SB-10057506-3572

V O L U N T A R Y
SUBJECT:
DATE:
CAMPAIGN NO.:
AFFECTED MODELS:

C A M P A I G N

B U L L E T I N

Hybrid ECU Replacement
01-13-2015
AA030
Certain 2013-2015 Model Year COE Trucks equipped with a J05 engine

IMPORTANT:
Verify the vehicle requires the work to be performed by referencing the vehicle by VIN within the Hino
Warranty System (DCS).
CONDITION:
Hybrid vehicles may sometimes produce a perceptible level of vibration when the engine is activated. The
following procedure provides instruction for replacement of the HV ECU with an enhanced ECU which delays
the initial combustion until after the engine reaches a certain speed.

SUBJECT VEHICLES:
Certain 2013-2015 Model Year COE (Cab Over Engine) trucks with J05 engine that were assembled at the
Hamura, Japan plant.
NOTICE: Refer to the appropriate Vehicle Identification Number (VIN) list to determine vehicle eligibility.
BEFORE YOU BEGIN:
- Read and understand all instructions and procedures before you begin the work.
- Read and follow all WARNINGS and NOTICES set forth in this publication. These alerts help to avoid damage
to components, serious personal injury, or both.
- Park the vehicle on a level and solid surface and apply the parking brake.
- Place the gear shift lever in “Neutral” or “N”.
- Confirm the starter switch is in the off (LOCK) position, and the key is removed.
- Wear safety glasses to prevent eye injuries.
- Place wheel chocks in front of and behind all wheels.

PARTS:
PART NUMBER
G9100-37051
G9100-37041
G9100-37032
G9121-37010
75397-35010
75495-35010
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DESCRIPTION
CONTROLLER ASSY (2015MY)
CONTROLLER ASSY (2014MY)
CONTROLLER ASSY (2013MY)
GASKET
CLIP (ORANGE)
CLIP (BULE)

QUANTITY
1
1
1
1
3
2
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VEHICLE PREPARATION:

1. Park the vehicle on level ground.

2. Confirm the engine is stopped, the
ignition switch is in the off (LOCK) position,
and the key is removed.

3. Apply the parking brake.

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4. Chock all of the wheels.

HYBRID VEHICLE SERVICE PRECAUTIONS
WARNING: NEVER allow any technician who has not received COE hybrid vehicle training
from Hino Motor Sales USA, INC. to work on the Hino hybrid HV System. The hybrid HV
system contains a high voltage battery and high voltage circuits. Improper handling of these
components can result in serious injury or death due to electrical shock. Ensure that all work
is performed correctly and follows closely the procedures set forth within this publication.
1. Technicians performing maintenance or repair on the HV system must have previously received training on
the Hino COE Hybrid system.

2. Create a safety zone and surround the work area with orange cones to notify people in the area that high
voltage service is being performed. During work on the HV system, prominently display warning signs on all
sides of the vehicle which state “Caution High Voltage Work, Do Not Touch this Vehicle!” or words with similar
language.

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3. ALWAYS REMOVE any loose hanging badges, jewelry, bracelets, belts, wrist watches, or any metal item
prior to service of the HV system.
4. ALWAYS wear Hybrid specific, high voltage insulating gloves (Class 0 1000V), safety glasses, and insulated
shoes when performing maintenance or repair of the HV system.

5. NEVER use insulating gloves that have expired. Prior to each use of the insulating gloves,
confirm that the certification date, stamped on the gloves, is within 6 months of the current
usage date. The gloves need to be recertified after every six months of use by an approved
facility. Check the gloves for cracks, tears, or damage by rolling the gloves to check for air
leaks. Do not use any leaking gloves.
CAUTION: The leather portion of the glove must be worn over the red rubber portion of the
glove.

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6. Remove the 4 bolts and the service plug cover. Retain the bolts for reinstallation.

Bolts

Cover
7. Confirm that the ignition switch is in the off (LOCK) position and the key is removed. The
HV system service plug must be removed whenever the HV system is being serviced. See the
illustration below. ALWAYS wait a minimum of seven (7) minutes after the service plug has
been removed before beginning service on the HV system to allow the system time to power
down fully. Place the service plug in a secure location, which is out of sight, to prevent
someone from accidentally connecting it to the vehicle while service is being performed. For
safety, reinstall the service plug cover and retaining bolts while the service plug is removed
for service of the HV system.
CAUTION: NEVER turn the ignition switch to the “ON” position any time the service plug is
removed. This can result in damage to the vehicle’s electrical system and create fault codes.

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8. Disconnect the negative terminal of the
12 volt battery.

9. While performing service, ensure that
the work area is clear of all loose metal
objects such as socket extensions, bolts,
nuts, etc. which could cause HV circuits to
short circuit if dropped. ALWAYS use the
Hybrid Insulated Tool kit (No. ZTB311)
provided when working with HV circuits or
terminals. NEVER use other tools.

10. High voltage circuit harnesses are
colored ORANGE. NEVER touch the
connections of these high voltage circuits
unless required to do so.

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11. Remove the 4 push pin retainers from underneath the Hybrid battery unit and retain
for reinstallation.

12. Remove the 4 retaining bolts and the
terminal inspection cover and retain for
reinstallation.

Cover

Bolts

13. ALWAYS wear the hybrid-specific
insulating gloves before touching any high
voltage circuit, and verify that the voltage
on that circuit is at 0V (zero voltage) using a
Megger Meter. The meter is shown in the
photograph to the right. The Megger Meter
must be able to generate up to 1000V DC
and deliver a resistance value in Mega
ohms.

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14. Ground the Megger Meter to the
inverter case. Verify that the meter
operates properly on a 12V system prior to
performing any high voltage checks. This
will ensure proper operation of the meter.
NEVER use two hands to check voltage
readings. Using only one hand (the one
hand rule), check each terminal within the
inverter opening for any voltage on the 5
terminals. The Megger Meter should
indicate .01 volts or less on each terminal
and circuit.
WARNING: NEVER proceed with this service campaign if any voltage is present on the HV
circuits. Verify that all steps, above, have been performed as directed. If all steps were
performed as directed, connect the HV service plug and the 12 volt battery. Use the Hino
DXII to check for any DTC’s (Diagnostic Trouble Codes) and follow the diagnostics in the
Workshop Manual as needed.

REPAIR PROCEDURE
WARNING: Be certain that all steps of the Hybrid Vehicle Service Precautions procedure,
specified above, have been completed prior to performing this Repair Procedure. Failure
to properly perform the HV system service disconnect, and complete all steps of the
procedure, can result in personal injury or death due to electrical shock.

NOTICE: Hino COE Hybrids are offered in both single cab and crew cab form. The
photographs throughout this procedure will depict a single cab vehicle, but the removal
and installation procedure for crew cab vehicles will be similar.
DISASSEMBLY PROCEDURE
1. Remove the 6 bolts retaining the U, V, and W cables to the inverter and retain for
reinstallation. Remove the U, V, and W cables from the inverter.
WARNING: ALWAYS use the insulated tools and insulated gloves during this step. Such use
is required. Failure to wear high voltage safety gloves may result in personal injury or death
due to electrical shock.
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NOTICE: Only remove the U, V, and W cables. Do not remove the other 2 cables.

Bolts

Bolts

2. Remove the 2 clips that secure the
connector cover to the side of the PCU
(Power Control Unit) lower cover (towards
the front of the vehicle). Retain the clips for
reinstallation. Remove the cover.

Clips

3. Disconnect the 2 wire connectors under
the cover which was removed, above.

Connector
s
4. Remove the 3 bolts and 10 clips which secure the bottom cover of the PCU. Retain the
bolts and clips for reinstallation. Pull the bottom cover towards the outside of the vehicle to
release the remaining clips from the outboard side of the PCU. Remove and discard the 3
orange and 2 blue clips which retain the cover to the outboard side of the PCU.
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Bolts
PCU

Bottom
Cover

Clip
s

Discard
Clips

5. Support the PCU with a suitable jack and a piece of wood which will stabilize it. Once
secure, remove the 6 nuts which secure the PCU to the frame and retain for reinstallation.
Remove the PCU from the vehicle and have an assistant help set it on the ground.
WARNING: NEVER attempt to lift or move the PCU without an assistant. The PCU is very
heavy.

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Nuts

6. Disconnect the wire connector on the
inboard side of the PCU. Remove the
connector clip from the PCU (black harness).
Remove the wire harness clip from the PCU
(orange harness).

Clip

Connector

Clip

7. Remove the 4 nuts which secure the
terminal cover to the PCU. Remove the
terminal cover. Retain the nuts and cover for
reinstallation.

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Nuts

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Nuts

8. Remove the 2 nuts securing the HV cables
to the battery terminals and retain for
reinstallation. Remove the cables and
grommets from the PCU.

Grommet
s
9. Remove the vent tube from the clip.
Remove the vent tube and grommet from
the PCU.

Vent
Tube

Clip

Grommet

NOTICE: During this next step, do not remove the silver cover from the top of the HV
battery assembly; removal is not required. The HV battery should not be tilted on a steep
angle (or flipped over) to prevent the liquid gel inside of the battery cells from leaking out.
Note that there is a check valve on the bottom of the battery which can be damaged by
mishandling. Care must be taken not to damage the check valve when setting the battery
down.

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