
pedal: 2  or less
BRAKE SW (FULL AIR)

SAPH16F041000059
YES NO
Go to step 8. Replace the brake switch.

drive.)
8 Inspect the brake switch power supply

NC+
Brake switch
(HYD) 2. Use the electrical tester to measure the voltage between the termi-
nal NC+ of the brake switch vehicle-side connector and the
ground.
Measurement Tester
Standard values
Brake switch vehi-

Starter switch: ON cle-side connector 10 – 16 V
NC+ – Ground
Brake switch
NC+ (FULL AIR)
SAPH16F041000060
YES NO
Repair or replace the wire harness between Repair or replace the brake switch power
the brake switch and the vehicle control ECU. supply circuit (Fuse, wire harness).
drive.) drive.)
NO ACTIVATION/RELEASE OF CRUISE FUNCTION

EN01H16F04100F03001020

YES NO

drive.)
4. Select [Vehicle control ECU] and [Engine ECU], and check if any
DTC has been detected.
SAPH16F041000061
Has any DTC been detected in the vehicle control ECU and in the engine ECU?
YES NO

3 Inspect the cruise main switch [HINO DX Ⅱ ]
measure them.
Measurement
conditions
Starter switch: ON
Cruise main
Cruise main ON
switch
SAPH16F041000062 switch: ON
YES NO
4 Inspect the cruise main switch signal circuit
A10 2. Connect the signal check harness to the vehicle-side connector of

ground.
Measurement Tester
Vehicle control Cruise main

- ON: 10 – 16 V
CRSW(A10) –
Ground - OFF: 0 V
YES NO

drive.)
5 Inspect the cruise main switch connector
1. Check the connection of the cruise main switch connector (Loose-

YES NO

drive.)
6 Inspect the cruise main switch unit
FSC COM
2. Disconnect the cruise main switch connector.

terminals of the cruise main switch.
Cruise main switch

Cruise main switch
COM – FSC
SAPH16F041000064
- OFF:  
YES NO
Go to step 7. Replace the cruise main switch

drive.)
7 Inspect the cruise main switch power supply
COM
COM FSC nal COM of the cruise main switch vehicle-side connector and the
KCZ KD0
ground.
Measurement Tester
Standard values
Cruise main
switch vehicle-
side connector
SAPH16F041000065 COM – Ground
YES NO
Go to step 8. • Check the fuse VCS_ACT2 (Fusing and

irregular contact).
• Repair or replace the wire harness
between the cruise main switch and the
vehicle control ECU.
drive.)
8 Inspect the brake switch [HINO DX Ⅱ ]
measure them.
Measurement
conditions
Depress the brake

pedal: ON
Starter switch: ON Brake switch
SAPH16F041000066 Release the brake
pedal: OFF

YES NO

drive.)
9 Inspect the brake switch signal circuit

ground.
Measurement Tester
Vehicle control
Depress the brake
ECU (signal check
pedal: 0 V
Release the brake
TBSW(B17) –
pedal: 10 – 16 V
Ground
YES NO
Replace the vehicle control ECU Go to step 10.

drive.)
10 Inspect the brake switch connector

and poor contact).
YES NO

drive.)
11 Inspect the brake switch
1. Check the installation of the brake switch.
2. Check if the brake switch is properly adjusted.
YES NO
Adjust the brake switch so that it is correctly Go to step 12.

installed.
drive.)
12 Inspect the brake switch unit

NC+
NC- 2. Disconnect the brake switch connector.

terminals of the brake switch.
Measurement Tester
Standard values
BRAKE SW (HYD) Depress the brake
Starter switch: Brake switch pedal:  
NC- NC+ LOCK NC+ – NC- Release the brake
pedal: 2  or less
BRAKE SW (FULL AIR)

SAPH16F041000068
YES NO
Go to step 13. Replace the brake switch.

drive.)
13 Inspect the brake switch power supply
NC+
Brake switch 2. Use the electrical tester to measure the voltage between the termi-
(HYD)
nal NC+ of the brake switch vehicle-side connector and the
ground.
Measurement Tester
Standard values
Brake switch vehi-

NC+ – Ground
Brake switch
NC+ (FULL AIR)
SAPH16F041000069
YES NO
Repair or replace the wire harness between Repair or replace the brake switch power
the brake switch and the vehicle control ECU. supply circuit (Fuse, wire harness).
drive.) drive.)
NO ACTIVATION/RELEASE OF ECO MODE

EN01H16F04100F03001021

YES NO

drive.)
4. Select [Vehicle control ECU] and check if any of the DTCs have
been detected.
SAPH16F041000070
Has DTC been detected?
YES NO

3 Inspect the economy running switch [HINO DX Ⅱ ]
measure them.
Measurement Tester
Standard values
Economy running
Starter switch: ON ON
switch
SAPH16F041000071
YES NO

drive.)
4 Inspect the economy running switch signal circuit

B23
ground.
Measurement Tester
Vehicle control Economy running

- ON: 10 – 16 V
AFSW(B23) –
Ground - OFF: 0 V

YES NO

drive.)
5 Inspect the economy running switch connector
1. Check the connection of the economy running switch connector

YES NO

drive.)
6 Inspect the economy running switch unit

SW- SW+
2. Disconnect the economy running switch connector.

terminals of the economy running switch.
Economy running switch

Economy running switch
SW+ – SW-
SAPH16F041000073
- OFF:  
YES NO
Go to step 7. Replace the economy running switch.

drive.)
7 Inspect the economy running switch power supply

SW+
nal SW+ of the economy running switch vehicle-side connector
SW+
KSR and the ground.
Measurement Tester
Standard values
Economy running
switch vehicle-
side connector
SAPH16F041000074 SW+ – Ground
YES NO
Repair or replace the wire harness between • Check the fuse VCS_ACT2 (Fusing and
the economy running switch and the vehicle irregular contact).
control ECU. • Repair or replace the wire harness
Perform After-inspection work. (Clear all past between the cruise main switch and the
DTC. Check no DTC is stored after test terminal AP1 of the vehicle control ECU.
drive.) Perform After-inspection work. (Clear all past
drive.)
CAN COMMUNICATION 12–1
CAN COMMUNICATION
12
12-001
CAN COMMUNICATION TROUBLESHOOTING.......12-2 PRE-INSPECTION FOR DIAGNOSIS CAN

Outline...................................................................12-2 COMMUNICATION LINE ....................................12-82
Definition of Terms ................................................ 12-2 DISCONNECTION INSPECTION FOR
Troubleshooting Procedure ...................................12-3 DIAGNOSIS CAN_H/L_COMMUNICATION
Work Flow .............................................................12-3 LINE ....................................................................12-85
ECU individual code list ........................................12-4 INSPECTION FOR SHORT-CIRCUIT IN
CAN communication circuit diagram ..................... 12-5 DIAGNOSIS CAN H-LINE ...................................12-89
CAN communication relation connector INSPECTION FOR SHORT-CIRCUIT IN
location.................................................................. 12-8 DIAGNOSIS CAN L-LINE....................................12-93
ENGINE CAN COMMUNICATION LINE ..................12-12 INSPECTION FOR DCU CAN
ABNORMAL CAN COMMUNICATION DTC COMMUNICATION LINE (DIAGNOSIS CAN
DETECTED.........................................................12-12 COMMUNICATION LINE) ...................................12-98
CONNECTION DIAGRAM ..................................12-12 INSPECTION FOR ENGINE ECU CAN
CAN COMMUNICATION LINE COMMUNICATION LINE ..................................12-102
MALFUNCTION PART DETERMINATION CONTROL CAN COMMUNICATION LINE ............12-107
TABLE .................................................................12-12 ABNORMAL CAN COMMUNICATION DTC
PRE-INSPECTION FOR ENGINE CAN DETECTED.......................................................12-107
COMMUNICATION LINE ....................................12-14 CONNECTION DIAGRAM (ALLISON
DISCONNECTION INSPECTION FOR ENGINE AUTOMATIC TRANSMISSION) ........................12-107
CAN_H/L_COMMUNICATION LINE ...................12-17 CAN COMMUNICATION LINE
INSPECTION FOR SHORT-CIRCUIT IN MALFUNCTION PART DETERMINATION
CAN H-LINE........................................................12-23 TABLE (ALLISON AUTOMATIC
INSPECTION FOR SHORT-CIRCUIT IN TRANSMISSION)..............................................12-107
CAN L-LINE ........................................................12-32 CONNECTION DIAGRAM (MANUAL
INSPECTION FOR EGR CONTROLLER TRANSMISSION)..............................................12-108
CAN COMMUNICATION LINE............................12-41 CAN COMMUNICATION LINE MALFUNCTION
INSPECTION FOR VNT CONTROLLER PART DETERMINATION TABLE (MANUAL
CAN COMMUNICATION LINE............................12-46 TRANSMISSION)..............................................12-108
INSPECTION FOR DCU PRE-INSPECTION FOR
CAN COMMUNICATION LINE CAN COMMUNICATION LINE ..........................12-109
(ENGINE CAN COMMUNICATION LINE)...........12-51 DISCONNECTION INSPECTION FOR
INSPECTION FOR NOx sensor 1 CAN CAN_H/L_COMMUNICATION LINE .................12-113
COMMUNICATION LINE ....................................12-56 INSPECTION FOR SHORT-CIRCUIT IN
INSPECTION FOR NOx sensor 2 CAN CAN H-LINE......................................................12-116
COMMUNICATION LINE ....................................12-62 INSPECTION FOR SHORT-CIRCUIT IN
INSPECTION FOR DEF SENSOR CAN CAN L-LINE ......................................................12-118
COMMUNICATION LINE ....................................12-68 INSPECTION FOR AUTOMATIC
DIAGNOSIS CAN COMMUNICATION LINE............12-80 TRANSMISSION ECU CAN
ABNORMAL CAN COMMUNICATION DTC COMMUNICATION LINE ..................................12-120
DETECTED.........................................................12-80
CONNECTION DIAGRAM ..................................12-80
CAN COMMUNICATION LINE
MALFUNCTION PART DETERMINATION
TABLE .................................................................12-80
12–2 CAN COMMUNICATION
CAN COMMUNICATION TROUBLESHOOTING
Outline
EN01H16ZZZ110F03002001
• A CAN (Controller Area Network) is a multiplex communication device for mounting on vehicles, using serial communi-
cation for real-time applications, and offering an excellent data communication speed (250 kbps/500 kbps), coupled with
an error detection function.
• For CAN communication, a twisted cable pair is used, consisting of a CAN H-line and a CAN L-line; communication is
performed using differential voltage.
• This vehicle uses the following 3 systems of CAN communication (lines).
Engine CAN communication: For controlling the engine and the after treatment system.
Diagnosis CAN communication: For communication between the diagnosis unit and the ECU, performing trouble code
output via the CAN communication system.
Control CAN communication: Control of combination meter, AT, and other vehicle-related items.
ECU JOINT CONNECTOR ECU

CAN COMMUNICATION H LINE CAN COMMUNICATION H LINE
CAN COMMUNICATION L LINE CAN COMMUNICATION L LINE
ECU
CAN COMMUNICATION H LINE
CAN COMMUNICATION L LINE
SAPH16ZZZ1100001
Definition of Terms
EN01H16ZZZ110F03002002
<Main line>
• The harness between two termination circuits on a CAN bus (communication line) is defined as the main line. It
becomes the trunk bus for CAN communication.
<Branch line>
• Lines branching from the main line - such as the trunk bus of the CAN bus to an ECU or a sensor - are defined as branch
lines.
<Termination circuit>
• Circuits consisting of resistors and capacitors, serving to convert the communication circuit of a CAN communication to
a bus voltage, are called termination circuits.
• Two termination circuits must be provided on a bus.
Troubleshooting Procedure
EN01H16ZZZ110F03002003
• As a CAN communication trouble code is put out when there is an internal fault in an ECU of a system using CAN com-
munication - or in case of power supply interruption -, attention must be paid to the simultaneous detection of an internal
fault in the respective ECU, even when there is no malfunction in the CAN communication line. If a power supply trouble
code is detected at the same time, the power supply trouble code must be checked first.
• When a CAN communication malfunction has been confirmed, first perform the "Pre-inspection for the CAN communica-
tion line" and confirm that there is no abnormality of the CAN bus main line circuit.
• When there is no response from an ECU performing CAN communication to the diagnosis unit (HINO DX Ⅱ ), make sure
that there are no abnormalities of the diagnosis connector (DLC) line of the diagnosis CAN communication line and the
CAN bus main line.
• When a CAN communication malfunction has been confirmed, make sure that no abnormalities (poor contact or loose-
ness, pulled) of related connectors exist. When a connector has been disengaged, confirm that connector terminals and
connector case are free of breakage, deformation, corrosion, etc.
Work Flow
EN01H16ZZZ110F03002004
1 Entry of the vehicle into the workshop
2 Inquiry and Malfunction Confirmation
3 Confirmation of the Vehicle Equipment Specifications

Confirm the vehicle equipment specifications.
4 Confirmation of the Trouble Code (DTC)
Use the diagnosis unit (Hino-DX) and confirm the DTC.
When P**** or C**** are detected in addition to a CAN communication fault U****, first perform the fault
diagnosis for the related DTC.
5 Pre-inspection for the CAN Communication Line
Refer to the "Pre-inspection for the CAN communication line" and confirm that the main line of the CAN
communication line is free of disconnections/short-circuits, termination resistor faults, etc.
In case of faults, go to step 7.
6 Inspection for Branch Lines of the CAN Communication Line
If the pre-inspection has shown no abnormalities, refer to the "CAN COMMUNICATION LINE MALFUNC-
TION PART DETERMINATION TABLE" and perform the diagnosis items for the detected trouble codes.
7 Repair or Replacement
8 Confirmation after Inspection (DTC confirmation)

Clear all past DTC and perform a test drive.
Use the diagnosis unit (Hino-DX) and confirm that no DTC is detected. In case of detection, go to step 4.
Procedure completed
SAPH16ZZZ1100002
ECU individual code list

EN01H16ZZZ110F03002005
1. Engine ECU
CAN COMMUNI-
DTC No DIAGNOSIS ITEM
CATION LINE
ENGINE POST-PROCESSING CAN COMMUNICATION LINE MALFUNCTION

U0073 ENGINE
(BUS OFF)
U010A EGR CONTROLLER CAN COMMUNICATION LINE MALFUNCTION ENGINE
U010C VNT CONTROLLER CAN COMMUNICATION LINE MALFUNCTION ENGINE
U010E DCU CAN COMMUNICATION LINE MALFUNCTION ENGINE
U029D NOx SENSOR1 CAN COMMUNICATION LINE MALFUNCTION ENGINE
U029E NOx SENSOR2 CAN COMMUNICATION LINE MALFUNCTION ENGINE
U02A2 DISCONNECTION OF CAN COMMUNICATION LINE(DEF SENSOR) ENGINE
U02A3 PM SENSOR CAN COMMUNICATION LINE MALFUNCTION ENGINE
U0301 SOFTWARE INCOMPATIBILITY WITH DeNOx ECU ENGINE
U1001 CAN COMMUNICATION LINE MALFUNCTION(VEHICLES) DIAGNOSIS
U110A CAN COMMUNICATION LINE MALFUNCTION(VEHICLES) DIAGNOSIS
2. DCU
CAN COMMUNI-
CATION LINE
U0029 CAN COMMUNICATION LINE MALFUNCTION(ENGINE) ENGINE
U0038 CAN COMMUNICATION LINE MALFUNCTION(VEHICLES) DIAGNOSIS
ENGINE/DIAG-
U0100 CAN COMMUNICATION LINE MALFUNCTION(ENGINE)
NOSIS
U029D NOx SENSOR1 CAN COMMUNICATION LINE MALFUNCTION ENGINE
U029E NOx SENSOR2 CAN COMMUNICATION LINE MALFUNCTION ENGINE
U02A2 DISCONNECTION OF CAN COMMUNICATION LINE(DEF SENSOR) ENGINE
U0597 INVALID DATA RECEIVED FROM AC TO DC CONVERTER (DeNOx ECU) –
3. VCS
CAN COMMUNI-
CATION LINE
U0101 DISCONNECTION OF CAN COMMUNICATION LINE(TRANSMISSION) CONTROL
U0105 DISCONNECTION OF CAN COMMUNICATION LINE(METER) DIAGNOSIS
U0155 DISCONNECTION OF CAN COMMUNICATION LINE(ENGINE) CONTROL

CAN communication circuit diagram

EN01H16ZZZ110F03002006
1. Engine CAN communication line

KRH %JC %JZ
Twist (CA2L) (EJ1L) %JV(CANL) (CANL)0.50 W - %NS
L L %NS
0.50 W -
Twist
0.50 R -
0.50 W -
(CANH)
(CANL)
(CANH)
(CANL)
%JW
%JR
%JX
%JS
Twist
(L4R) %J8
(L4S) %J5
(KV8) %J3
(KV9) %J2
Common rail #SD #SD
0.50 W -
Twist Twist
J/C2 (LEY)
#CQ 0.50 W -
#CP 0.50 R -
0.50 R -
%JA %J6
LE8 0.75 W -
LEC 0.75 W -
LE9 0.75 V -
LED 0.75 V -
0.50 R -
(EJ2L) (LEZ) Twist

L Twist
%JB %J7
(CANH)
(CANL)
0.50 W -
0.50 B -
(CANH)
(CANH)
(CANL)
(CANL)
(EJ2H)
F2E
F2F
H (LEY)
Twist
0.50 W -
(K6V) %J4
(K6W) %J1
0.50 B -
Twist Twist
0.50 B - #CP
0.50 W - #CQ
(CAH0)
(CAL0)
LEY
NOx NOx
LEZ
sensor 1 sensor 2
CAN TMN
Twist
Twist Common rail CAN J/C1
%KL %KE
(CANL)
%KM
L (CANL)
%KF
DCU
0.50 W -
0.50 W -
0.50 W -
0.50 R -
0.50 R -
0.50 R -
(CANH) H (CANH)
%KR
%KQ
%KP
(CANH)
%KN
(CANL)
(CANH)
(CANL)
Twist
-
B-
0.50 W -
B-
0.50 W
(EGRH)
(CANH)
(EGRL)
(VNTH)
(CANL)
(VNTL)
0.50
LEK 0.50
K6W
KV8
KV9
K6V
L4R
L4S
(CANH)
(CANH)
(CANL)
(CANL)
L0N
LEJ
L0K
EGR VNT Engine
DEF PM
SAPH16ZZZ1100003
2. Diagnosis CAN communication line
Diagnosis
Vehicle Control ECU
Connector Combination meter
(16P)
(CDGH)
(ECAH)
L83
L84
L8Y
L8Z
(CDGL)
(ECAL)
(MC5-)
(CAN+)
ER0
(MC5+)
(CAN-)
ER1
KS4
KS3
Twist
Twist
0.50 P -
0.50 V -
Twist Twist
0.50 P -
%L6 0.50 V -
0.50 P -
0.50 V -
Twist
(METL)
(CANL)
%JG
CAN_J/C2_Low CAN_J/C3_Low
Twist Twist
%JF %JH 0.50 V - %L5 %L4
(CANL) (CANL) (METL) (METL)
0.50 V -
Telematics
(DLC3)
(METH)
%F5
(CANH)
(DLC3)
%F4
%K1 Unit
%L3
%JC
0.50 P -
(CANH) Twist
0.50 P -
0.50 P -
0.50 P - ESU
(ENCH)
0.50 V - ESV (ENCL)
0.50 P -
%L2 %L1 %K2
%JB %JD 0.50 V -
(CANL)
(METH) (METH)
#S1
#S3
(CANH) (CANH)
CAN_J/C3_High
CAN_J/C2_High
0.50 P -
0.50 P - #S1
0.50 V - #S3
0.50 V -
(#S6)
0.50 P - #S5 #S5
0.50 V - #S7
Twist #S7
Twist
(#S8)
#AW
#AV
Twist
(CA1L)
%NM
(CA1H)
%NN
%JP
%JL
0.50 P -
0.50 V -
#AW
#AV
%JM
%NN
%NM
Twist (CA1H) H L
0.50 G -
V_J/C
0.50 R - %JK
(CA1L)
(CA1L)
(CA1H)
%JN
%JJ
0.50 G -
0.50 R -
Twist
0.50 P -
0.50 V -
(CAH1)
(CA1H)
(CA1L)
(CAL1)
LF6
LCM
LF5
LCN
DCU ECU
SAPH16ZZZ1100004
3. Control CAN communication
Twist
(CANH)
%JT
%CT (CAN+)
CAN J/C %BA E4L
%CU (CAN-) %BF 0.50 R - 0.50 R -
(CAN+) (CAN+) 0.50 W - (MMT+)
0.50 W -
Twist METER
(CANL)
%JY
E4M
Twist
%BK
0.50 W-
0.50 W-
0.50 W-
0.50 R-
0.50 R-
0.50 R-
(MMT-)
%BR
(CAN-)
(CAN-)
0.50 W-
Twist
0.50 R-
0.50 R - (CAN+)
(CAN-)
(CAN-)
0.50 R - (CAN+)
%BD
%BL
%BB
0.50 W - %BN
Twist
0.50 W -
0.50 G -
0.50 Y -
Twist
(CASH)
(CASL)
O9G
O9H
Twist Twist
(HCAH)
(CAN+)
(HCAL)
(CAN-)
ESW
ESX
N6S
N6T
Selector
L81
L82
L8C
(VCAH) L8B
(VCAL)
(VHCH)
(VHCL)
0.50 R -
0.50 W -
Diagnosis
connector
Vehicle control ECU (9P)
Telematics unit
Twist
Twist
#H3
#H5
#H4
#H2
MAIN W/H
FR W/H
#H2
#H3
#H5
#H4
Twist Twist
0.50 W -
0.50 R -
0.50 R -
0.50 W -
%K4
(CANL)
(CANH) %K3
0.85 W -
0.85 R -
Twist
(CAN+)
(CAN-)
NXG
NXF
TRANS ECU
SAPH16ZZZ1100005
CAN communication relation connector location

EN01H16ZZZ110F03002007
5
6
4 3
FUSE AND RELAY BLOCK
1: J/C SIGNAL
2: Common rail J/C No.1
3: Common rail J/C No.2
4: CAN J/C 2 High
5: CAN J/C 2 Low
6: CAN TMN6
SAPH16ZZZ1100006
1 5
1: J/C EARTH
2: J/C EARTH 4P
3: CAN J/C 3 High
4: CAN J/C 3 Low
5: CAN J/C
SAPH16ZZZ1100007
18
4 5 16 14 1 7 6 11 12
8 10
15 17
13
1: Common rail CAN J/C No.1 8: DEF sensor 15: DEF heater 1
2: Common rail CAN J/C No.2 9: Exhaust gas temperature sensor 2 (DOC inlet) 16: DEF heater 2
3: Common rail CAN J/C No.3 10: Exhaust gas temperature sensor 3 (DOC outlet) 17: DEF heater 3
4: DCU 53P 11: Exhaust gas temperature sensor 4 (DPR outlet) 18: PM sensor
5: DCU 86P 12: Differential gas pressure sensor
6: NOx sensor 1 13: Ambient temperature sensor
7: NOx sensor 2 14: SCR front temperature sensor
SAPH16ZZZ1100008
1: No.30 J/C
2: VNT controller
3: EGR controller
SAPH16ZZZ1100009
ENGINE CAN COMMUNICATION LINE
ABNORMAL CAN COMMUNICATION DTC DETECTED

EN01H16ZZZ110F03003001
If any DTC of "CAN communication abnormal" is detected, carry out "PRE-INSPECTION FOR ENGINE CAN COMMUNI-
CATION LINE" first.
CONNECTION DIAGRAM
EN01H16ZZZ110F03003002
CAN - TMN6 DCU

(Terminator) Common rail Common rail Common rail Common rail (Terminator)
6 11 8 9 10
J/C1 J/C2 CAN J/C1 CAN J/C3
1 2 7 3 12 4 5
EGR VNT DEF PM NOx NOx

Controller Controller Engine ECU
Sensor Sensor Sensor1 Sensor2
SAPH16ZZZ1100010
CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE

EN01H16ZZZ110F03003003
1. Engine ECU
Estimated mal-
Detected DTC DTC diagnosis/inspection item
function part
• Pre-inspection for Engine CAN communication line

U010A 1
• Inspection for EGR controller CAN communication line
U010C 2
• Inspection for VNT controller CAN communication line
U02A2 3
• Inspection for DEF sensor CAN communication line
• Prior inspection of CAN communication line
U02A3 12
• Inspecting the PM sensor CAN communication line
U029D 4
• Inspection for NOx sensor1 CAN communication line
U029E 5
U010E 10 • Inspection for DCU CAN communication line (Engine CAN communica-
tion line)
U010A, U010C, U029D, • Pre-inspection for Engine CAN communication line

U029E, U0073, U010E, 6, 7, 8, 9, 10, 12
U02A2, U0301 • Disconnection inspection for Engine CAN H/L communication line
2. DCU
Estimated mal-
function part

U02A2 3
• Inspection for DEF sensor CAN communication line
U029D 4
U029E 5
U0029 10 • Inspection for DCU CAN communication line (Engine CAN communica-
tion line)
U0029, U0100, U029D,

6, 7, 8, 9, 10, 11 Pre-inspection for Engine CAN communication line
U029E, U02A2
PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE

EN01H16ZZZ110F03003004
1 Inspect for +B/GND short-circuit in CAN H-line

+24V SGND
2. Disconnect the following sensors and controllers connected to the
+B2
LEP
GND4
LEW
GND1
LET +24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ
Engine CAN line.
+B3
LEQ
GND5
LEX
GND2
LEU ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
• DCU(53P)
+B4
LER
+B1
LEN
GND3
LEV • EGR controller, VNT controller
• NOx sensors 1 & 2, DEF sensor
CAH1
LF5
• CAN-TMN6 (terminating resistance)
CAL1
LF6 • PM sensor
TE1B
LF2 CAH0
TE1A CAH0
LF1
TE2B
LEY
CAL0
3. Use the electrical tester to check the continuity between the follow-
LF4 LEZ
TE2A
ing terminals.
LF3
(1) Between the CAH0 terminal in the DCU(53P) vehicle-side

connector and the +24V(K9G) terminal in the DLC(16P) con-
ISGW
LES nector.
(2) Between the CAH0 terminal in the DCU(53P) vehicle-side
connector and the SGND(K9H) terminal in the DLC(16P) con-
nector.
SAPH16ZZZ1100011 Measurement Tester

Standard values
DCU vehicle-side
connector –
DLC(16P) connec-
Starter switch:
tor No Continuity
LOCK
CAH0 – +24V(K9G)
CAH0 –
SGND(K9H)
YES NO
Go to step 2. Refer to "INSPECTION FOR SHORT-CIRCUIT

IN CAN H-line" and check the CAN bus line.
2 Inspect for +B/GND short-circuit in CAN L-line
+24V SGND ing terminals.
(1) Between the CAL0 terminal in the DCU(53P) vehicle-side
+B2
LEP
GND4
LEW
GND1
LET +24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ
+B3
LEQ
GND5
LEX
GND2
LEU ISOK CAN+ SGND CGFR +
nector.
K9E KS3 K9H L30 KE4
+B4 +B1 GND3

(2) Between the CAL0 terminal in the DCU(53P) vehicle-side
LER LEN LEV

nector.
CAH1
LF5
CAL1 Measurement Tester

LF6
Standard values
TE1B
LF2 conditions connections
TE1A CAH0
CAL0
LF1 LEY
TE2B
LF4
CAL0
LEZ DCU vehicle-side
TE2A
LF3 connector –
DLC(16P) connec-
Starter switch:
tor No Continuity
ISGW LOCK
LES
CAL0 – +24V(K9G)
CAL0 –
SGND(K9H)
SAPH16ZZZ1100012
YES NO

IN CAN L-LINE" and check the CAN bus line.
3 Inspect the terminating resistance
ing terminals.
(1) Between the CAH0 terminal and CAL0 terminal in the DCU
(53P).
(2) Between CANL terminal and CANH terminal in CAN-TMN6.
ISGW
LES
Measurement Tester
CAL0 Standard values
TE2A
LF3
TE2B CAL0
LF4 LEZ
DCU(53P):
CAH0 – CAL0
TE1A CAH0
LF1 LEY
Starter switch:
TE1B
120   10 
LOCK CAN-TMN6:
LF2
CAL1
CANL – CANH
LF6
CAH1
CAH0
LF5
+B4 +B1 GND3

LER LEN LEV
+B3 GND5 GND2

LEQ LEX LEU
+B2 GND4 GND1

LEP LEW LET
CANH
CANL
SAPH16ZZZ1100013
YES NO
Check if the terminals of each connector of Replace the faulty part.

the vehicle-side harness, DCU and CAN- After replacing the part, confirm that no CAN
TMN6 are no abnormality, then connect each communication system DTC is detected.
connector properly, and procedure com- Perform After-inspection work. (Clear all past
pleted. DTC. Check no DTC is stored after test
Refer to "CAN COMMUNICATION LINE MAL- drive.)
FUNCTION PART DETERMINATION TABLE",
and inspect the detected DTC.
DISCONNECTION INSPECTION FOR ENGINE CAN_H/L_COMMUNICATION

LINE
EN01H16ZZZ110F03003005
1 Check for disconnection in CAN bus line between Common rail_CAN_J/C3 and DCU (mal-
function part 10)

1 2 3 4 Engine CAN line. (Leave the DCU, engine ECU, and CAN-TMN6
%JR %JQ %JV %JW
5 6 7 8
connected.)
%JS %JU %JZ %JX
• EGR controller, VNT controller
• NOx sensor 12, DEF sensor
3. Disconnect the Common rail_CAN_J/C3 connector.
4. Use the electrical tester to measure the resistance between

SAPH16ZZZ1100014
No.6(CANH) terminal and No.7(CANL) terminal at the Common
rail_CAN_J/C3 connector. (DCU side)
Measurement Tester
Standard values
Common
rail_CAN_J/C3
Starter switch: connector (DCU
110  – 130 
LOCK side)
No.6(CANH) –
No.7(CANL)
YES NO
Connect the Common rail_CAN_J/C3 con- CAN bus line disconnection or poor continu-
nector, and go to step 2. ity between Common rail_CAN_J/C3 and the
DCU
Repair or replace the harness.
drive.)
2 Check for disconnection in CAN bus line between Common rail_CAN_J/C1 and Common
rail_CAN_J/C3 (malfunction part 9)

1 2 3 4 No.2(CANH) terminal and No.3(CANL) terminal at the Common
%KR %KF %KE %KQ
6 7
rail_CAN_J/C1 connector. (Common rail_CAN_J/C3 side)
%KM %KL
Measurement Tester
Standard values
Common
rail_CAN_J/C1
connector (Com-
Starter switch:
SAPH16ZZZ1100015 mon rail_CAN_J/ 110  – 130 
LOCK
C3 side)
No.2(CANH) –
No.3(CANL)
YES NO
Connect the Common rail_CAN_J/C1 con- CAN bus line disconnection or poor continu-
nector, and go to step 3. ity between Common rail_CAN_J/C1 and the
Common rail_CAN_J/C3
drive.)
3 Check for disconnection in CAN bus line between Common rail_J/C2 and Common
1. Disconnect the Common rail_J/C2 connector.
2. Use the electrical tester to measure the resistance between (LEY)

K6W LEZ LEY K6V terminal and (LEZ) terminal at the Common rail_J/C2 connector.
%J1 %J6 %J7 %J4
EJ2L EJ2H
(Common rail_CAN_J/C1 side)
%JA %JB
Measurement Tester
Standard values
Common rail_J/C2
connector (Com-
mon rail_CAN_J/
Starter switch:
SAPH16ZZZ1100016 C1 side) 110  – 130 
LOCK
LEY terminal
(CANH) – LEZ ter-
minal (CANL)

YES NO
Connect the Common rail_J/C2 connector, CAN bus line disconnection or poor continu-
and go to step 4. ity between Common rail_J/C2 and the Com-
mon rail_CAN_J/C1.
drive.)
4 Check for disconnection in CAN bus line between Common rail_J/C1 and Common rail_J/C2
(malfunction part 11)

KV9 EJ1L EJ1H KV8
%J2 %JC %JD %J3 (EJ1H) terminal and (EJ1L) terminal at the Common rail_J/C1
L4S CA2L CA2H L4R connector. (Common rail_J/C2 side)
%35 KRH KRG %J8
Measurement Tester
Standard values
Common rail_J/C1
connector (Com-
Starter switch: mon rail_J/C2
110  – 130 
SAPH16ZZZ1100017 LOCK side)
EJ1H(CANH) –
EJ1L(CANL)
YES NO
Connect the Common rail_J/C1 connector, CAN bus line disconnection or poor continu-
and go to step 5. ity between Common rail_J/C1 and the Com-
mon rail_J/C2
drive.)
5 Check for disconnection in CAN bus line between CAN-TMN6(terminating resistance) and
Common rail_J/C1 (malfunction part 6)

KV9 EJ1L EJ1H KV8
%J2 %JC %JD %J3 (CA2H) terminal and (CA2L) terminal at the Common rail_J/C1
L4S CA2L CA2H L4R connector. (Common rail_J/C2 side)
%J5 KRH KRG %J8
Measurement Tester
Standard values
Common rail_J/C1
connector (Com-
Starter switch: mon rail_J/C2
110  – 130 
SAPH16ZZZ1100018 LOCK side)
CA2H(CANH) –
CA2L(CANL)
YES NO
Connect the Common rail_J/C1 connector. CAN bus line disconnection or poor continu-
Procedure completed. ity between CAN-TMN6(terminating resis-
If another CAN communication system DTC tance) and the Common rail_J/C1
is detected, refer to "CAN COMMUNICATION Repair or replace the harness.
LINE MALFUNCTION PART DETERMINA- Perform After-inspection work. (Clear all past
TION TABLE" , and inspect the detected DTC. DTC. Check no DTC is stored after test
Perform After-inspection work. (Clear all past drive.)
drive.)
6 Check for disconnection in CAN bus line between engine ECU and Common rail_J/C1 (mal-
function part 7)
1. Disconnect the engine ECU connector (both 2 connectors).
D E59 2. Connect the signal check harness to the engine ECU vehicle-side
E79 connector. (Do not connect harness to the ECU)
HINT
Refer to "PRECAUTIONS" in the chapter "ENGINE CONTROL SYS-
TEM (J08E)".

(CANH) terminal and (CANL) terminal at the signal check harness.
These circuits are identified as terminal E79 and terminal E59 on
the signal check harness D.
SAPH16ZZZ1100019
Measurement Tester
Standard values
Signal check har-

Starter switch: ness (Engine ECU)
110  – 130 
LOCK E59(CANH) –
E79(CANL)
YES NO
Go to step 5. CAN bus line disconnection or poor continu-

ity between engine ECU and Common rail_J/
C1.
drive.)
7 Check for disconnection in CAN bus line between engine ECU and CAN-TMN6 (terminating
resistance) (malfunction part 6)
1. Use electrical tester to measure the resistance between (CA2L)

terminal and (CA2H) terminal at the signal check harness. These
A V17 circuits are identified as terminal V17 and terminal V37 on the sig-
V37 nal check harness A.
Measurement Tester
Standard values
Signal check har-

Starter switch: ness (Engine ECU)
110  – 130 
LOCK V37(CA2H) –
V17(CA2L)
SAPH16ZZZ1100020
YES NO
Procedure completed. CAN bus line disconnection or poor continu-

If another CAN communication system DTC ity between engine ECU and CAN-TMN6 (ter-
is detected, refer to "CAN COMMUNICATION minating resistance).
LINE MALFUNCTION PART DETERMINA- Repair or replace the harness.
TION TABLE" , and inspect the detected DTC. Perform After-inspection work. (Clear all past
Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test
DTC. Check no DTC is stored after test drive.)
drive.)
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE

EN01H16ZZZ110F03003006
1 Check for short-circuit in CAN H-line between Common rail_CAN_J/C3 to DCU (malfunction
part 10)

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ engine CAN line.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 • DCU(53P)
1 2 3 4
%JR %JQ %JV %JW
• PM sensor
5 6 7 8
%JS %JU %JZ %JX
ing terminals.
(1) Between the CAN H-line #6 terminal in the Common
rail_CAN_J/C3, DCU side connector and the +24V(K9G) ter-
SAPH16ZZZ1100021
minal in the DLC(16P) connector.
rail_CAN_J/C3, DCU side connector and the SGND(K9H) ter-
Measurement Tester
Standard values
Common
rail_CAN_J/C3
connector (DCU-
side) – DLC(16P)
Starter switch:
connector No Continuity
LOCK
#6(CANH) –
+24V(K9G)
#6(CANH) –
SGND(K9H)
YES NO
Connect the Common rail_CAN_J/C3 and go Short-circuit in CAN H-line +B/GND between
to step 2. Common rail_CAN_J/C3 and DCU.
Repair or replace the wire harness.
drive.)
2 Check for short-circuit in CAN H-line between Common rail_CAN_J/C1 and Common

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ ing terminals.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
rail_CAN_J/C1, Common rail_CAN_J/C3 side connector and
the +24V(K9G) terminal in the DLC(16P) connector.
rail_CAN_J/C1, Common rail_CAN_J/C3 side connector and
1 2 3 4 the SGND(K9H) terminal in the DLC(16P) connector.
%KR %KF %KE %KQ
5 6 7 8
%KP %KM %KL %KN
Measurement Tester
Standard values
Common
rail_CAN_J/C1
connector (Com-
SAPH16ZZZ1100022 mon rail_CAN_J/
C3 side) –
Starter switch:
DLC(16P) connec- No Continuity
LOCK
tor
#2(CANH) –
+24V(K9G)
#2(CANH) –
SGND(K9H)
YES NO
Connect the Common rail_CAN_J/C1 and go Short-circuit in CAN L-line +B/GND between
to step 3. Common rail_CAN_J/C1 and Common
rail_CAN_J/C3.
drive.)
3 Check for short-circuit in CAN H-line between Common rail_J/C2 and Common rail_CAN_J/
C1 (malfunction part 8)

+24V SGND
ing terminals.
+24V CAN- TC DSW
K9G KS4 KS2 KPZ
(1) Between the CAN H-line LEY(CANH) terminal in the Com-
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
mon rail_J/C2, Common rail_CAN_J/C1 side connector and
the +24V(K9G) terminal in the DLC(16P) connector.
(2) Between the CAN H-line LEY(CANH) terminal in the Com-
mon rail_J/C2, Common rail_CAN_J/C1 side connector and
K6W LEZ LEZ K6V
%J1 %J6 %J7 %J4 the SGND(K9H) terminal in the DLC(16P) connector.
EJ2L EJ2H
%JA %JB
Measurement Tester
Standard values
Common rail_J/C2
connector (Com-
mon rail_CAN_J/
SAPH16ZZZ1100023 C1 side) –
Starter switch: DLC(16P) connec-
No Continuity
LOCK tor
LEY(CANH) –
+24V(K9G)
LEY(CANH) –
SGND(K9H)
YES NO
Connect the Common rail_J/C2 and go to Short-circuit in CAN H-line +B/GND between
step 4. Common rail_J/C2 and Common rail_CAN_J/
C1.
drive.)
4 Check for short-circuit in CAN H-line between Common rail_J/C1 and Common rail_J/C2

+24V SGND
+24V CAN- TC DSW
K9G KS4 KS2 KPZ
ing terminals.
ISOK CAN+ SGND CGFR +
K9E KS3 K9H L30 KE4
(1) Between the CAN H-line EJ1H(CANH) terminal in the Com-
mon rail_J/C1, Common rail_J/C2 side connector and the
+24V(K9G) terminal in the DLC(16P) connector.
(2) Between the CAN H-line EJ1H(CANH) terminal in the Com-
mon rail_J/C1, Common rail_J/C2 side connector and the
KV9 EJ1L EJ1H KV8
%J2 %JC %JD %J3 SGND(K9H) terminal in the DLC(16P) connector.
L4S CA2L CA2H L4R
%J5 KRH KRG %J8
Measurement Tester
Standard values
Common rail_J/C1
connector (Com-
mon rail_J/C2
SAPH16ZZZ1100024 side) – DLC(16P)
Starter switch:
LOCK
EJ1H(CANH) –
+24V(K9G)
EJ1H(CANH) –
SGND(K9H)
YES NO
Connect the Common rail_J/C1 and go to Short-circuit in CAN H-line +B/GND between
step 5. Common rail_J/C1 and Common rail_J/C2.
drive.)
5 Check for short-circuit in CAN H-line between engine ECU and Common rail_J/C1 (malfunc-
tion part 7)
1. Disconnect the engine ECU.

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ connector (Do not connect harness to the ECU.)
K9E KS3 K9H L30 KE4
ing terminals.
D E59 (1) Between the E59(CANH) terminal in the signal check harness
and the +24V(K9G) terminal in the DLC(16P) connector.
(2) Between the E59(CANH) terminal in the signal check harness
and the SGND(K9H) terminal in the DLC(16P) connector.
Measurement Tester
Standard values
Signal check har-

SAPH16ZZZ1100025 ness (Engine ECU)
– DLC(16P) con-
No Continuity
LOCK E59(CANH) –
+24V(K9G)
E59(CANH) –
SGND(K9H)
YES NO
Go to step 5. Short-circuit in CAN H-line +B/GND between

engine ECU and Common rail_J/C1.
drive.)
6 Check for short-circuit in CAN H-line between engine ECU and CAN-TMN6 (terminal resis-
tance) (malfunction part 6)
(1) Between the V37(CA2H) terminal in the signal check harness
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ and the +24V(K9G) terminal in the DLC(16P) connector.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
A Measurement Tester
Standard values
V37 conditions connections
Signal check har-

ness (Engine ECU)
– DLC(16P) con-
No Continuity
LOCK V37(CA2H) –
+24V(K9G)
SAPH16ZZZ1100026
V37(CA2H) –
SGND(K9H)
YES NO

engine ECU and CAN-TMN6 (terminal resis-
tance).
drive.)
7 Inspect the EGR controller [HINO DX Ⅱ ]
2. Connect the connector of the engine ECU.
5. Erase the malfunction history and set the starter switch to the
"LOCK" position.
6. Connect the EGR controller connector.

SAPH16ZZZ1100027
8. Check that the EGR controller communication failure (U010A) is

not detected in HINO DX Ⅱ menu.
Did the EGR controller communication failure (U010A) disappear?
YES NO
Go to step 7. Inspect the EGR controller CAN communica-

tion line.
8 Inspect the VNT controller [HINO DX Ⅱ ]
1. Erase the trouble history and set the starter switch to the "LOCK"
position.
2. Connect the VNT controller connector.
4. Check that the VNT controller communication failure (U010C) is

SAPH16ZZZ1100028
Did the VNT controller communication failure (U010C) disappear?
YES NO
Go to step 8. Inspect the VNT controller CAN communica-

tion line.
9 NOx sensor 1 [HINO DX Ⅱ ]
position.
2. Connect the NOx sensor 1 connector.
4. Check that the NOx sensor 1 communication failure (U029D) is not

detected in HINO DX Ⅱ menu.
SAPH16ZZZ1100029
Did the NOx sensor 1 communication failure (U029D) disappear?
YES NO
Go to step 9. Inspect the NOx sensor 1 CAN communica-

tion line.
position.
4. Check that the NOx sensor 2 communication failure (U029E) is not

SAPH16ZZZ1100030
Did the NOx sensor 2 communication failure (U029E) disappear?
YES NO

tion line.
11 Check the DEF sensor [HINO DX Ⅱ ]
position.
2. Disconnect the DEF sensor connector.
4. Check that the DEF sensor communication failure (U02A2) is not

SAPH16ZZZ1100031
Did the DEF sensor communication failure (U02A2) disappear?
YES NO
Go to step 12. Inspect the DEF sensor CAN communication

line
12 Check the PM sensor [HINO DX Ⅱ ]
position.
2. Disconnect the PM sensor connector.
4. Check that the PM sensor communication failure (U02A3) is not

SAPH16ZZZ1100032
Did the PM sensor communication failure (U02A3) disappear?
YES NO
Procedure completed. Inspect the PM sensor CAN communication

If another CAN communication system DTC line
is detected, refer to "CAN COMMUNICATION
LINE MALFUNCTION PART DETERMINA-
TION TABLE" , and inspect the detected DTC.
drive.)
INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE

EN01H16ZZZ110F03003007
1 Check for short-circuit in CAN L-line between Common rail_CAN_J/C3 to DCU (malfunction
part 10)

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ Engine CAN line.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 • DCU(53P)
1 2 3 4
%JR %JQ %JV %JW
• PM sensor
5 6 7 8
%JS %JU %JZ %JX
ing terminals.
(1) Between the CAN L-line #7 terminal in the Common
rail_CAN_J/C3, DCU side connector and the +24V(K9G) ter-
SAPH16ZZZ1100033
rail_CAN_J/C3, DCU side connector and the SGND(K9H) ter-
Measurement Tester
Standard values
Common
rail_CAN_J/C3
connector (DCU-
side) – DLC(16P)
Starter switch:
LOCK
#7(CANL) –
+24V(K9G)
#7(CANL) –
SGND(K9H)
YES NO
to step 2. Common rail_CAN_J/C3 and DCU.
drive.)
2 Check for short-circuit in CAN L-line between Common rail_CAN_J/C1 and Common

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ ing terminals.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
rail_CAN_J/C1, J/C3 side connector and the +24V(K9G) ter-
rail_CAN_J/C1, J/C3 side connector and the SGND(K9H) ter-
1 2 3 4 minal in the DLC(16P) connector.
%KR %KF %KE %KQ
5 6 7 8
%KP %KM %KL %KN
Measurement Tester
Standard values
Common
rail_CAN_J/C1
connector (Com-
SAPH16ZZZ1100034 mon rail_CAN_J/
C3 side) –
Starter switch:
DLC(16P) connec- No Continuity
LOCK
tor
#3(CANL) –
+24V(K9G)
#3(CANL) –
SGND(K9H)
YES NO
to step 3. Common rail_CAN_J/C1 and Common
rail_CAN_J/C3.
drive.)
3 Check for short-circuit in CAN L-line between Common rail_J/C2 and Common rail_CAN_J/
C1 (malfunction part 8)

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ ing terminals.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 (1) Between the CAN L-line LEZ(CANL) terminal in the Common
rail_J/C2, J/C1 side connector and the +24V(K9G) terminal in
the DLC(16P) connector.
(2) Between the CAN L-line LEZ(CANL) terminal in the Common
rail_J/C2, J/C1 side connector and the SGND(K9H) terminal
K6W LEZ LEY K6V in the DLC(16P) connector.
%J1 %J6 %J7 %J4
EJ2L EJ2H
%JA %JB
Measurement Tester
Standard values
Common rail_J/C2
connector (Com-
mon rail_CAN_J/
SAPH16ZZZ1100035 C1 side) –
Starter switch: DLC(16P) connec-
No Continuity
LOCK tor
LEZ(CANL) –
+24V(K9G)
LEZ(CANL) –
SGND(K9H)
YES NO
Connect the Common rail_J/C2 and go to Short-circuit in CAN L-line +B/GND between
step 4. Common rail_J/C2 and Common rail_CAN_J/
C1.
drive.)
4 Check for short-circuit in CAN L-line between Common rail_J/C1 and Common rail_J/C2 (mal-
function part 11)

+24V SGND
+24V CAN- TC DSW
K9G KS4 KS2 KPZ
ing terminals.
K9E KS3 K9H L30 KE4
(1) Between the CAN L-line EJ1L(CANL) terminal in the Com-
mon rail_J/C1, J/C4 side connector and the +24V(K9G) termi-
nal in the DLC(16P) connector.
(2) Between the CAN L-line EJ1L(CANL) terminal in the Com-
mon rail_J/C1, J/C1 side connector and the SGND(K9H) ter-
KV9 EJ1L EJ1H KV8
%J2 %JC %JD %J3 minal in the DLC(16P) connector.
L4S CA2L CA2H L4R
%J5 KRH KRG %J8
Measurement Tester
Standard values
Common rail_J/C1
connector (Com-
mon rail_J/C2
SAPH16ZZZ1100036 side) – DLC(16P)
Starter switch:
LOCK
EJ1L(CANL) –
+24V(K9G)
EJ1L(CANL) –
SGND(K9H)
YES NO
Connect the Common rail_J/C1 and go to Short-circuit in CAN L-line +B/GND between
step 5. Common rail_J/C1 and Common rail_J/C2.
drive.)
5 Check for short-circuit in CAN L-line between engine ECU and Common rail_J/C1 (malfunc-
tion part 7)
1. Disconnect the engine ECU.

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ connector (Do not connect harness to the ECU.)
K9E KS3 K9H L30 KE4
ing terminals.
D (1) Between the E79(CANL) terminal in the signal check harness
and the +24V(K9G) terminal in the DLC(16P) connector.
(2) Between the E79(CANL) terminal in the signal check harness
E79
Measurement Tester
Standard values
Signal check har-

SAPH16ZZZ1100037 ness (Engine ECU)
– DLC(16P) con-
No Continuity
LOCK E79(CANL) –
+24V(K9G)
E79(CANL) –
SGND(K9H)
YES NO
Go to step 5. Short-circuit in CAN L-line +B/GND between

engine ECU and Common rail_J/C1.
drive.)
6 Check for short-circuit in CAN L-line between engine ECU and CAN-TMN6 (terminal resis-
tance) (malfunction part 6)
(1) Between the V17(CA2L) terminal in the signal check harness
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ and the +24V(K9G) terminal in the DLC(16P) connector.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
A V17 Measurement Tester

Standard values
Signal check har-

ness (Engine ECU)
– DLC(16P) con-
No Continuity
LOCK V17(CA2L) –
+24V(K9G)
SAPH16ZZZ1100038
V17(CA2L) –
SGND(K9H)
YES NO

engine ECU and CAN-TMN6 (terminal resis-
tance).
drive.)
2. Connect the connector of the engine ECU.
5. Erase the malfunction history and set the starter switch to the
"LOCK" position.
6. Connect the EGR controller connector.

SAPH16ZZZ1100039
8. Check that the EGR controller communication failure (U010A) is

Did the EGR controller communication failure (U010A) disappear?
YES NO
Go to step 7. Inspect the EGR controller CAN communica-

tion line.
position.
2. Connect the VNT controller connector.
4. Check that the VNT controller communication failure (U010C) is

SAPH16ZZZ1100040
Did the VNT controller communication failure (U010C) disappear?
YES NO
Go to step 8. Inspect the VNT controller CAN communica-

tion line.
9 NOx sensor 1 [HINO DX Ⅱ ]
position.
4. Check that the NOx sensor 1 communication failure (U029D) is not

SAPH16ZZZ1100041
Did the NOx sensor 1 communication failure (U029D) disappear?
YES NO

tion line.
position.
4. Check that the NOx sensor 2 communication failure (U029E) is not

SAPH16ZZZ1100042
Did the NOx sensor 2 communication failure (U029E) disappear?
YES NO

tion line.
11 Check the DEF sensor [HINO DX Ⅱ ]
position.
2. Disconnect the DEF sensor connector.
4. Check that the DEF sensor communication failure (U02A2) is not

SAPH16ZZZ1100043
Did the DEF sensor communication failure (U02A2) disappear?
YES NO
Go to step 12. Inspect the DEF sensor CAN communication

line
12 Check the PM sensor [HINO DX Ⅱ ]
position.
2. Disconnect the PM sensor connector.
4. Check that the PM sensor communication failure (U02A3) is not

SAPH16ZZZ1100044
Did the PM sensor communication failure (U02A3) disappear?
YES NO
Procedure completed. Inspect the PM sensor CAN communication

If another CAN communication system DTC line
is detected, refer to "CAN COMMUNICATION
LINE MALFUNCTION PART DETERMINA-
TION TABLE" , and inspect the detected DTC.
drive.)
INSPECTION FOR EGR CONTROLLER CAN COMMUNICATION LINE

EN01H16ZZZ110F03003008
1. Check the installation of the joint connector Common rail_J/C1

and EGR controller connector (Looseness and poor contact).
YES NO
step 2.
2 Check the DTC detected [HINO DX Ⅱ ]
2. Select [Engine] and check if U010A has been detected.
SAPH16ZZZ1100045
Has DTC U010A been detected?
YES NO
Go to step 3. Procedure completed.

drive.)
3 Check for disconnection in CAN H-line between Common rail_J/C1 and EGR controller (mal-
function part 1)

EGRH
2. Disconnect the Common rail_J/C1 and EGR controller connector.
KV9 EJ1L EJ1H KV8
%J2 %JC %JD %J3
L4S CA2L CA2H L4R
%J5 KRH KRG %J8 Common rail_J/C1 L4R terminal and the EGRH terminal in the
EGR controller vehicle-side connector.
Measurement Tester
Standard values
Common rail_J/C1
SAPH16ZZZ1100046 – EGR controller
Starter switch:
vehicle-side con- 1  or less
LOCK
nector
L4R – EGRH
YES NO
Go to step 4. Disconnection or faulty continuity in CAN H-

line between Common rail_J/C1 and EGR
controller.
drive.)
4 Check for disconnection in CAN L-line between Common rail_J/C1 and EGR controller (mal-
function part 1)

EGRL Common rail_J/C1 L4S terminal and the EGRL terminal in the
EGR controller vehicle-side connector.
KV9 EJ1L EJ1H KV8
%J2 %JC %JD %J3
Measurement Tester
L4S CA2L CA2H L4R Standard values
%J5 KRH KRG %J8 conditions connections
Common rail_J/C1
– EGR controller
Starter switch:
LOCK
nector
L4S – EGRL
SAPH16ZZZ1100047

YES NO
Go to step 5. Disconnection or faulty continuity in CAN L-

line between Common rail_J/C1 and EGR
controller.
drive.)
5 Check for short-circuit in CAN H-line between Common rail_J/C1 and EGR controller (mal-
function part 1)
(1) Between the EGRH terminal in the EGR controller vehicle-
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ side connector and the +24V(K9G) terminal in the DLC(16P)
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
connector.
(2) Between the EGRH terminal in the EGR controller vehicle-
side connector and the SGND(K9H) terminal in the DLC(16P)
EGRH connector.
Measurement Tester
Standard values
EGR controller
vehicle-side con-
nector – DLC(16P)
Starter switch: connector
No Continuity
LOCK EGRH –
SAPH16ZZZ1100048 +24V(K9G)
EGRH –
SGND(K9H)
YES NO

CAN Common rail_J/C1 and EGR controller.
drive.)
6 Check for +B/GND short-circuit in CAN L-line
(1) Between the EGRL terminal in the EGR controller vehicle-
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
connector.
(2) Between the EGRL terminal in the EGR controller vehicle-
EGRL
connector.
Measurement Tester
Standard values
EGR controller
vehicle-side con-
nector – DLC(16P)
Starter switch:
LOCK
EGRL – +24V(K9G)
SAPH16ZZZ1100049 EGRL –
SGND(K9H)
YES NO

CAN Common rail_J/C1 and EGR controller.
drive.)
1. Connect the Common rail_J/C1 and EGR controller connector.
3. Select [Engine] and check if U010A has been detected.
SAPH16ZZZ1100050
Has DTC U010A been detected?
YES NO
Replace the EGR controller. Procedure completed.

drive.) drive.)
INSPECTION FOR VNT CONTROLLER CAN COMMUNICATION LINE

EN01H16ZZZ110F03003009
1. Check the connection of the joint connector Common rail_J/C1

and VNT controller connector (Looseness and poor contact).
YES NO
step 2.
2. Select [Engine] and check if U010C has been detected.
SAPH16ZZZ1100051
Has DTC U010C been detected?
YES NO

drive.)
3 Check for disconnection in CAN H-line between Common rail_J/C1 and VNT controller (mal-
function part 2)
2. Disconnect the Common rail_J/C1 and VNT controller connector.

KV9 EJ1L EJ1H KV8
%J2 %JC %JD %J3
L4S CA2L CA2H L4R
%J5 KRH KRG %J8
Common rail_J/C1 KV8 terminal and VNTH terminal in the VNT
controller vehicle-side connector.
Measurement Tester
VNTH Standard values
Common rail_J/C1
SAPH16ZZZ1100052 – VNT controller
Starter switch:
LOCK
nector
KV8 – VNTH
YES NO

line between Common rail_J/C1 and VNT
controller.
drive.)
4 Check for disconnection in CAN L-line between Common rail_J/C1 and VNT controller (mal-
function part 2)

Common rail_J/C1 KV9 terminal and VNTL terminal in the VNT
controller vehicle-side connector.
KV9 EJ1L EJ1H KV8
%J2 %JC %JD %J3
Measurement Tester
L4S CA2L CA2H L4R Standard values
%J5 KRH KRG %J8 conditions connections
Common rail_J/C1
– VNT controller
Starter switch:
VNTL vehicle-side con- 1  or less
LOCK
nector
KV9 – VNTL
SAPH16ZZZ1100053

YES NO

line between Common rail_J/C1 and VNT
controller.
drive.)
5 Check for short-circuit in CAN H-line between Common rail_J/C1 and VNT controller (mal-
function part 2)
(1) Between the VNTH terminal in the VNT controller vehicle-side
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ connector and the +24V(K9G) terminal in the DLC(16P) con-
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
nector.
(2) Between the VNTH terminal in the VNT controller vehicle-side
nector.
Measurement Tester
Standard values
VNT controller
vehicle-side con-
VNTH nector – DLC(16P)
Starter switch:
LOCK
VNTH – +24V(K9G)
SAPH16ZZZ1100054 VNTH –
SGND(K9H)
YES NO

CAN Common rail_J/C1 and VNT controller.
drive.)
6 Check for short-circuit in CAN L-line between Common rail_J/C1 and VNT controller (mal-
function part 2)
(1) Between the VNTL terminal in the VNT controller vehicle-
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
connector.
(2) Between the VNTL terminal in the VNT controller vehicle-
connector.
Measurement Tester
Standard values
VNT controller
vehicle-side con-
VNTL nector – DLC(16P)
Starter switch:
LOCK
VNTL – +24V(K9G)
SAPH16ZZZ1100055 VNTL –
SGND(K9H)
YES NO

CAN Common rail_J/C1 and VNT controller.
drive.)
1. Connect the Common rail_J/C1 and VNT controller connector.
3. Select [Engine] and check if U010C has been detected.
SAPH16ZZZ1100056
Has DTC U010C been detected?
YES NO
Replace the VNT controller. Procedure completed.

drive.) drive.)
INSPECTION FOR DCU CAN COMMUNICATION LINE (ENGINE CAN COMMU-

NICATION LINE)
EN01H16ZZZ110F03003010
1. Check the connection of the joint connector Common rail_CAN_J/

C3 and DCU connector (Looseness and poor contact).
YES NO
step 2.
2. Select [Engine] and check if U010E has been detected.
3. Select [DCU] and check if U0029 has been detected
SAPH16ZZZ1100057
Has DTC U010E or U0029 been detected?
YES NO

drive.)
3 Check harness in CAN H-line between Common rail_CAN_J/C3 and DCU (malfunction part
10)
+B2 GND4 GND1

2. Disconnect the Common rail_CAN_J/C3 and DCU(53P) connec-
LEP LEW LET
tor.
+B3 GND5 GND2
LEQ LEX LEU
+B4
LER
+B1
LEN
GND3
LEV 3. Use the electrical tester to measure the resistance between the
#6 Common rail_CAN_J/C3 #6 terminal and the DCU vehicle-side
connector(53P) CAH0 terminal.
CAH1
LF5
CAL1
CAH0 Measurement Tester

LF6
TE1B
LF2 Standard values
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4
TE2A
LEZ
Common
rail_CAN_J/C3 –
LF3
Starter switch:
DCU vehicle-side 1  or less
LOCK
ISGW
LES
connector(53P)
#6 – CAH0
SAPH16ZZZ1100058
YES NO

line between Common rail_CAN_J/C3 and
DCU.
drive.)
4 Check harness in CAN L-line between Common rail_CAN_J/C3 and DCU (malfunction part
10)

Common rail_CAN_J/C3 #7 terminal and the DCU vehicle-side
+B2 GND4 GND1
connector(53P) CAL0 terminal.
LEP LEW LET
+B3 GND5 GND2

LEQ LEX LEU
Measurement Tester
Standard values
+B4
LER
+B1
LEN
GND3
LEV conditions connections
#7 Common
CAH1 rail_CAN_J/C3 –
LF5
Starter switch:
CAL1
LF6 DCU vehicle-side 1  or less
LOCK
TE1B
connector(53P)
CAL0
LF2
TE1A
LF1
CAH0
LEY
#7 – CAL0
TE2B CAL0
LF4 LEZ
TE2A
LF3
ISGW
LES
SAPH16ZZZ1100059
YES NO

DCU.
drive.)
5 Check the DCU power supply
1. Connect the Common rail_CAN_J/C3 and DCU(53P) connector.

GND1
+B3
+B2 GND4 GND1
LEP LEW LET
+B3 GND5 GND2
LEQ LEX LEU
measure the voltage between the terminals of the DCU.
+B4 +B1 GND3
LER LEN LEV
Measurement Tester
Standard values
CAH1
LF5
CAL1
LF6 DCU vehicle-side
9 – 16 V
TE1B
LF2
Starter switch: ON connector(53P)
+B3 – GND1
TE1A CAH0
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A
LF3
ISGW
LES
SAPH16ZZZ1100060
YES NO
Go to step 6. Check the DCU power supply circuit.

drive.)
6 Inspect the DCU [HINO DX Ⅱ ]
2. Connect DCU (53P) connector.
4. Select [Engine] and check if U010E has been detected.
5. Select [DCU] and check if U0029 has been detected
SAPH16ZZZ1100061
Has DTC U010E or U0029 been detected?
YES NO

drive.) drive.)
INSPECTION FOR NOx sensor 1 CAN COMMUNICATION LINE

EN01H16ZZZ110F03003012

Harness NOx sensor C3 and NOx sensor 1 connector (Looseness and poor contact).
connector controller
Sensor
Clip
SAPH16ZZZ1100062
YES NO
step 2.
3. Select [Engine] and [DCU], and check if the DTC has been
detected.
SAPH16ZZZ1100063
YES NO

drive.)

GND
GND 2. Disconnect the NOx sensor 1 connector.

terminals of the NOx sensor 1 vehicle-side connector.
Measurement Tester
Standard values
NOx sensor 1
Continuity exists
SAPH16ZZZ1100064 LOCK nector
GND – GND
YES NO

drive.)

VCC
GND 2. Use the electrical tester to measure the voltage between the termi-
Measurement Tester
Standard values
NOx sensor 1
vehicle-side con-
Starter switch: ON 9 – 16V
nector
VCC – GND
SAPH16ZZZ1100065
YES NO

drive.)
5 Inspect for disconnection in CAN H-line between Common rail_CAN_J/C3 and NOx sensor 1

CANH
1 2 3 4
%JR %JQ %JV %JW
5 6 7 8
3. Use the electrical tester to measure the resistance between #1 ter-
%JS %JU %JZ %JX
minal of the Common rail_CAN_J/C3 and CANH terminal of the
NOx sensor 1 vehicle-side connector.
Measurement Tester
Standard values
Common
SAPH16ZZZ1100066 rail_CAN_J/C3 –
Starter switch: NOx sensor 1
1  or less
nector
#1 – CANH
YES NO
Go to step 6. Disconnection or poor continuity in CAN H-

NOx sensor 1. Repair or replace the harness.
drive.)
6 Inspect for disconnection in CAN L-line between Common rail_CAN_J/C3 and NOx sensor 1

CANL minal of the Common rail_CAN_J/C3 and CANL terminal of the
1 2 3 4
%JR %JQ %JV %JW
Measurement Tester
5 6 7 8
%JS %JU %JZ %JX
Standard values
Common
rail_CAN_J/C3 –
1  or less
nector
SAPH16ZZZ1100067 #4 – CANL
YES NO
Go to step 7. Disconnection or poor continuity in CAN L-

drive.)
7 Check for short-circuit in CAN H-line between Common rail_CAN_J/C3 and NOx sensor 1
(1) Between the CANH terminal in the NOx sensor 1 vehicle-side
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
nector.
CANH nector.
Measurement Tester
Standard values
NOx sensor 1
vehicle-side con-
nector – DLC(16P)
No Continuity
LOCK CANH –
SAPH16ZZZ1100068 +24V(K9G)
CANH –
SGND(K9H)

YES NO

Common rail_CAN_J/C3 and NOx sensor 1.
drive.)
8 Check for short-circuit in CAN L-line between Common rail_CAN_J/C3 and NOx sensor 1
(1) Between the CANL terminal in the NOx sensor 1 vehicle- side
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
nector.
CANL
nector.
Measurement Tester
Standard values
NOx sensor 1
vehicle-side con-
nector – DLC(16P)
Starter switch:
LOCK
CANL – +24V(K9G)
SAPH16ZZZ1100069 CANL –
SGND(K9H)
YES NO

CAN_J/C3 and NOx sensor 1.
drive.)
1. Connect the Common rail_CAN_J/C3 and NOx sensor 1 connec-

tor.
3. Select [Engine] and [DCU], and check if U029D has been

detected.
SAPH16ZZZ1100070
YES NO
Replace the NOx sensor 1. Procedure completed.

drive.) drive.)
INSPECTION FOR NOx sensor 2 CAN COMMUNICATION LINE

EN01H16ZZZ110F03003013

NOx sensor 2 C3 and NOx sensor 2 connector (Looseness and poor contact).
connector
Clip
Sensor Clip
SAPH16ZZZ1100071
YES NO
step 2.
3. Select [Engine] and [DCU], and check if the DTC has been
detected.
SAPH16ZZZ1100072
Has any DTC been detected?
YES NO

drive.)

GND

GND terminal in the NOx sensor 2 vehicle-side connector and the
ground.
Measurement Tester
Standard values
NOx sensor 2
SAPH16ZZZ1100073
1  or less
LOCK nector – Ground
GND – Ground
YES NO

drive.)

GND
VCC 2. Use the electrical tester to measure the voltage between the termi-
Measurement Tester
Standard values
NOx sensor 2
vehicle-side con-
Starter switch: ON 9 – 16V
nector
VCC – GND
SAPH16ZZZ1100074
YES NO

drive.)
5 Inspect for disconnection in CAN H-line between Common rail_CAN_J/C3 and NOx sensor 2

CANH
1 2 3 4
%JR %JQ %JV %JW
5 6 7 8
%JS %JU %JZ %JX
minal of the Common rail_CAN_J/C3 and CANH terminal of the
Measurement Tester
Standard values
Common
1  or less
nector
#5 – CANH
YES NO

drive.)
6 Inspect for disconnection in CAN L-line between Common rail_CAN_J/C3 and NOx sensor 2

CANL minal of the Common rail_CAN_J/C3 and CANL terminal of the
1 2 3 4
%JR %JQ %JV %JW
Measurement Tester
5 6 7 8
%JS %JU %JZ %JX
Standard values
Common
rail_CAN_J/C3 –
1  or less
nector
SAPH16ZZZ1100076 #8 – CANL
YES NO

drive.)
7 Check for short-circuit in CAN H-line between Common rail_CAN_J/C3 and NOx sensor 2
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
nector.
CANH nector.
Measurement Tester
Standard values
NOx sensor 2
vehicle-side con-
nector – DLC(16P)
No Continuity
LOCK CANH –
SAPH16ZZZ1100077 +24V(K9G)
CANH –
SGND(K9H)

YES NO

drive.)
8 Check for short-circuit in CAN L-line between Common rail_CAN_J/C3 and NOx sensor 2
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
nector.
CANL
nector.
Measurement Tester
Standard values
NOx sensor 2
vehicle-side con-
nector – DLC(16P)
Starter switch:
LOCK
CANL – +24V(K9G)
SGND(K9H)
YES NO

drive.)
1. Connect the Common rail_CAN_J/C3 and NOx sensor 2 connec-

tor.
3. Select [Engine] and [DCU], and check if U029E has been

detected.
SAPH16ZZZ1100079
YES NO
Replace the NOx sensor 2. Procedure completed.

drive.) drive.)
INSPECTION FOR DEF SENSOR CAN COMMUNICATION LINE

EN01H16ZZZ110F03003014

C1 and DEF sensor connector (Looseness and poor contact).
YES NO
step 2.
2. Select [Engine ECU] and [DCU], and check if U02A2 has been
detected.
SAPH16ZZZ1100080
YES NO

drive.)
3 Inspect the DEF sensor harness (GND circuit)
GND 2. Disconnection the DEF sensor connector.

GND terminal in the DEF sensor vehicle-side connector and the
ground.
Measurement Tester
Standard values
DEF sensor vehi-

Starter switch: cle-side connec-
SAPH16ZZZ1100081
1  or less
LOCK tor – Ground
GND – Ground
YES NO
Go to step 4. Inspect the DEF sensor ground circuit.

drive.)
4 Inspect the DEF sensor harness (Power supply circuit)
VCC GND
nals of the DEF sensor vehicle-side connector.
Measurement Tester
Standard values
DEF sensor vehi-

VCC – GND
SAPH16ZZZ1100082
YES NO
Go to step 5. Inspect the DEF sensor power supply circuit.

(between fuse and relay block B and DEF
sensor)
drive.)
5 Inspect for disconnection in CAN H-line between Common rail_CAN_J/C1 and DEF sensor
CANH 2. Disconnect the Common rail_CAN_J/C1 connector.

1 2 3 4
%KH %KF %KE %KG 3. Use the electrical tester to measure the resistance between the
5 6 7 8
%KP %KM %KL %KN Common rail_CAN_J/C1 #5 terminal and CANH terminal of the
DEF sensor.
Measurement Tester
Standard values
Common
Starter switch:
DEF sensor vehi- 1  or less
LOCK
cle-side connector
#5 – CANH
YES NO

DEF sensor. Repair or replace the harness.
drive.)
6 Check for disconnection in CAN L-line between Common rail_CAN_J/C1 and DEF sensor

Common rail_CAN_J/C1 #8 terminal and CANL terminal of the
CANL
DEF sensor.
1 2 3 4
%JH %JF %JE %JG Measurement Tester
5 6 7 8
Standard values
%JP %JM %JL %JN conditions connections
Common
rail_CAN_J/C1 –
Starter switch:
DEF sensor vehi- 1  or less
LOCK
cle-side connector
#8 – CANL
SAPH16ZZZ1100084

YES NO

DEF sensor. Repair or replace the harness.
drive.)
7 Check for short-circuit in CAN H-line between Common rail_CAN_J/C1 and DEF sensor (mal-
function part 3)
(1) Between the CANH terminal in the DEF sensor vehicle-side
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
nector.
(2) Between the CANH terminal in the DEF sensor vehicle-side
nector.
CANH
Measurement Tester
Standard values
DEF sensor vehi-

cle-side connec-
tor –
DLC(16P)connec-
Starter switch:
tor 1  or less
LOCK
SAPH16ZZZ1100085 CANH –
+24V(K9G)
CANH –
SGND(K9H)
YES NO

CAN_J/C1 and DEF sensor.
drive.)
8 Check for short-circuit in CAN L-line between Common rail_CAN_J/C1 and DEF sensor (mal-
function part 3)
(1) Between the CANL terminal in the DEF sensor vehicle- side
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
nector.
(2) Between the CANL terminal in the DEF sensor vehicle- side
CANL nector.
Measurement Tester
Standard values
DEF sensor vehi-

cle-side connec-
tor – DLC(16P)
Starter switch:
connector 1  or less
LOCK
CANL – +24V(K9G)
SGND(K9H)
YES NO

CAN_J/C1 and DEF sensor.
drive.)
9 Inspect the DEF sensor [HINO DX Ⅱ ]
1. Connect the Common rail_CAN_J/C1 and DEF sensor connector.
3. Select [Engine] and [DCU], and check if U02A2 has been

detected.
SAPH16ZZZ1100087
YES NO
Replace the DEF sensor. Procedure completed.

drive.) drive.)
INSPECTION FOR PM SENSOR CAN COMMUNICATION LINE

C1 and PM sensor connector (Looseness and poor contact).
YES NO
step 2.
2. Select [Engine ECU], and check if U02A3 has been detected.
SAPH16ZZZ1100088
YES NO

drive.)
3 Inspect the PM sensor harness (GND circuit)
GND
2. Disconnection the PM sensor connector.

GND terminal in the PM sensor vehicle-side connector and the
ground.
Measurement Tester
Standard values
DEF sensor vehi-

SAPH16ZZZ1100089 Starter switch: cle-side connec-
1  or less
LOCK tor – Ground
GND – Ground
YES NO
Go to step 4. Inspect the PM sensor ground circuit.

drive.)
4 Inspect the PM sensor harness (Power supply circuit)

PWR GND
nals of the PM sensor vehicle-side connector.
Measurement Tester
Standard values
PM sensor vehi-
PWR – GND
SAPH16ZZZ1100090
YES NO
Go to step 5. Inspect the PM sensor power supply circuit.

(between fuse and relay block B and PM sen-
sor)
drive.)
5 Inspect for disconnection in CAN H-line between Common rail_CAN_J/C1 and PM sensor
CANH 2. Disconnect the Common rail_CAN_J/C1 connector.

1 2 3 4
%KR %KF %KE %KQ
5 6 7 8
%KP %KM %KL %KN
Common rail_CAN_J/C1 #1 terminal and CANH terminal of the
PM sensor.
Measurement Tester
Standard values
Common
Starter switch:
PM sensor vehi- 1  or less
LOCK
cle-side connector
#1 – CANH
YES NO

PM sensor. Repair or replace the harness.
drive.)
6 Check for disconnection in CAN L-line between Common rail_CAN_J/C1 and PM sensor (mal-
function part 12)

CANL
Common rail_CAN_J/C1 #4 terminal and CANL terminal of the PM
sensor.
1 2 3 4
%KR %KF %KE %KQ Measurement Tester
5 6 7 8
Standard values
%KP %KM %KL %KN conditions connections
Common
rail_CAN_J/C1 –
Starter switch:
PM sensor vehi- 1  or less
LOCK
cle-side connector
#4 – CANL
SAPH16ZZZ1100092

YES NO

PM sensor. Repair or replace the harness.
drive.)
7 Check for short-circuit in CAN H-line between Common rail_CAN_J/C1 and PM sensor (mal-
function part 12)
+24V CAN- TC DSW

(1) Between the CANH terminal in the PM sensor vehicle-side
K9G KS4 KS2 KPZ

K9E KS3 K9H L30 KE4
nector.
(2) Between the CANH terminal in the PM sensor vehicle-side
CANH nector.
Measurement Tester
Standard values
PM sensor vehi-
cle-side connec-
tor –
DLC(16P)connec-
Starter switch:
tor 1  or less
SAPH16ZZZ1100093 LOCK
CANH –
+24V(K9G)
CANH –
SGND(K9H)
YES NO

CAN_J/C1 and PM sensor.
drive.)
8 Check for short-circuit in CAN L-line between Common rail_CAN_J/C1 and PM sensor (mal-
function part 12)
(1) Between the CANL terminal in the PM sensor vehicle- side
+24V
K9G
CAN- TC
KS4 KS2
DSW
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
nector.
(2) Between the CANL terminal in the PM sensor vehicle- side
CANL
nector.
Measurement Tester
Standard values
PM sensor vehi-
cle-side connec-
tor – DLC(16P)
Starter switch:
LOCK
CANL – +24V(K9G)
SAPH16ZZZ1100094
CANL –
SGND(K9H)
YES NO

CAN_J/C1 and PM sensor.
drive.)
9 Inspect the PM sensor [HINO DX Ⅱ ]
1. Connect the Common rail_CAN_J/C1 and PM sensor connector.
3. Select [Engine], and check if U02A3 has been detected.
SAPH16ZZZ1100095
YES NO
Replace the PM sensor. Procedure completed.

drive.) drive.)
DIAGNOSIS CAN COMMUNICATION LINE

EN01H16ZZZ110F03004001
If any DTC of "CAN communication abnormal" is detected, carry out "PRE-INSPECTION FOR DIAGNOSIS CAN COM-
MUNICATION LINE" first.
CONNECTION DIAGRAM
EN01H16ZZZ110F03004002
Vehicle Control DCU

ECU CAN J/C 2_ CAN J/C 3_ (Terminator)
1 2 3 4 No.30 J/C 5
(Terminator) High, Low High, Low
8 7 6
Diagnostic Combination Engine

connector Meter ECU
(16P) (DLC)
SAPH16ZZZ1100096

EN01H16ZZZ110F03004003
1. Engine ECU
Estimated mal-
function part
• Pre-inspection for diagnosis CAN communication line

U110A, U1001 1, 2, 3, 4, 5, 6, 8 • Disconnection inspection for diagnosis CAN H/L communication line
• Inspection for engine ECU CAN communication line
Failure to communicate • Pre-inspection for diagnosis CAN communication line
the engine ECU with the 1, 2, 3, 4, 5, 6, 8
HINO DX Ⅱ • Inspection for engine ECU CAN communication line
Indicate engine system

"** indication is stopped"
or "** abnormal" are indi- • Pre-inspection for diagnosis CAN communication line
1, 2, 3, 4, 5, 6
cated on the multi-infor- • Inspection for engine ECU CAN communication line
mation indicator
(combination meter).
2. DCU
Estimated mal-
function part

U0038 1, 2, 3, 4, 5 • Disconnection inspection for diagnosis CAN H/L communication line
U0100 with engine ECU • Pre-inspection for diagnosis CAN communication line
1, 2, 3, 4, 5
/ U110A, U1001 • Disconnection inspection for diagnosis CAN H/L communication line
Failure to communicate
the DCU with the HINO 1, 2, 3, 4, 5, 8 • Pre-inspection for diagnosis CAN communication line
DX Ⅱ
3. Vehicle control ECU
Estimated mal-
function part

U0105 1, 2, 3, 4, 5, 6 • Disconnection inspection for diagnosis CAN H/L communication line
Failure to communicate
the Vehicle control ECU 1, 2, 3, 4, 5, 8 • Pre-inspection for diagnosis CAN communication line
with the HINO DX Ⅱ
Indicate engine system

"** indication is stopped"
or "** abnormal" are indi-
1, 2, 3, 4, 5, 8 • Pre-inspection for diagnosis CAN communication line
cated on the multi-infor-
mation indicator
PRE-INSPECTION FOR DIAGNOSIS CAN COMMUNICATION LINE

EN01H16ZZZ110F03004004
1 Check for +B/GND short-circuit in CAN H-line

+24V SGND
2. Disconnect the connector of the controller below that are con-
+B2
LEP
GND4
LEW
GND1
LET +24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ
nected to the diagnosis CAN line.
+B3
LEQ
GND5
LEX
GND2
LEU ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
• DCU(53P), Engine ECU
+B4
LER
+B1
LEN
GND3
LEV • Combination meter, vehicle control ECU
CAH1 3. Use the electrical tester to check the continuity between the CAH1
CAH1
LF5
terminal in the DCU vehicle-side connector(53P) and the
CAL1
TE1B
LF6
+24V(K9G) terminal and SGND(K9H) terminal in the DLC(16P)
LF2
TE1A CAH0
connector.
LF1 LEY
TE2B CAL0
LF4 LEZ
TE2A Measurement Tester

LF3
Standard values
ISGW
LES
DCU vehicle-side
connector –
DLC(16P) connec-
Starter switch:
tor No Continuity
LOCK
CAH1 – +24V(K9G)
SAPH16ZZZ1100097 CAH1 –
SGND(K9H)
YES NO

IN DIAGNOSIS CAN H-line"
2 Check for +B/GND short-circuit in CAN L-line
1. Use the electrical tester to check the continuity between the CAL1
+24V SGND terminal in the DCU vehicle-side connector(53P) and the
+24V(K9G) terminal and SGND(K9H) terminal in the DLC(16P)
+B2
LEP
GND4
LEW
GND1
LET +24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ
connector.
+B3 GND5 GND2
LEQ LEX LEU ISOK CAN+ SGND CGFR +
K9E KS3 K9H L30 KE4
Measurement Tester
+B4
LER
+B1
LEN
GND3
LEV Standard values
DCU vehicle-side
CAH1 CAL1
LF5
CAL1
connector –
LF6
DLC(16P) connec-
TE1B
LF2 Starter switch:
TE1A CAH0 tor No Continuity
LF1 LEY
LOCK
TE2B
LF4
CAL0
LEZ
CAL1 – +24V(K9G)
TE2A
LF3 CAL1 –
SGND(K9H)
ISGW
LES
SAPH16ZZZ1100098
YES NO

IN DIAGNOSIS CAN L-line"
3 Check the DCU (terminating resistance)
1. Use the electrical tester to measure the terminating resistance of

DCU(53P).
Measurement Tester
Standard values
ISGW
LES
Starter switch: DCU(53P):

120   10 
LOCK CAH1 – CAL1
TE2A
LF3
TE2B CAL0
LF4 LEZ
TE1A
LF1
CAH0
LEY CAL1
TE1B
LF2
CAL1
LF6
CAH1
LF5
CAH1
+B4 +B1 GND3
LER LEN LEV
+B3 GND5 GND2

LEQ LEX LEU
+B2 GND4 GND1

LEP LEW LET
SAPH16ZZZ1100099

YES NO
Go to step 4. Replace the DCU.

After replacing the DCU, confirm that no CAN
communication system DTC is detected.
drive.)
4 Check the vehicle control ECU (terminating resistance)
1. Use the electrical tester to measure the terminating resistance of

the vehicle control ECU.
Measurement Tester
Standard values
Vehicle control
Starter switch:
ECU 120   10 
ECAH LOCK
ECAH – ECAL
ECAL
SAPH16ZZZ1100100
YES NO
Procedure completed. Replace the vehicle control ECU.

Check if the terminals of each connector are After replacing the ECU, confirm that no CAN
no abnormality, and then connect each con- communication system DTC is detected.
nector properly. Perform After-inspection work. (Clear all past
Go to the diagnostic procedure for the DTC. Check no DTC is stored after test
detected DTC. drive.)
DISCONNECTION INSPECTION FOR DIAGNOSIS CAN_H/

L_COMMUNICATION LINE
EN01H16ZZZ110F03004005
1 Check harness in CAN bus line between No. 30_J/C and DCU (malfunction parts 5)
2. Disconnect the following controller connectors connected to the

CA1H CA1H CA1L Diagnosis_CAN line (Leave the DCU and vehicle control ECU con-
%JM %JL %JJ
CA1H CA1H CA1L
nected).
%JP %JN %JK
• Engine ECU
• Combination meter
3. Disconnect the No.30_J/C connector.

SAPH16ZZZ1100101
terminals in the CAN H-line and L-line DCU side connector.
Measurement Tester
Standard values
No.30_J/C:
Starter switch:
CA1H(%JM) – 110  – 130 
LOCK
CA1L(%JK)
YES NO
Connect the No.30_J/C connector, and go to CAN bus line disconnection or poor continu-
step 2. ity between No. 30_J/C and the DCU.
drive.)
2 Check harness in CAN bus line between CAN_J/C3 High/Low and No. 30_J/C (malfunction
part 4)
1. Disconnect the CAN_J/C3_High and Low connector.

METH METL
%L1 %L4 2. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the No. 30_J/C side con-
nector.
Measurement Tester
Standard values
CAN_J/C3_High:
Starter switch: METH(%L1) –
110  – 130 
LOCK CAN_J/C3_Low:
SAPH16ZZZ1100102 METL(%L4)
YES NO
Connect the CAN_J/C3_HighLow connector, CAN bus line disconnection or poor continu-
and go to step 3. ity between CAN_J/C3 and No. 30_J/C
drive.)
3 Check harness in CAN bus line between CAN_J/C2 High/Low and CAN_J/C3 High/Low (mal-
function parts 2 and 3)
1. Disconnect the CAN_J/C2_High and Low connector.

CANH CANL
%JD %JH 2. Use the electrical tester to measure the resistance between the
terminals in the CAN H-line and L-line on the CAN_J/C3 side con-
nector.
Measurement Tester
Standard values
CAN_J/C2_High:
Starter switch: CANH(%JD) –
110  – 130 
LOCK CAN_J/C2_Low:
SAPH16ZZZ1100103 CANL(%JH)
YES NO

ity between CAN_J/C2 and CAN_J/C3
drive.)
4 Check harness in CAN bus line between DLC(16P) and CAN_J/C3 High/Low (malfunction part
3 & 8)

CAN+ DLC(16P) connector CAN H-line terminal and L-line terminal.
CAN-
Measurement Tester
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ Standard values
K9E KS3 K9H L30 KE4
DLC(16P) connec-
Starter switch: tor:
110 – 130 
LOCK CAN+(KS3) – CAN-
(KS4)
SAPH16ZZZ1100104
YES NO

ity between DLC(16P) connector and CAN_J/
C3 High-Low.
drive.)
5 Check harness in CAN bus line between CAN_J/C2 High/Low and the vehicle control ECU

CANH CANL terminals in the CAN H-line and L-line on the vehicle control ECU
%JC %JG side connector.
Measurement Tester
Standard values
CAN_J/C2_High –
Starter switch: CAN_J/C_Low
110  – 130 
LOCK CANH(%JC) –
CANL(%JG)
SAPH16ZZZ1100105
YES NO
Procedure completed. CAN bus line disconnection or poor continu-

If another CAN communication system DTC ity between CAN_J/C2 and vehicle control
is detected, refer to "CAN COMMUNICATION ECU
LINE MALFUNCTION PART DETERMINA- Repair or replace the harness.
TION TABLE" , go to the diagnostic proce- Perform After-inspection work. (Clear all past
dure for the detected DTC. DTC. Check no DTC is stored after test
drive.)
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN H-LINE

EN01H16ZZZ110F03004006
1 Check for short-circuit in CAN H-line between No.30 J/C and DCU (malfunction part 5)

+24V SGND
2. Disconnect the following controllers connected to the diagnosis
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ CAN line.
CA1H CA1H CA1L
• DCU(53P), Engine ECU
%JM %JL %JJ
K9E KS3 K9H L30 KE4
CA1H CA1H CA1L

%JP %JN %JK • Vehicle control ECU
3. Disconnect the No.30 J/C connector.
ing terminals.
SAPH16ZZZ1100106
(1) Between the CAN H-line CA1H(%JM) terminal in the DCU
side connector and the +24V(K9G) terminal in the DLC(16P)
connector.
(2) Between the CAN H-line CA1H(%JM) terminal in the DCU
connector.
Measurement Tester
Standard values
No.30 J/C –
DLC(16P) connec-
tor
Starter switch:
CA1H(%JM) – No Continuity
LOCK
+24V(K9G)
CA1H(%JM) –
SGND(K9H)
YES NO
Go to step 2. Short +B/GND in CAN H-line between No.30

J/C and DCU.
drive.)
2 Check for short-circuit in CAN H-line between CAN_J/C3 High and No. 30_J/C (malfunction
part 4)
1. Disconnect the CAN_J/C3_High connector.

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ ing terminals.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 (1) Between the CAN H-line METH(%L1) terminal in the
No.30_J/C side connector and the +24V(K9G) terminal in the
DLC(16P) connector.
METH
%L1
(2) Between the CAN H-line METH(%L1) terminal in the
No.30_J/C side connector and the SGND(K9H) terminal in
Measurement Tester
Standard values
SAPH16ZZZ1100107 conditions connections
CAN_J/C3_High –
DLC(16P) connec-
tor
Starter switch:
METH(%L1) – No continuity
LOCK
+24V(K9G)
METH(%L1) –
SGND(K9H)
YES NO
Connect the CAN_J/C3_High connector, and Short +B/GND in CAN H-line between CAN_J/
go to step 3. C3 High and No. 30_J/C.
drive.)
3 Check for short-circuit in CAN H-line between CAN_J/C2 High and CAN_J/C3 (malfunction
parts 2 & 3)
1. Disconnect the CAN_J/C3_High connector.

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ ing terminals.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 (1) Between the CAN H-line CANH(%JD) terminal in the CAN_J/
C3 High side connector and the +24V(K9G) terminal in the
DLC(16P) connector.
CANH (2) Between the CAN H-line CANH(%JD) terminal in the CAN_J/
%JD
C3 High side connector and the SGND(K9H) terminal in the
DLC(16P) connector.
Measurement Tester
Standard values
CAN_J/C2_High –
DLC(16P) connec-
tor
Starter switch:
CANH(%JD) – No Continuity
LOCK
+24V(K9G)
CANH(%JD) –
SGND(K9H)
YES NO
Go to step 4. Short +B/GND in CAN H-line between CAN_J/

C2 High and CAN_J/C3 High.
drive.)
4 Check for short-circuit in CAN H-line between DLC(16P) and CAN_J/C3 High (malfunction
part 3 & 8)
+24V
ing terminals.
(1) Between the CAN+(KS3) terminal and the +24V(K9G) termi-
+24V CAN- TC DSW
K9G KS4 KS2 KPZ
(2) Between the CAN+(KS3) terminal and the SGND(K9H) termi-
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 nal in the DLC(16P) connector.
Measurement Tester
Standard values
CAN+
DLC(16P) connec-
SGND
tor
SAPH16ZZZ1100109 Starter switch: CAN+(KS3) –
No continuity
LOCK +24V(K9G)
CAN+(KS3) –
SGND(K9H)
YES NO
Go to step 5. Short +B/GND in CAN H-line between

DLC(16P) connector and CAN_J/C3 High.
drive.)
5 Check for short-circuit in CAN H-line between CAN_J/C2 High and the vehicle control ECU
(1) Between the CAN H-line CANH(%JC) terminal in the vehicle
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ control ECU side connector and the +24V(K9G) terminal in
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
(2) Between the CAN H-line CANH(%JC) terminal in the vehicle
control ECU side connector and the SGND(K9H) terminal in
CANH the DLC(16P) connector.
%JC
Measurement Tester
Standard values
SAPH16ZZZ1100110 CAN_J/C2_High –
DLC(16P) connec-
tor
Starter switch:
CANH(%JC) – No continuity
LOCK
+24V(K9G)
CANH(%JC) –
+SGND(K9H)
YES NO
Procedure completed. Short +B/GND in CAN H-line between CAN_J/

If another CAN communication system DTC C2 High and vehicle control ECU.
TION TABLE" , go to the diagnostic proce- DTC. Check no DTC is stored after test
dure for the detected DTC. drive.)
drive.)
INSPECTION FOR SHORT-CIRCUIT IN DIAGNOSIS CAN L-LINE

EN01H16ZZZ110F03004007
1 Check for short-circuit for short-circuit in CAN L-line between No.30 J/C and DCU (malfunc-
tion parts 5)

+24V SGND
2. Disconnect the following controller connectors connected to the
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ Engine_control/Diagnosis_CAN line.
CA1H CA1H CA1L ISOK CAN+ SGND CGFR +
%JM %JL %JJ
K9E KS3 K9H L30 KE4
• DCU(53P), engine ECU
CA1H CA1H CA1L
%JP %JN %JK • Combination meter, vehicle control ECU
3. Disconnect the No.30_J/C connector.
ing terminals.
SAPH16ZZZ1100111
(1) Between the CAN L-line CA1L(%JK) terminal in the DCU side
nector.
(2) Between the CAN L-line CA1L(%JK) terminal in the DCU side
nector.
Measurement Tester
Standard values
No.30_J/C:
CA1L(%JK) –
Starter switch:
+24V(K9G) No continuity
LOCK
CA1L(%JK) –
SGND(K9H)
YES NO
Go to step 2. CAN L-line +B/GND short-circuit between No.

30_J/C and the DCU.
drive.)
2 Check for short-circuit in CAN L-line between CAN_J/C3 Low and No. 30_J/C (malfunction
part 4)
1. Disconnect the CAN_J/C3 Low connector.

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ ing terminals.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 (1) Between the CAN L-line METL(%L4) terminal in the No.30_J/
C side connector and the +24V(K9G) terminal in the
DLC(16P) connector.
METL
%L4
(2) Between the CAN L-line METL(%L4) terminal in the No.30_J/
C side connector and the SGND(K9H) terminal in the
DLC(16P) connector.
Measurement Tester
Standard values
CAN_J/C3_Low –
DLC(16P) connec-
tor
Starter switch:
METL(%L4) – No Continuity
LOCK
+24V(K9G)
METL(%L4) –
SGND(K9H)
YES NO
Connect the CAN_J/C3 Low connector, and Short +B/GND in CAN L-line between CAN_J/
go to step 3. C3 Low and No. 30_J/C.
drive.)
3 Check for short-circuit in CAN L-line between CAN_J/C2 Low and CAN_J/C3 Low (malfunc-
tion parts 2 & 3)
1. Disconnect the CAN_J/C2 Low connector.

+24V SGND
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ ing terminals.
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 (1) Between the CAN L-line CANL(%JH) terminal in the CAN_J/
C3 High side connector and the +24V(K9G) terminal in the
DLC(16P) connector.
CANL (2) Between the CAN L-line CANL(%JH) terminal in the CAN_J/
%JH
C3 High side connector and the SGND(K9H) terminal in the
DLC(16P) connector.
Measurement Tester
Standard values
CAN_J/C2_Low –
DLC(16P) connec-
tor
Starter switch:
CANL(%JH) – No continuity
LOCK
+24V(K9G)
CANL(%JH) –
+SGND(K9H)
YES NO
Go to step 4. Short +B/GND in CAN L-line between CAN_J/

C2 Low and CAN_J/C_3 Low.
drive.)
4 Check for short-circuit for short-circuit in CAN L-line between DLC connector (16P) and
CAN_J/C 3 Low (malfunction part 3 & 8)
+24V
ing terminals.
(1) Between the CAN-(KS4) terminal and the +24V(K9G) termi-
+24V CAN- TC DSW
K9G KS4 KS2 KPZ
(2) Between the CAN-(KS4) terminal and the SGND(K9H) termi-
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4 nal in the DLC(16P) connector.
Measurement Tester
CAN- Standard values
DLC(16P) connec-
SGND
tor
SAPH16ZZZ1100114 Starter switch: CAN-(KS4) –
No continuity
LOCK +24V(K9G)
CAN-(KS4) –
SGND(K9H)
YES NO
Go to step 5. Short +B/GND in CAN L-line between

DLC(16P) connector and CAN_J/C 3 Low.
drive.)
5 Check for short-circuit for short-circuit in CAN L-line between CAN_J/C2 Low and vehicle
control ECU (malfunction part 1)
(1) Between the CAN L-line CANL(%JG) terminal in the vehicle
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ control ECU side connector and the +24V(K9G) terminal in
ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
(2) Between the CAN L-line CANL(%JG) terminal in the vehicle
control ECU side connector and the SGND(K9H) terminal in
CANL the DLC(16P) connector.
%JG
Measurement Tester
Standard values
SAPH16ZZZ1100115 CAN_J/C2_Low:
CANL(%JG) –
Starter switch:
+24V(K9G) No continuity
LOCK
CANL(%JG) –
SGND(K9H)
YES NO
Procedure completed. Short +B/GND in CAN L-line between CAN_J/

If another CAN communication system DTC C2 Low and vehicle control ECU.
TION TABLE" , go to the diagnostic proce- DTC. Check no DTC is stored after test
dure for the detected DTC. drive.)
drive.)
INSPECTION FOR DCU CAN COMMUNICATION LINE (DIAGNOSIS CAN COM-

MUNICATION LINE)
EN01H16ZZZ110F03004008
1. Check the connection of the joint connector No.30_J/C and DCU

YES NO
step 2.
SAPH16ZZZ1100116
YES NO

drive.)
3 Check harness in CAN H-line between No.30_J/C and DCU (malfunction part 5 of Diagnosis
CAN line)

+B2 GND4 GND1
LEP LEW LET
+B3 GND5 GND2

2. Disconnect the No.30_J/C and DCU 53P connector.
LEQ LEX LEU
CA1H
+B4
LER
+B1
LEN
GND3
LEV
%JM
CA1H CA1L
%JL %JJ
CA1H CA1H CA1L No.30_J/C CA1H(%JM) terminal and the DCU 53P vehicle-side
%JP %JN %JK
CAH1
connector CA1H terminal.
LF5
CAL1
LF6
Measurement Tester
TE1B
LF2
Standard values
TE1A
LF1
CAH0
LEY
TE2B CAL0
No.30_J/C – DCU
LF4 LEZ
TE2A
LF3
53P vehicle-side
Starter switch:
LOCK
IGSW
LES CA1H (%JM) –
CAH1
SAPH16ZZZ1100117
YES NO

line between No.30_J/C and DCU. Repair or
replace the harness.
drive.)
4 Check harness in CAN L-line between No.30J/C and DCU (malfunction part 5 of Diagnosis
CAN line)

+B2
LEP
GND4
LEW
GND1
LET
No.30_J/C CA1L(%JK) terminal and each terminal of the DCU
+B3 GND5 GND2
53P vehicle-side connector CAL1 terminal.
LEQ LEX LEU
+B4
LER
+B1
LEN
GND3
LEV CA1H
%JM
CA1H CA1L
%JL %JJ
Measurement Tester
Standard values
CA1H CA1H CA1L conditions connections
%JP %JN %JK
CAH1
LF5 No.30_J/C – DCU
CAL1
LF6
53P vehicle-side
Starter switch:
1  or less
TE1B
LF2
connector
TE1A CAH0 LOCK
LF1
TE2B
LEY
CAL0
CA1L(%JK) –
LF4 LEZ
TE2A
CAL1
LF3
IGSW
LES
SAPH16ZZZ1100118
YES NO

line between No.30_J/C and DCU. Repair or
replace the harness.
drive.)
5 Check the DCU power supply
1. Connect the No.30_J/C and DCU 53P connector.

GND1
+B3 2. Set the starter switch to the "ON" position.
cle-side connector.
Measurement Tester
Standard values
DCU 53P vehicle-

SAPH16ZZZ1100119 Starter switch: ON side connector 9 – 16V
+B3 – GND1
YES NO
Go to step 6. Check the DCU power supply circuit.

drive.)
6 Inspect the DCU [HINO DX Ⅱ ]
2. Connect the DCU 53P connector.
SAPH16ZZZ1100120
YES NO

drive.) drive.)
INSPECTION FOR ENGINE ECU CAN COMMUNICATION LINE

EN01H16ZZZ110F03004009
1. Check the connection of the joint connector No.30_J/C and engine

ECU connector (Looseness and poor contact).
YES NO
step 2.
4. Select [Engine] and check if the DTC (U1001 or U110A) has been
detected.
SAPH16ZZZ1100121
Has the DTC (U1001 or U110A) been detected?
YES NO

drive.)
3 Check for disconnection in CAN H-line between No. 30_J/C and engine ECU (malfunction part
6)
A V36 2. Disconnect the No.30_J/C connector.

CA1H CA1H CA1L
%JM %JL %JJ 3. Connect the signal check harness to the engine ECU vehicle-side
CA1H CA1H
%JP %JN
CA1L
%JK connector (Do not connect harness to the ECU.).

No.30_J/C CA1H(%JN) terminal and the V36(CA1H) terminal in
the signal check harness (engine ECU).
Measurement Tester
SAPH16ZZZ1100122
Standard values
No.30_J/C – sig-
nal check harness
Starter switch:
(Engine ECU) 1  or less
LOCK
CA1H(%JN) –
V36(CA1H)
YES NO

line between No.30_J/C and engine ECU.
drive.)
4 Check for disconnection in CAN L-line between No. 30_J/C and engine ECU (malfunction part
6)

No.30_J/C CA1L(%JJ) terminal and the V16(CA1L) terminal in the
A V16
signal check harness (engine ECU).
CA1H CA1H CA1L
%JM %JL %JJ Measurement Tester
CA1H CA1H
Standard values
%JP %JN
CA1L
%JK conditions connections
No.30_J/C – sig-
nal check harness
Starter switch:
(Engine ECU) 1  or less
LOCK
CA1L(%JJ) –
V16(CA1L)
SAPH16ZZZ1100123

YES NO

line between No.30_J/C and engine ECU.
drive.)
5 Check for short-circuit in CAN H-line between No.30_J/C and engine ECU (malfunction part 6)
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ (Engine ECU) and the +24V(K9G) terminal in the DLC(16P)
A ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
connector.
(Engine ECU) and the SGND(K9H) terminal in the DLC(16P)
connector.
V36 Measurement Tester

Standard values
SAPH16ZZZ1100124 signal check har-

ness (Engine ECU)
– DLC(16P) con-
No Continuity
LOCK V36(CA1H) –
+24V(K9G)
V36(CA1H) –
SGND(K9H)
YES NO
Go to step 6. Short-circuit for CAN H-line +B/GND between

No.30_J/C and engine ECU.
drive.)
6 Check for short-circuit in CAN L-line between No.30_J/C and engine ECU (malfunction part 6)
+24V
K9G
CAN- TC
KS4 KS2
DSW
KPZ (Engine ECU) and the +24V(K9G) terminal in the DLC(16P)
A ISOK CAN+ SGND CGFR
K9E KS3 K9H L30
+
KE4
connector.
(Engine ECU) and the SGND(K9H) terminal in the DLC(16P)
connector.
V16
Measurement Tester
Standard values
SAPH16ZZZ1100125 Signal check har-

ness (Engine ECU)
– DLC(16P) con-
No Continuity
LOCK V16(CA1L) –
+24V(K9G)
V16(CA1L) –
SGND(K9H)
YES NO
Go to step 7. Short-circuit for CAN L-line +B/GND between

No.30_J/C and engine ECU.
drive.)
7 Inspect the engine ECU [HINO DX Ⅱ ]
1. Connect the No.30_J/C and engine ECU connector.
3. Select [Engine] and check if DTC U1001 or U110A has been

detected.
SAPH16ZZZ1100126
Has DTC U1001 or U110A been detected?
YES NO
Replace the engine ECU. Procedure completed.

drive.) drive.)
CONTROL CAN COMMUNICATION LINE

EN01H16ZZZ110F03005001
If any DTC of "CAN communication abnormal" is detected, carry out "PRE-INSPECTION FOR ENGINE CAN COMMUNI-
CATION LINE" first.
CONNECTION DIAGRAM (ALLISON AUTOMATIC TRANSMISSION)

EN01H16ZZZ110F03005002
Vehicle Control Combination

ECU meter
1 2 3 CAN_J/C 4
(Terminator) (Terminator)
5 6
Automatic transmission ECU Selector Diagnostic

(ALLISON) (ALLISON 3000, 3500) connector
SAPH16ZZZ1100127

(ALLISON AUTOMATIC TRANSMISSION)
EN01H16ZZZ110F03005003
Estimated mal-
function part
U0101, U0155 1, 2, 3, 4, 5 • Pre-inspection for CAN communication line.

U0155 1, 2, 3, 4 • Pre-inspection for CAN communication line.
• U0101
• No shift position is
indicating on the multi- 5 • Inspection for automatic transmission ECU CAN communication line.
information indicator
Indicate two or more "**

indication is stopped" or
"** abnormal" are indi-
1, 2, 3, 4, 5 • Pre-inspection for CAN communication line.
mation indicator
CONNECTION DIAGRAM (MANUAL TRANSMISSION)

EN01H16ZZZ110F03005004
Vehicle Control Combination

ECU Meter
1 CAN_J/C 2
(Terminator) (Terminator)
SAPH16ZZZ1100128

(MANUAL TRANSMISSION)
EN01H16ZZZ110F03005005
Estimated mal-
function part
U0155 1, 2 • Pre-inspection for CAN communication line.

Indicate two or more "**
indication is stopped" or
"** abnormal" are indi-
1, 2 • Pre-inspection for CAN communication line.
mation indicator
PRE-INSPECTION FOR CAN COMMUNICATION LINE

EN01H16ZZZ110F03005006
1 Inspect for +B/GND short-circuit in CAN H-line

VCAH +24V
SGND 2. Disconnect the connectors of following controllers that connected
to the control CAN line.
• Vehicle control ECU
• AT ECU (ALLISON)
• SELECTOR (ALLISON 3000, 3500)
ing terminals.
SAPH16ZZZ1100129 (1) Between the VCAH (L8B) terminal in the vehicle control ECU
vehicle-side connector (32P) and the +24V(K9G) terminal in
(2) Between the VCAH (L8B) terminal in the vehicle control ECU
vehicle-side connector (32P) and the SGND (K9H) terminal in
Measurement Tester
Standard values
Vehicle control
ECU vehicle-side
connector (32P) –
DLC(16P) connec-
Starter switch:
tor No Continuity
LOCK
VCAH(L8B) –
+24V(K9G)
VCAH(L8B) –
SGND(K9H)
YES NO

FOR CAN H-line", and inspect the CAN bus
line.
drive.)
2 Inspect for +B/GND short-circuit in CAN L-line
VCAL +24V ing terminals.
SGND (1) Between the VCAL(L8C) terminal in the vehicle control ECU
vehicle-side connector(32P) and the +24V(K9G) terminal in
(2) Between the VCAL (L8C) terminal in the vehicle control ECU
vehicle-side connector(32P) and the SGND(K9H) terminal in
Measurement Tester
Standard values
SAPH16ZZZ1100130 Vehicle control

ECU vehicle-side
connector(32P) –
DLC(16P) connec-
Starter switch:
tor No Continuity
LOCK
VCAL(L8C) –
+24V(K9G)
VCAL(L8C) –
SGND(K9H)
YES NO

FOR CAN L-LINE", and inspect the CAN bus
line.
drive.)
3 Inspect the combination meter (Terminator)

MMT- MMT+ terminals MMT+(E4L) and MMT-(E4M) in the combination meter
combination meter side connector(40P).
Measurement Tester
Standard values
Combination
meter combination
Starter switch: meter side con-
120   10 
LOCK nector (40P)
MMT+(E4L) – MMT-
SAPH16ZZZ1100131 (E4M)
YES NO
Go to step 4. Replace the combination meter.

drive.)
4 Inspect the vehicle control ECU (Terminator)

terminals VCAH(L8B) and VCAL(L8C) in the vehicle control ECU
vehicle control ECU side connector.
Measurement Tester
Standard values
VCAL
Vehicle control
VCAH ECU side connec-
Starter switch:
tor: 120   10 
LOCK
VCAH(L8B) –
VCAL(L8C)
SAPH16ZZZ1100132
YES NO
Go to step 5. Replace the vehicle control ECU.

drive.)
5 Inspect for the resistance of CAN line
1. Connect the connectors of the combination meter and the vehicle

VCAH VCAL control ECU.

terminals VCAH(L8B) and VCAL(L8C) of the vehicle control ECU
vehicle-side connector(32P).
Measurement Tester
Standard values
Vehicle control
ECU vehicle-side
Starter switch:
SAPH16ZZZ1100133 connector(32P) 45 – 75 
LOCK
VCAH(L8B) –
VCAL(L8C)
YES NO
Procedure completed. Refer to "DISCONNECTION INSPECTION

Refer to "CAN COMMUNICATION LINE MAL- FOR CAN H-line COMMUNICATION" , and
FUNCTION PART DETERMINATION TABLE" inspect the CAN bus line.
(for Allison automatic transmission , for Man- Perform After-inspection work. (Clear all past
ual transmission), and inspect detected DTC DTC. Check no DTC is stored after test
or Malfunction symptom. drive.)
drive.)
DISCONNECTION INSPECTION FOR CAN_H/L_COMMUNICATION LINE

EN01H16ZZZ110F03005007
1 Inspect for disconnection in the CAN bus line between the CAN_J/C and the vehicle control
ECU. (Automatic transmission: malfunction part 1, 2, 3. Manual transmission: malfunction
part 1)

CAN+(%BF) CAN-(%BR)
2. Disconnect the connectors of following controllers that connected
to the control CAN line. (Leave the combination meter and vehicle
control ECU connected.).
• AT ECU (ALLISON)
3. Disconnect the CAN_J/C connector.

SAPH16ZZZ1100134
terminals CAN+(%BF) (CAN H-line) and CAN-(%BR) (CAN L-line)
in the vehicle control ECU side connector of the CAN_J/C.
Measurement Tester
Standard values
CAN_J/C:
Starter switch:
CAN+(%BF) – 110  – 130 
LOCK
CAN-(%BR)
YES NO
Go to step 2. Disconnection or poor continuity in the CAN

bus line between the CAN_J/C and the vehi-
cle control ECU.
drive.)
2 Inspect for disconnection in the CAN bus line between the CAN_J/C and the combination
meter. (Automatic transmission: malfunction part 4. Manual transmission: malfunction part 2)

terminals CAN+(%BA) (CAN H-line) and CAN-(%BK) (CAN L-line)
CAN+(%BA) CAN-(%BK)
in the vehicle control ECU side connector of the CAN_J/C.
Measurement Tester
Standard values
CAN_J/C:
Starter switch:
CAN+(%BA) – 110  – 130 
LOCK
CAN-(%BK)
SAPH16ZZZ1100135
YES NO
Automatic transmission: Go to step 3. Disconnection or poor continuity in the CAN

Manual transmission: Connect all connec- bus line between the CAN_J/C and the com-
tors that disconnected, and check DTC bination meter.
again. Repair or replace the wire harness.
drive.) drive.)
3 Inspect for disconnection of the CAN bus line between the automatic transmission ECU and
the vehicle control ECU. (Automatic transmission: malfunction part 5.)

terminals CAN+(NXF) (CAN H-line) and CAN-(NXG) (CAN L-line)
CAN-(NXG) CAN+(NXF)
in the vehicle-side connector of the automatic transmission ECU.
Measurement Tester
Standard values
Automatic trans-
Starter switch: mission ECU:
110  – 130 
LOCK CAN+(NXF) –
CAN-(NXG)
SAPH16ZZZ1100136
YES NO
Procedure completed. Disconnection or poor continuity in the CAN

If any other DTC related to CAN communica- bus line between the automatic transmission
tion is detected, refer to "CAN COMMUNICA- ECU and the vehicle control ECU.
TION LINE MALFUNCTION PART Repair or replace the wire harness.
DETERMINATION TABLE" , and inspect the Perform After-inspection work. (Clear all past
detected DTC. DTC. Check no DTC is stored after test
drive.)
INSPECTION FOR SHORT-CIRCUIT IN CAN H-LINE

EN01H16ZZZ110F03005008
1 Inspect for short-circuit in CAN H-line between CAN_J/C and vehicle control ECU. (Automatic
transmission: malfunction part 1, 2, 3, 5, 6. Manual transmission: malfunction part 1)

+24V
CAN+ • AT ECU (ALLISON)
(%BF) • SELECTOR (3000, 3500)
ing terminals.
(1) Between the CAN+(%BF) terminal in the CAN_J/C connector
vehicle control ECU side and +24V(K9G) terminal in the
DLC(16P) connector.
(2) Between the CAN+(%BF) terminal in the CAN_J/C connector
SAPH16ZZZ1100137
vehicle control ECU side and SGND(K9H) terminal in the
DLC(16P) connector.
Measurement Tester
Standard values
CAN_J/C vehicle
control ECU side
connector –
DLC(16P) connec-
Starter switch:
tor No Continuity
LOCK
CAN+(%BF) –
+24V(K9G)
CAN+(%BF) –
SGND(K9H)
YES NO

CAN_J/C and vehicle control ECU.
drive.)
2 Inspect for short-circuit in CAN H-line between CAN_J/C and combination meter. (Automatic
transmission: malfunction part 4. Manual transmission: malfunction part 2)
+24V ing terminals.
SGND (1) Between the CAN+(%BA) terminal in the CAN_J/C connector
combination meter side and +24V(K9G) terminal in the
DLC(16P) connector.
(2) Between the CAN+(%BA) terminal in the CAN_J/C connector
CAN+
(%BA)
combination meter side and SGND(K9H) terminal in the
DLC(16P) connector.
Measurement Tester
Standard values
CAN_J/C connec-
tor combination
meter side –
DLC(16P) connec-
Starter switch:
tor No Continuity
LOCK
CAN+(%BA) –
+24V(K9G)
SAPH16ZZZ1100138
CAN+(%BA) –
SGND(K9H)
YES NO
Procedure completed. Short-circuit in CAN H-line +B/GND between

If any other DTC related to CAN communica- CAN_J/C and vehicle control ECU.
tion is detected, refer to "CAN COMMUNICA- Repair or replace the wire harness.
TION LINE MALFUNCTION PART Perform After-inspection work. (Clear all past
DETERMINATION TABLE" , and inspect the DTC. Check no DTC is stored after test
drive.)
INSPECTION FOR SHORT-CIRCUIT IN CAN L-LINE

EN01H16ZZZ110F03005009
1 Inspect for short-circuit in CAN L-line between CAN_J/C and vehicle control ECU. (Automatic
transmission: malfunction part 1, 2, 3, 5, 6. Manual transmission: malfunction part 1)

+24V
CAN- • AT ECU (ALLISON)
(%BR)
ing terminals.
(1) Between the CAN-(%BR) terminal in the CAN_J/C connector
vehicle control ECU side and +24V(K9G) terminal in the
DLC(16P) connector.
(2) Between the CAN-(%BR) terminal in the CAN_J/C connector
SAPH16ZZZ1100139
vehicle control ECU side and SGND(K9H) terminal in the
DLC(16P) connector.
Measurement Tester
Standard values
CAN_J/C vehicle
control ECU side
connector –
DLC(16P) connec-
Starter switch:
tor No Continuity
LOCK
CAN-(%BR) –
+24V(K9G)
CAN-(%BR) –
SGND(K9H)
YES NO
Go to step 2. Short-circuit in CAN H-line TB/GND between

CAN_J/C and vehicle control ECU.
drive.)
2 Inspect for short-circuit in CAN L-line between CAN_J/C and combination meter. (Automatic
transmission: malfunction part 4. Manual transmission: malfunction part 2)
+24V ing terminals.
SGND (1) Between the CAN-(%BK) terminal in the CAN_J/C connector
combination meter side and +24V(K9G) terminal in the
DLC(16P) connector.
(2) Between the CAN-(%BK) terminal in the CAN_J/C connector
CAN-
combination meter side and SGND(K9H) terminal in the
(%BK) DLC(16P) connector.
Measurement Tester
Standard values
CAN_J/C connec-
tor combination
meter side –
DLC(16P) connec-
Starter switch:
tor No Continuity
LOCK
CAN-(%BK) –
+24V(K9G)
SAPH16ZZZ1100140
CAN-(%BK) –
SGND(K9H)
YES NO
Procedure completed. Short-circuit in CAN L-line +B/GND between

If any other DTC related to CAN communica- the CAN_J/C and the vehicle control ECU.
tion is detected, refer to "CAN COMMUNICA- Repair or replace the wire harness.
TION LINE MALFUNCTION PART Perform After-inspection work. (Clear all past
DETERMINATION TABLE" , and inspect the DTC. Check no DTC is stored after test
drive.)
INSPECTION FOR AUTOMATIC TRANSMISSION ECU CAN COMMUNICATION

LINE
EN01H16ZZZ110F03005010
1 Inspect for disconnection in CAN H-line between automatic transmission ECU (ALLISON)
and vehicle control ECU. (Automatic transmission: malfunction part 5)

CAN+(NXF)
2. Disconnect the connectors of vehicle control ECU and automatic
transmission ECU.

VCAH(L8B) terminal in the vehicle control ECU vehicle-side con-
nector(53P) and the CAN+(NXF) terminal in the automatic trans-
VCAH mission ECU vehicle-side connector.
(L8B)
Measurement Tester
Standard values
Vehicle control
ECU vehicle-side
connector(53P) –
Starter switch: Automatic trans-
SAPH16ZZZ1100141 Less than 1 
LOCK mission ECU vehi-
cle-side connector
VCAH(L8B) –
CAN+(NXF)
YES NO

line between automatic transmission ECU
and vehicle control ECU.
drive.)
2 Inspect for disconnection in CAN L-line between automatic transmission ECU (ALLISON) and
vehicle control ECU. (Automatic transmission: malfunction part 5)

CAN-(NXG) VCAL(L8C) terminal in the vehicle control ECU vehicle-side con-
nector(53P) and the CAN+(NXG) terminal in the automatic trans-
mission ECU vehicle-side connector.
Measurement Tester
Standard values
VCAL Vehicle control

(L8B) ECU vehicle-side
connector(53P) –
Starter switch: Automatic trans-
Less than 1 
LOCK mission ECU vehi-
cle-side connector
VCAL(L8C) –
CAN-(NXG)
SAPH16ZZZ1100142
YES NO
Replace the automatic transmission ECU. Disconnection or poor continuity in CAN L-

Perform After-inspection work. (Clear all past line between automatic transmission ECU
DTC. Check no DTC is stored after test and vehicle control ECU.
drive.) Repair or replace the wire harness.
drive.)
Hino Motors Sales U.S.A., Inc.

41180 Bridge Street, Novi, MI 48375
Telephone: (248) 699-9300
PRINTED IN JAPAN
Pub.No. S7-UNAE13A 3/3 '15. 11

Printed in the U.S.A.

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book 1 ページ ２０１５年１１月６日 金曜日 午後７時４３分

Manual Name Pub. No.

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Production Code NE8J, NF8J, NJ8J, NV8J, NH8J

GENERAL INTRODUCTION 1-001

ENGINE CONTROL SYSTEM (J08E) 4-001

DEF SCR SYSTEM (DCU) 5-001

VEHICLE CONTROL SYSTEM (VCS) 11-001

CAN COMMUNICATION 12-001

This manual does not contain items on half-tone dot meshing.

INDEX: TROUBLE SHOOTING

TROUBLE SHOOTING - COMPONENTS

WORKSHOP ENGINE CONTROL SYSTEM (J08E)

MANUAL DEF SCR SYSTEM (DCU)

BRAKE CONTROL SYSTEM

VEHICLE CONTROL SYSTEM (VCS)

DEF SCR SYSTEM (DCU) 5–1

DEF SCR SYSTEM (DCU)

DEF SCR SYSTEM ......................................................5-2 DTC: P208C........................................................5-158

5–2 DEF SCR SYSTEM (DCU)

Symptom Related Diagnostic Procedures

DEF SCR SYSTEM

PRECAUTIONS FOR DIAGNOSIS

• Ensure that individual connectors are certainly connected before

DEF SCR SYSTEM (DCU) 5–3

1. ILLUSTRATION OF CONNECTOR AND MEASUREMENT ON

NUMBERING OF CONNECTOR TERMINALS

PRECAUTIONS FOR TERMINAL MEASUREMENT

ILLUSTRATION OF CONNECTOR AND

5–4 DEF SCR SYSTEM (DCU)

SYSTEM BLOCK DIAGRAM

Power source FUSE FUSE DEF heater relay

Coolant cut off valve drive signal

I Coolant cut off valve

O DEF pump motor drive signal

DEF pump temperature sensor 2

DEF line pressure sensor

DEF line with heater 1

T DEF tank temperature sensor 1

T DEF tank temperature sensor 2

DEF SCR SYSTEM (DCU) 5–5

0.50 B- %JQ (CANH)

CAN_J/C3 %JX 0.75 W- LEC L LEB

(CANL) (CANL) (GND)

A7R sensor 1 0.50 W-

Air flow sensor Common rail_

LCH 0.50 Y- R KTQ LCH

sensor 1.25 W-B

(CA1H) LCM #S5 #S5

(CA1L) LCN #S7 #S7

5–6 DEF SCR SYSTEM (DCU)

DEF tank SCR catalyst front exhaust gas

Bumper Ambient air temperature

DEF SCR SYSTEM (DCU) 5–7

SCR catalyst PM sensor

Coolant cut off NOx sensor 1

Wire harness Exhaust gas Exhaust gas

5–8 DEF SCR SYSTEM (DCU)

Exhaust gas temperature sensor 1

Coolant Injector Coolant

NOx sensor 1 Exhaust gas NOx sensor 2

book 1 ページ２０１５年１１月６日　金曜日　午後７時４３分