ECU Diagnostics Software · (1) for the ECU. > Please refer to the User's Manual for the position of the connector in the vehicle. In the case of the universal system, the 4-pin connector

User's Manual

Diagnostics software(as of Version 2.1.12)

ECU Diagnostics Software

www.hjs.com

2

ContentGeneral information / Components and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

Installing the ECU diagnostics software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7

ECU Diagnostics Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 9

Diagnostics/Maintenance of the HJS-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12

Measured Data Evaluation of the HJS-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 14

Other HJS-ECU buttons / FAQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Diagnostics/Maintenance of the SCR dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 19

Measured Data Evaluation of the SCR dosing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

HJS-ECU Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 - 28

SCR dosing pump Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 - 31

Dear customer!The ECU (Electronic Control Unit) diagnostics software is requiredfor installing, servicing and troubleshooting with an exhaust-gas af-tertreatment system from HJS. With the aid of a commercially avai-lable laptop computer and a diagnostics cable, the diagnosticssoftware can be used to communicate with the HJS ECU of the DPF®

system or with the SCR dosing pump of a SCR/SCRT® system. Datacan be read out, commands given and actions executed. The pro-gram is split up into different modules for recording characteristicvalues and the procedures of putting the system into operation,maintenance and troubleshooting. This manual provides you withan overview of the main functions of the software.

In view of the fact that the software is the subject of continuous im-provement, certain points described in this manual may differslightly from the software version you are running on your compu-ter. No part of this document may be stored in a database or trans-mitted in any form (electronically, photomechanically or on a soundrecording medium) without the prior written permission of HJS Emis-sion Technology GmbH & Co. KG.

© 2017 HJS Emission Technology GmbH & Co. KG. All rights reserved.

We reserve the right to make technical changes.Date: 08/2017

The ECU diagnostics software of HJS Emission Technology GmbH & Co. KG is to be used solely in conjunction with HJS diesel particulate filter systems (DPF® systems) and HJS SCR/SCRT® systems! The latest version of the software can be downloadedfrom www.hjs.com.

SCR dosing pump

HJS-ECU

3

Components and accessories

> The following components are required to perform diagnostics onthe HJS ECU (together with a SMF®/CSMF diesel particulate filter system or SMF®-AR and FBC systems):• Commercially available PC running Windows XP, Windows Vista,Windows 7 or Windows 10

• ECU Diagnostics Software 2010 (Version 2.1.11 or higher)• ECU diagnostics kit, incl. diagnostics cable with serial connector (1)or USB connector (2).

In addition, the following components are required for diagnostics ona SCR/SCRT® system with SCR dosing pump:• UDA2 diagnostics kit, incl. Peak PCAN-USB (3) and adapter cable (4)

A number of functions of ECU Diagnostics Software 2010 require an activation key. Please contact Support. The driverfor the diagnostics cable with USB connector and a user guidewith installation hints can be found on the CD supplied.

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Prerequisites for using the ECU diagnostics software

PCCompatibility with Windows versions Windows XP, Windows Vista, Windows 7 and Windows 10Minimum screen resolution: 1024x768

HJS ECU for exhaust-gas aftertreatment systemsFor all systems based on the HJS ECU as of software release 0.10.157SMF®-AR, CRT®, FBC, SCRT®

HardwareDiagnostics cable: all versions

Software:Microsoft.Net 3.5

© 2010 Microsoft Corporation. All rights reserved. Microsoft, Windows, the Windows logo and Windows Vista and/or otherproducts from Microsoft are registered trademarks of Microsoft Corporation in the USA and/or other countries. All othernames used in this manual are trademarks or registered trademarks of the respective manufacturer. This document is in-tended solely for informational purposes. Subject to change with respect to product data, versions and availability.

General informationSafety instructions and warnings

These safety instructions must be observed for the sake ofyour own safety and the safety of others.

General instructions and additional pieces of informationmust be observed in order to prevent damage to the vehicle or the exhaust-gas aftertreatment system.

All work procedures with the HJS ECU diagnostics software must be carried out by qualified staff of a vehicle workshop.

The internal components of your electronics can becomedamaged by electrostatic discharges.

General information on ECU diagnostics

4

> The ECU diagnostics software requires Microsoft's.NET Framework as its runtime environment. This software package from Microsoft will in most cases already be installed on your PC. If not, you candownload the latest version from the Microsoft web-site free of charge.

The steps necessary to do this are describedin the relevant documentation from Microsoft.

> You are now ready to install the ECU diagnosticssoftware, which you do by double-clicking the"setup.exe" file (1) on the Installation CD. The latestversion of the software can also be downloaded fromHJS's website under Service & Customers / ECU Diag-nostics.

> An installation wizard (2) then navigates you throughthe steps to be followed.

During the installation process, a check ismade to see if a PEAK OEM driver is alreadyinstalled on the computer. If it is not installed,installation of the PEAK OEM driver is started.The work steps that follow must be observed!

If the PEAK OEM driver is installed on the computer, installation of the ECU diagnosticssoftware is completed and the software isready for use (see also end of this section).

Installing the ECU diagnostics software / Installing the PEAK OEM driver

The HJS system contains components (HJS ECU, HJS Service Unit, and sensors) that can be damaged or destroyed by electrostatic discharge (ESD). For thisreason, whenever handling components of the HJS system, always take the necessary precautionary measures against electrostatic discharge (ESD) as laiddown in EN 61340-5-1 and EN 61340-5-2. Always follow the ESD-related instructions when installing and putting the HJS system into operation, in orderto prevent damage to the unit and the entire system.

The internal components of your electronics can become damaged by electrostatic discharges. To prevent such damage from occurring, you must conduct static electricityout of your body by, for example, touching an uncoated metal surface before you touch electronic components of the system (e.g. cables). This measure of touching uncoa-ted metal surfaces must be repeated regularly while working on the system, in order to discharge static charges that may build up in the body in the interim periods. Mea-sures taken in the electronics themselves against static discharges and electrical fields are described in EN 61340-5-1. Please follow all instructions strictly.

General information

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2

A

B

C

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> We recommend that you do not connect the PCAN-USB adapter until after the driver has been installed.

> The Windows operating system indicates that it hasfound new hardware and depending on the version ofWindows you are running, starts an installation wizard. If necessary, confirm the steps for initialisingthe driver.

> Starting installation

Installing the ECU diagnostics software

> Accepting the license agreement

> Selecting the destination directory

6

> Prompt for starting installation

> Driver installation

> Selecting the driver to install

Please select only the PCAN-USB driver (1) asillustrated. Selecting one of the other driverslisted can lead to failure of the installationroutine! 1

7

> Once installed, you can start the ECU diagnosticssoftware either from the icon on the desktop or fromPrograms after clicking the Start button.

> Finishing driver installation

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ECU Diagnostics SoftwareFirst steps> When you start the ECU diagnostics software, thestart screen of the user interface appears on the monitor (1). This start screen lets you reach all the software modules required. By clicking the [Home]button (2) in the top toolbar, you can return to this startscreen whenever you want. Clicking the [Back] button(3) will display the last screen you used.

> Before you use the ECU diagnostics software for thefirst time, you have to make a number of basic settingsvia the [Settings] button (4). You can switch betweenthe HJS ECU and SCR dosing pump diagnostics modules by means of the two tabs (5) at the bottom ofthe screen [HJS-ECU] and [SCR dosing pump].

Port> The first setting to make is to select the COM port (1)to be used. If the computer is already connected to theECU by the HJS diagnostics cable and the vehicle's ignition is on, you can also use the automatic searchfunction (2). If not, you have to select the COM port orvirtual COM port of the USB-RS232 adapter.

Language> The language used by the ECU diagnostics software ischosen automatically based on the system language setin your computer. Optionally, you can select a differentlanguage here (3).

Path for temporary files> All temporary files generated by the ECU diagnosticssoftware are saved to this path (1). This path can bechanged if necessary.

Simulation mode> Under (2) the diagnostic software can be used in simulation mode.

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9

Activation key, step 1:> For safety reasons, you can only access basic functions in the ECU diagnostics software if you havenot registered it. Functions such as measured data evaluation and maintenance mechanisms are not supported until the software has been registered andactivated. You register the software by clicking the [Askfor the activation key] button (1).

1

Activation key, step 3:> Once you have entered the activation key (1), all necessary functions the software offers are availablefor you to use.

> Click the [OK] button (2) to complete registration.

Activation key, step 2:> All registration fields have to be filled in correctlyfor registration to be successful.

> After filling in the necessary details for registration,you then have to contact the sales partner responsibleby e-mail, phone or fax in order to request an activation key.

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10

This section of the User's Manual relates to diagnostics/maintenance of the HJS ECU madeby HJS Emission Technology GmbH & Co KG.

You can switch between the HJS ECU and SCR dosingpump diagnostics modules by means of the two tabs (1)at the bottom of the screen [HJS-ECU] and [SCR dosing pump].> The [Diagnostics / Maintenance] module (2) is intended specifically for diagnosis and maintenance purposes.

This module can only be used once the PC hasbeen connected to an HJS ECU by means of theHJS diagnostics cable and the vehicle's ignitionhas been switched on.

Connecting the diagnostics software tothe ECU> The cable harness includes the diagnostics connector(1) for the ECU.

> Please refer to the User's Manual for the position ofthe connector in the vehicle.

In the case of the universal system, the 4-pinconnector on the display module (2) also serves as the diagnostics connector.

> Make the connection between the PC and the diagnostics port using the diagnostics cable with serialconnector (3) or USB connector (4).

> Make the connection between the ECU diagnosticssoftware and the ECU.

> Switch on the ignition of the vehicle and start the diagnostics program.

> In the case of systems with a display module integrated, the plug connection has to be disconnectedfirst in order to connect the HJS diagnostics cable.

Diagnostics/Maintenance of the HJS ECU

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3

4

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11

> Click the [Diagnose / maintenance] button (1). Thesoftware now connects to the HJS ECU. This step maytake a few seconds.

Maintenance> The [Maintenance] module (1) lets you confirmthat a filter cleaning operation or additive service hasbeen carried out. The details of these operations are described in the maintenance documentation suppliedwith your system.

Diagnostics via "System Behaviour"> The [System behaviour]module (1) enables you toanalyse all aspects of your system's behaviour.

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2 3

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4

5

6

12

> How the various commands function depends on the HJS systemconnected. With some systems, certain commands may be inactive.

> The following real-time information is displayed:(1) Instantaneous system data (actual values that are displayed

graphically when selected)(2) Instantaneous error (or errors that were active) in HJS system(3) Instantaneous system behaviour

> The button on the right-hand side (4) can be used to send specific system commands to the HJS ECU.

> The [Export / printing] function (5) lets you generate an overview of the system's behaviour (as a PDF). This information isnecessary in order, among other things, to be able to offer the bestpossible support in the case of a complaint or a request for support.

> For all shown errors further information to the possible root causes as well as recommendations for counter actions can be foundat the (6) guided troubleshooting.

> The configuration number (7) can be used to determine the setexhaust gas aftertreatment technology and the additive used. Numbers outside this range are customer-specific configurations.

> Pressing the [Home] button in the top toolbar will take you backto the start screen.

Diagnostics/Maintenance of the HJS ECU

Technology Additive type CFG-No.-area

SMF-AR/ IKD

F51 1000 - 1999

DT8 20000 - 22000

DT8i 18000 - 19999

FBC

F51 253 - 254

DT8 353 - 354

DT8i 475 - 476

13

This section of the User's Manual relates tomeasured data evaluation of the HJS ECU madeby HJS Emission Technology GmbH & Co KG.

> The [Measured Data Evaluation] module (1) letsyou read and evaluate the system data stored in the HJSECU (logger function).

You require an activation key to be able to select and use this function.

Measured Data Evaluation of the HJS ECU

> By clicking the [Load data from file] button (1),you can retrieve data stored on the PC and display the evaluation of these data.

> The [Load data from ECU] button (2) enables youto load the measured data from the HJS ECU connected. The vehicle's ignition must be switched onfor this function. This procedure can take up to 15 minutes

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14

Measured Data Evaluation of the HJS ECU

> This screen has a similar setup and layout to the "System Behaviour" screen. The various tabs in the centre section allowyou to view the following system parameters:(1) Instantaneous error in the HJS system(2) Fault memory (error history)(3) Instantaneous system behaviour

> You can sort the order in which the entries are displayed by selecting one of the columns in the area above the table markedblue. > The left-hand section of the screen lets you select the systemdata recorded by the HJS ECU (4) and display them in the formof a graph. You can choose from a number of options on whichto base how the data are visualised, e.g. according to time.

> The bottom section (5) of the screen contains the graph orgraphs you select. The [Statistics] tab (6) also enables you todisplay characteristic values, such as a mean value or frequencydistribution, in addition to the system data selected. A zoomfunction also allows you to analyse the data more closely.

> Clicking the [Save] button (7) on the right-hand side saves themeasured data to a file. This information is necessary in order,among other things, to be able to offer the best possible supportin the case of a complaint or a request for support.

> The [Print] button (8) lets you generate an overview of the sys-tem's behaviour (as a PDF).

> Pressing the [Home] button in the top toolbar will take youback to the start screen.

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5

7

8

6

15

> All modules can also be started at any time via theicons in the toolbar. You require an activation key to beable to select and use these modules.

> Many of the functions of the software are explainedon the screen by a tooltip that appears when you holdthe mouse over the button or icon for a few seconds.

Why does the software have to be activated?> The software is capable of making changes to the HJS ECU and the exhaust-gas aftertreatment system. In extreme cases, this could lead to malfunctioning of the system. To ensure that only appropriately trained per-sons perform such actions, these functions can only be used once the soft-ware has been activated.

How do I know which COM port I have to use?> The easiest way is to connect your computer and to use the automatic COMport search function in the "Settings" module. If this doesn't work, pleasecheck whether the USB adapter is properly installed and connected to theright USB port, or whether a different application has been assigned to theCOM port.

[Read-out all data] (1)> This button executes a function that reads out all datafrom the ECU and the SCR dosing pump. A correspondingwarning appears if no SCR dosing pump is connected.

[Applications] (2)> The [Applications] module (2) is required for setting up modular DPF® systems. Instructions on how touse this module can be found in the respective system documentation.

[Firmware Upgrade] (3)> This wizard can be used to install a firmware upgrade forthe HJS ECU. The wizard guides the user through the HJSECU software update.

Other buttons

Notes FAQ

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This section of the User's Manual relates to diagnostics/maintenance of the SCR dosingpump (1) of SCR/SCRT® systems made by HJSEmission Technology GmbH & Co KG.

Diagnostics/Maintenance of the SCR dosing pump

You can switch between the HJS ECU and SCR dosingpump diagnostics modules by means of the two tabs (4)at the bottom of the screen [HJS-ECU] and [SCR dosing pump].

This module can only be used once the PC hasbeen connected to an HJS ECU by means of theHJS diagnostics cable and the vehicle's ignitionhas been switched on.

The software is to be put to use whenever the yellowindicator lamp (3) lights up constantly and "SCR error"appears on the display of the HJS ServiceCheck displaymodule (2).

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Error 41SCR error

Menu Ok

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Overview of functions

A corresponding warning appears if no SCRdosing pump is connected.

> Simple command control during maintenance or di-agnostic [Diagnostic / Maintenance] (1)

> Simple evaluation function for the internal fault memory [Data Evaluation] (2)

> By clicking [Read Out All Data] (3), you can read outall relevant HJS ECU and SCR dosing pump data in order,for example, to provide assistance and technical sup-port quickly.

> [Settings] (4)

Connecting the diagnostics software tothe SCR dosing pump> To be able to use the diagnostics software for the SCR dosing pump, the PCAN-USB (1) must be connected to the computer. Using the adapter cable (2)SCR Logger CAN Diagnostics, connect the PCAN-USB tothe CAN bus diagnostics connector in the HJS cable harness (5-pin connector; see cable harness diagram inthe vehicle-specific Installation Instructions manual).

> The vehicle's ignition must be switched on before diagnostics can begin.

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> A clear display of the measured values, active faults, productionparameters of the pump and of the internal fault memory, withintegrated report function.

> How the various commands function depends on the HJS system connected. With some systems, certain commands maybe inactive.

> The following real-time information is displayed:

(1) Instantaneous system data (2) Instantaneous error (or errors that were active) in HJS sys-

tem (3) Basic data of the AdBlue® dosing pump 2013

Diagnostics/Maintenance of the SCR dosing pump

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Diagnostics/Maintenance of the SCR dosing pumpMaintenance

> The entering of commands during maintenance workis prompted by means of simple wizards.

The following control element tests are available: Valve Test (air valve)Tank Heater TestLine Heater Test Flow Test (pump)NOx Test Dosing Test

For example:

Valve Test (air valve)

20

> A clear display of the measured values, active faults, productionparameters of the pump and of the internal fault memory.

> How the various commands function depends on the HJS sys-tem connected. With some systems, certain commands may beinactive.

> The following real-time information is displayed:

(1) Instantaneous system data(2) Basic data of the AdBlue® dosing pump 2013

> You can switch between the active errors and the internal faultmemory by means of the two tabs (3).

> You can generate a report by clicking button (4) and updatethe contents by clicking button (5).

Measured Data Evaluation of the SCR dosing pump

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5

21

HJS ECU Fault List

SMF-

AR

®FB

CC

RT

SCR

SCR

T®N

o.Ta

sk N

o.R

un.N

o.D

escr

iptio

nPo

ssib

le C

ause

of F

ault

Test

Ste

psFa

ult R

ectif

icat

ion

xx

xx

x1)

Sho

rt ci

rcui

t to

grou

nd1)

Tes

t wire

s to

gro

und.

Dis

conn

ect c

onne

ctor

s fro

m E

CU

and

tank

sen

sor

1) T

est w

ire a

nd re

pair

if ne

c.

2) T

ank

sens

or s

hort-

circ

uite

d to

gro

und

2) C

heck

tank

sen

sor

2) R

epai

r tan

k se

nsor

in a

cc. w

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anuf

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rer's

spe

cific

atio

ns3)

Ope

n ci

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t in

wiri

ng3)

Dis

conn

ect c

onne

ctor

s fro

m E

CU

and

tank

se

nsor

and

che

ck w

ire fo

r con

tinui

ty3)

Tes

t wire

and

repa

ir if

nec.

4) L

oose

con

tact

or p

oor c

onta

ct a

t con

nect

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ank

sens

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igna

l fro

m v

ehic

le4)

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ck c

onne

ctor

s/w

iring

of t

ank

sens

or4)

Rep

lace

plu

g co

nnec

tors

if n

ec.

xx

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nd1)

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t wire

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and

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1) T

est w

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CU

and

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se

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and

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ty

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CU

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and

che

ck w

ire fo

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tinui

ty

3) T

est w

ire a

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pair

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c.

4) L

oose

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onne

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of t

ank

sens

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lace

plu

g co

nnec

tors

if n

ec.

xx

xx

x1)

Add

itive

tank

em

pty

1) C

heck

fill

leve

l of a

dditi

ve ta

nk1)

Top

up

addi

tive

and

vent

line

(usi

ng E

CU

di

agno

stic

s so

ftwar

e or

Ser

vice

Che

ck)

2) S

uppl

y lin

e be

twee

n ta

nk a

nd p

ump

defe

ctiv

e2)

Che

ck li

nes

betw

een

addi

tive

tank

, add

itive

filte

r a n

d do

sing

pum

p2)

Che

ck li

nes

and

filte

r and

repa

ir if

nec.

Top

up a

dditi

ve a

nd v

ent l

ines

(usi

ng E

CU

di

agno

stic

s so

ftwar

e or

Ser

vice

Che

ck)

3) F

ault

in E

CU

3) A

scer

tain

ser

ial n

umbe

r and

so

ftwar

e/co

nfig

urat

ion

vers

ions

and

con

tact

HJS

3) R

epla

ce E

CU

if n

ec.

xx

xx

x1)

Sho

rt ci

rcui

t in

dosi

ng w

ire1)

Che

ck w

ires

betw

een

HJS

EC

U a

nd d

osin

g pu

mp

for c

ontin

uity

1) T

est w

ire a

nd re

pair

if ne

c.

2) S

hort

circ

uit i

n pu

mp

2) C

onne

ct re

plac

emen

t pum

p, im

plem

ent 2

0 do

sing

pul

ses

and

chec

k w

heth

er fa

ult s

till p

rese

nt2)

Inst

all n

ew d

osin

g pu

mp

3) E

lect

rical

def

ect i

n pu

mp

3) C

heck

resi

stan

ce o

f dos

ing

pum

pW

ith a

12V

dos

ing

pum

p, re

sist

ance

mus

t be

betw

een

4 an

d 7

ohm

s.W

ith a

24V

dos

ing

pum

p, re

sist

ance

mus

t be

betw

een

17 a

nd 2

5 oh

ms.

Impl

emen

t dos

ing

puls

es m

anua

lly b

y m

eans

of

EC

U d

iagn

ostic

s so

ftwar

e (m

in. 3

0 pu

lses

) and

ch

eck

dosi

ng p

ump

is fu

nctio

ning

pro

perly

3) R

epla

ce d

osin

g pu

mp

if ne

c.

4) F

ault

in E

CU

4) A

scer

tain

ser

ial n

umbe

r and

so

ftwar

e/co

nfig

urat

ion

vers

ions

and

con

tact

HJS

4) R

epla

ce E

CU

if n

ec.

3 4 5 1

2, 1

2

Faul

t:A

ir m

eter

ed

Faul

t: Ta

nk s

enso

r sig

nal

22

Faul

t: Ta

nk s

enso

r sig

nal

55

Faul

t: D

osin

g sy

stem

32

Faul

t: Ta

nk s

enso

r sig

nal

12

45

x

xx

xx

xxx

xx

22

HJS ECU Fault ListSM

F-A

R®

FBC

CR

TSC

RSC

RT®

No.

Task

No.

Run

.No.

Des

crip

tion

Poss

ible

Cau

se o

f Fau

ltTe

st S

teps

Faul

t Rec

tific

atio

n

xx

xx

x1)

Add

itive

line

from

pum

p to

T-p

iece

has

bl

ocka

ge1)

Che

ck w

heth

er li

ne fr

om p

ump

to T

-pie

ces

is

bloc

ked

1) C

heck

line

and

repa

ir if

bloc

ked

2) A

dditi

ve p

ump

defe

ctiv

e2)

Rem

ove

conn

ectin

g ho

se b

etw

een

addi

tive

p um

p an

d T-

piec

e on

pum

p. M

ake

sure

add

itive

is

deliv

ered

by

dosi

ng m

anua

lly b

y m

eans

of H

JS

EC

U

2) If

no

addi

tive

is d

eliv

ered

, rep

lace

pum

p

3) A

dditi

ve p

ump

conn

ecte

d to

fuel

sup

ply

line

3) C

onne

ct d

osin

g pu

mp

to fu

el re

turn

line

1) E

lect

rical

def

ect i

n pu

mp

1) Im

plem

ent d

osin

g pu

lses

man

ually

by

mea

ns o

f E

CU

dia

gnos

tics

softw

are

(min

. 30

puls

es) a

nd

chec

k do

sing

pum

p is

func

tioni

ng p

rope

rly

1) R

epla

ce d

osin

g pu

mp

if ne

c.

2) T

ry u

sing

an

inco

rrec

t dos

ing

pum

p (1

2V

inst

ead

of 2

4V, o

r vic

e ve

rsa)

2) C

heck

on-

boar

d po

wer

sup

ply

syst

em a

nd

com

pare

with

dos

ing

pum

p us

ed2)

Rep

lace

dos

ing

pum

p if

nec.

xx

xx

x

xx

85

10Ev

ent:

Add

itive

on

rese

rve

Add

itive

tank

is a

lmos

t em

pty

Visu

al c

heck

on

addi

tive

leve

l in

addi

tive

tank

Car

ry o

ut m

aint

enan

ce w

ork

as d

escr

ibed

in

Use

r's M

anua

lx

xx

xx

1) E

lect

rical

def

ect i

n pu

mp

1) C

heck

resi

stan

ce o

f dos

ing

pum

pW

ith a

12V

dos

ing

pum

p, re

sist

ance

mus

t be

betw

een

4 an

d 7

ohm

s.W

ith a

24V

dos

ing

pum

p, re

sist

ance

mus

t be

betw

een

17 a

nd 2

5 oh

ms.

Impl

emen

t dos

ing

puls

es m

anua

lly b

y m

eans

of

EC

U d

iagn

ostic

s so

ftwar

e (m

in. 3

0 pu

lses

) and

ch

eck

dosi

ng p

ump

is fu

nctio

ning

pro

perly

1) R

epla

ce d

osin

g pu

mp

if ne

c.

2) E

CU

def

ectiv

e2)

Asc

erta

in s

eria

l num

ber a

nd

softw

are/

conf

igur

atio

n ve

rsio

ns a

nd c

onta

ct H

JS2)

Rep

lace

EC

U if

nec

.

xx

xx

x1)

Fau

lt in

wiri

ng to

dos

ing

pum

p1)

Che

ck w

ires

betw

een

EC

U a

nd d

osin

g pu

mp

for

cont

inui

ty1)

Tes

t wire

and

repa

ir if

nec.

2) D

efec

tive

dosi

ng p

ump

2) C

heck

dos

ing

pum

p fo

r con

tinui

ty u

sing

m

ultim

eter

2) If

no

cont

inui

ty, r

epla

ce d

osin

g pu

mp

xx

xx

x1)

Sho

rt ci

rcui

t to

grou

nd1)

Tes

t wire

s to

gro

und.

Dis

conn

ect c

onne

ctor

s fro

m E

CU

and

tank

sen

sor

1) T

est w

ire a

nd re

pair

if ne

c.

2) T

ank

sens

or s

hort-

circ

uite

d to

gro

und

2) C

heck

tank

sen

sor

2) R

epai

r tan

k se

nsor

in a

cc. w

. m

anuf

actu

rer's

spe

cific

atio

ns3)

Ope

n ci

rcui

t in

wiri

ng3)

Dis

conn

ect c

onne

ctor

s fro

m E

CU

and

tank

se

nsor

and

che

ck w

ire fo

r con

tinui

ty

3) T

est w

ire a

nd re

pair

if ne

c.

4) L

oose

con

tact

or p

oor c

onta

ct a

t con

nect

or

for t

ank

sens

or s

igna

l fro

m v

ehic

le4)

Che

ck c

onne

ctor

s/w

iring

of t

ank

sens

or4)

Rep

lace

plu

g co

nnec

tors

if n

ec.

xx

xx

x

x12

92,

3Fa

ult:

CA

N b

us

1) C

onta

ct p

robl

ems/

shor

t circ

uit/o

pen

circ

uit

in C

AN

bus

con

nect

ion

from

veh

icle

to H

JS

EC

U.

2) W

iring

faul

ty: C

AN

hig

h/C

AN

low

mis

take

nly

swap

ped

over

(pin

66

yello

w/w

hite

and

pin

86

yello

w)

3) C

onta

ct p

robl

ems/

shor

t circ

uit/o

pen

circ

uit

in C

AN

bus

con

nect

ion

Afte

rtrea

tmen

t CA

N

Bus

of E

FS to

HJS

EC

U.

Wiri

ng fa

ulty

: CA

N h

igh/

CA

N lo

w m

ista

kenl

y sw

appe

d ov

er (p

in 1

ora

nge/

whi

te a

nd p

in 2

or

ange

)

1) C

heck

con

nect

ion

betw

een

EC

U a

nd C

AN

te

rmin

al, i

nclu

ding

plu

g co

nnec

tion

2) C

heck

pla

usib

ility

of a

ctua

l val

ues.

Spe

ed a

nd/o

r ta

nk le

vel d

epen

ding

on

syst

em3)

Che

ck w

heth

er 2

term

inat

ing

resi

stor

s (2

-pin

co

nnec

tor w

ith re

d cl

osur

e ca

p) a

re c

onne

cted

to

EC

U a

nd in

vic

inity

of s

enso

r

1) T

est w

ire a

nd c

onne

ctor

and

repa

ir if

nec.

2) In

stal

l ter

min

atin

g re

sist

ors

xx

xx

x

x13

187

Even

t: Em

erge

ncy

rege

nera

tion

Filte

r mon

itorin

g ev

ent

No

faul

tx

xx

xx

x14

181

Even

t: Fi

lter l

oadi

ngFi

lter m

onito

ring

even

tN

o fa

ult

75

Faul

t: D

osin

g sy

stem

11

Faul

t: D

osin

g sy

stem

510

2Fa

ult:

Tank

sen

sor s

igna

l

9 6, 7

95

Faul

t: D

osin

g sy

stem

65

Faul

t: D

osin

g sy

stem

4 5, 6 8

xx

xx

xx

xx

xx

23

SMF-

AR

®FB

CC

RT

SCR

SCR

T®N

o.Ta

sk N

o.R

un.N

o.D

escr

iptio

nPo

ssib

le C

ause

of F

ault

Test

Ste

psFa

ult R

ectif

icat

ion

xx

xx

x

x15

189

Even

t: R

egen

erat

ion

inte

rlock

Filte

r mon

itorin

g ev

ent

No

faul

tx

xx

xx

1

1) F

ault

in w

iring

or s

enso

r def

ectiv

e (P

ossi

ble

open

circ

uit)

2

2) F

ault

in w

iring

or s

enso

r def

ectiv

e (P

ossi

ble

shor

t circ

uit)

xx

xx

x

x17

176

Even

t: D

PFFi

lter m

onito

ring

even

tN

o fa

ult

xx

xx

x1)

On-

boar

d su

pply

vol

tage

low

1) C

heck

on-

boar

d su

pply

vol

tage

,if

nec.

car

ry o

ut m

anua

l reg

ener

atio

n (2

4-ho

ur

pass

wor

d is

requ

ired

for E

CU

sof

twar

e ve

rsio

n 0.

10.1

73 a

nd lo

wer

) and

mon

itor o

pera

ting

volta

ge

at ra

ted

spee

d by

mea

ns o

f EC

U d

iagn

ostic

s so

ftwar

e. V

alue

sho

uld

not f

all b

elow

11.

5V/2

4V

1) R

epla

ce b

atte

ry a

nd/o

r alte

rnat

or if

nec

.

2) V

olta

ge d

ip in

on-

boar

d su

pply

sys

tem

w

hen

star

ting

engi

ne (s

tarte

r).

2) S

witc

h on

igni

tion

and

chec

k w

heth

er fa

ult

d ete

cted

aga

in2)

If o

n-bo

ard

supp

ly v

olta

ge b

elow

13V

w

hen

idlin

g ->

trou

bles

hoot

: rep

lace

bat

tery

an

d/or

alte

rnat

or if

nec

.x

xx

xx

xx

1925

7Ev

ent:

SCR

dos

ing

syst

em

activ

eN

o fa

ult

xx

xx

x

x20

1012

Even

t: Fi

lter l

oadi

ngFi

lter m

onito

ring

even

tN

o fa

ult

xx

xx

x

x21

103,

8SM

F®-A

R s

yste

ms:

Even

t: Pr

essu

re s

enso

rFi

lter m

onito

ring

even

tN

o fa

ult

xx

xx

x

xx

2119

10, 2

1C

RT

syst

ems:

Faul

t: Pr

essu

re s

enso

r

1) F

ault

aver

agin

g di

ffere

ntia

l pre

ssur

e C

heck

wiri

ng o

f diff

eren

tial p

ress

ure

sens

or a

nd

s ens

or it

self.

Use

EC

U d

iagn

ostic

s so

ftwar

e to

ch

eck

plau

sibi

lity

of d

iffer

entia

l pre

ssur

e va

lue

1) R

epla

ce w

iring

and

/or r

epla

ce s

enso

r if

nec.

xx

xx

x

x22

143

Even

t: R

egen

erat

ion

Filte

r mon

itorin

g ev

ent:

rege

nera

tion

is/h

as

been

car

ried

out

No

faul

tx

xx

xx

x23

101

Even

t: M

onito

r ave

ragi

ngFi

lter m

onito

ring

even

tN

o fa

ult

xx

xx

x

x24

104

Even

t: Fi

lter l

oadi

ngFi

lter m

onito

ring

even

tN

o fa

ult

1) C

heck

wiri

ng fo

r sho

rt ci

rcui

t/ope

n ci

rcui

t or

repl

ace

sens

or if

nec

.

Faul

t: C

harg

e-ai

r pre

ssur

e op

en c

ircui

t/sho

rt c

ircui

t

1815

Faul

t: H

eate

rx

26

17

1) C

heck

ope

ratio

n us

ing

EC

U d

iagn

ostic

s so

ftwar

e. A

pla

usib

le c

harg

e-ai

r pre

ssur

e va

lue

mus

t be

disp

laye

d in

"Act

ual V

alue

s" ta

b w

hile

en

gine

is ru

nnin

g.If

read

ing

for c

harg

e-ai

r pre

ssur

e is

"sho

rt" o

r ru

nnin

g nu

mbe

r of e

rror

= 2

, the

re is

pro

babl

y a

shor

t circ

uit i

n w

iring

.If

read

ing

for c

harg

e-ai

r pre

ssur

e is

"ope

n" o

r ru

nnin

g nu

mbe

r of e

rror

= 1

, the

re is

pro

babl

y an

op

en c

ircui

t (w

ire b

reak

) in

wiri

ng.

xx

16

HJS ECU Fault List

24


F-A

R®

FBC

CR

TSC

RSC

RT®

No.

Task

No.

Run

.No.

Des

crip

tion

Poss

ible

Cau

se o

f Fau

ltTe

st S

teps

Faul

t Rec

tific

atio

n

xx

xx

x1)

Mis

sing

or d

efec

tive

earth

ing

stra

p1)

Che

ck w

heth

er e

arth

ing

stra

p is

fitte

d. C

heck

for

good

con

tact

to fi

lter a

nd v

ehic

le b

odyw

ork

1) In

stal

l ear

thin

g st

rap.

Che

ck c

onta

ct

resi

stan

ce to

filte

r and

bod

ywor

k

157,

14

2) H

eate

r circ

uits

def

ectiv

e2)

Car

ry o

ut m

anua

l reg

ener

atio

n (p

assw

ord

is

requ

ired

for E

CU

sof

twar

e ve

rsio

n 0.

10.1

73 a

nd

low

er),

mon

itor h

eatin

g ou

tput

and

hea

ting

curr

ent

of th

e tw

o he

ater

circ

uits

at r

ated

spe

ed b

y m

eans

of

EC

U d

iagn

ostic

s so

ftwar

e an

d ch

eck

plau

sibi

lity

(cur

rent

of h

eate

rs s

houl

d be

bet

wee

n 28

A an

d

54A

with

a 1

2V o

n-bo

ard

supp

ly s

yste

m (3

3A to

60A

w

ith 2

4V o

n-bo

ard

supp

ly s

yste

m) a

nd ro

ughl

y th

e sa

me

for b

oth

heat

ing

circ

uits

). If

this

err

or is

set

w

ith ru

nnin

g no

. = 7

, hea

ting

circ

uit A

is a

ffect

ed

(wiri

ng c

olou

r red

); in

cas

e of

runn

ing

no. =

14,

he

atin

g ci

rcui

t B is

affe

cted

(wiri

ng c

olou

r blu

e)

2) R

epla

ce fi

lter m

odul

e if

nec.

3) S

trong

ele

ctric

al in

terfe

renc

es

(ele

ctro

plat

ing

shop

, etc

.)3)

Sam

e as

2)

3) C

hang

e ro

utin

g of

hig

h-cu

rren

t lin

e b e

twee

n fil

ter

and

EC

Ux

xx

xx

1) H

eate

r fus

e (1

00A

) def

ectiv

e1)

Che

ck fu

se a

nd p

ower

lead

from

bat

tery

to E

CU

1) R

epla

ce fu

se.

I f le

ad is

def

ectiv

e, re

plac

e ca

ble

harn

ess

2) O

pen

circ

uit/s

hort

circ

uit i

n he

ater

pow

er

lead

2) C

heck

con

nect

ion

betw

een

HJS

EC

U a

nd

heat

er, i

nclu

ding

plu

g co

nnec

tion

2) If

lead

is d

efec

tive,

repl

ace

cabl

e ha

rnes

s

xx

xx

x1)

Ope

n ci

rcui

t/sho

rt ci

rcui

t in

heat

er p

ower

le

ad1)

Che

ck e

arth

ing

stra

p at

filte

r. C

heck

pow

er le

ad

betw

een

EC

U a

nd h

eate

r for

sho

rt ci

rcui

t and

co

ntin

uity

1) R

epla

ce e

arth

ing

stra

p an

d/or

pow

er le

ad

i f ne

c.

2) D

efec

tive

heat

er2)

Car

ry o

ut m

anua

l reg

ener

atio

n (2

4-ho

ur

pass

wor

d is

requ

ired

for E

CU

sof

twar

e ve

rsio

n 0.

10.1

73 a

nd lo

wer

), m

onito

r hea

ting

outp

ut a

nd

heat

ing

curr

ent o

f the

two

heat

er c

ircui

ts a

t rat

ed

spee

d by

mea

ns o

f EC

U d

iagn

ostic

s so

ftwar

e an

d ch

eck

plau

sibi

lity

(cur

rent

of h

eate

rs s

houl

d be

be

twee

n 28

A an

d 5

4A w

ith a

12V

on-

boar

d su

pply

sy

stem

(33A

to 6

0A w

ith 2

4V o

n-bo

ard

supp

ly

syst

em) a

nd ro

ughl

y th

e sa

me

for b

oth

heat

ing

circ

uits

)

Run

ning

num

ber.

8: h

eatin

g ci

rcui

t A (r

ed w

ire) c

urre

nt to

o hi

gh11

: hea

ting

circ

uit B

(blu

e w

ire) c

urre

nt to

o hi

gh9:

hea

ting

circ

uit A

(red

wire

) cur

rent

too

low

12: h

eatin

g ci

rcui

t B (b

lue

wire

) cur

rent

too

low

2) R

epla

ce fi

lter m

odul

e if

nec.

xx

xx

x

x28

167,

8Fa

ult:

EGR

1) S

pora

dic:

term

. 15

has

loos

e co

ntac

t or w

ire

to E

GR

val

ve o

pen-

or s

hort-

circ

uite

d

1) C

heck

fuse

and

wire

at t

erm

. 15

2 ) D

elet

e fa

ult m

emor

y th

ree

times

and

che

ck

whe

ther

faul

t is

still

pre

sent

1) C

heck

wiri

ng fo

r bre

ak/o

xidi

satio

n2)

Rep

lace

EC

U

xx

xx

x

Type

of E

CU

con

figur

atio

n.IK

D –

Inte

llige

nt C

ontin

uous

Dos

ing

activ

eN

o fa

ult

Faul

t: H

eate

r

Faul

t: H

eate

r

2921

Even

t: In

telli

gent

Con

tinuo

us

Dos

ing

2715

8, 9

, 11,

12

2

25 2615

Faul

t: H

eate

r5

x xx x

25

SMF-

AR

®FB

CC

RT

SCR

SCR

T®N

o.Ta

sk N

o.R

un.N

o.D

escr

iptio

nPo

ssib

le C

ause

of F

ault

Test

Ste

psFa

ult R

ectif

icat

ion

xx

xx

x

181)

Fau

lt in

wiri

ng o

r sen

sor d

efec

tive

(Sho

rt ci

rcui

t tem

pera

ture

sen

sor 1

)

192)

Fau

lt in

wiri

ng o

r sen

sor d

efec

tive

(Ope

n ci

rcui

t tem

pera

ture

sen

sor 1

)

233)

Fau

lt in

wiri

ng o

r sen

sor d

efec

tive

(Sho

rt ci

rcui

t tem

pera

ture

sen

sor 2

)

244)

Fau

lt in

wiri

ng o

r sen

sor d

efec

tive

(Ope

n ci

rcui

t tem

pera

ture

sen

sor 2

)

2, 3

5) F

ault

in w

iring

or d

efec

tive

diffe

rent

ial

pres

sure

sen

sor (

shor

t circ

uit r

unni

ng n

o. 2

, op

en c

ircui

t run

ning

no.

3)

6) D

iffer

entia

l pre

ssur

e ho

se H

i blo

cked

.

2) C

heck

ope

ratio

n us

ing

EC

U d

iagn

ostic

s so

ftwar

e. A

pla

usib

le d

iffer

entia

l pre

ssur

e va

lue

mus

t be

disp

laye

d in

"Act

ual V

alue

s" ta

b.If

read

ing

for d

iffer

entia

l pre

ssur

e is

"sho

rt", t

here

is

prob

ably

a s

hort

circ

uit i

n w

iring

.If

read

ing

for d

iffer

entia

l pre

ssur

e is

"ope

n", t

here

is

p rob

ably

an

open

circ

uit (

wire

bre

ak) i

n w

iring

.

Furth

erm

ore,

a p

laus

ible

bac

kpre

ssur

e (>

1 m

bar)

m

ust b

e di

spla

yed

whe

n en

gine

idlin

g, w

hich

mus

t in

crea

se a

s re

vs/lo

ad in

crea

ses

3) C

heck

hos

e

2) C

heck

wiri

ng fo

r sho

rt ci

rcui

t/ope

n ci

rcui

t o r

repl

ace

diffe

rent

ial p

ress

ure

sens

or if

ne

cess

ary

261

7) F

ault

in th

e w

iring

or t

he s

econ

dary

ele

men

t of

the

EFS

. The

re m

ay b

e a

shor

t circ

uit o

pen

circ

uit.

4) C

heck

the

func

tion

with

the

EC

U d

iagn

ostic

s so

ftwar

e. U

nder

the

tab

actu

al v

alue

s a

pla

usib

le

mas

s flo

w v

alue

sho

uld

be e

nter

ed. W

ith n

o lo

ad

gove

rned

spe

ed a

s 4x

eng

ine

perfo

rman

ce. T

he

valu

e m

ust i

ncre

ase

with

the

engi

ne s

peed

. If t

he

mea

sure

d va

lue

for t

he a

ir m

ass

is "m

issi

ng",

ther

e is

pro

babl

y a

faul

t in

the

wiri

ng o

r the

sen

sor.

3) C

heck

if a

t the

sam

e tim

e th

e er

ror 1

2 " C

AN

-BU

S" i

s pr

esen

t, th

en c

heck

CA

N b

us

a nd

pow

er s

uppl

y (5

V to

gro

und)

of t

he

sens

or..

xx

xx

x

xx

xx

314

14, 1

6Fa

ult:

Diff

eren

tial p

ress

ure

sens

orFa

ulty

diff

eren

tial p

ress

ure

sens

orFa

ult m

ust b

e re

ctifi

ed b

y sp

ecia

list w

orks

hop

with

in 5

00 k

m /

6 h

ours

.

xx

xx

x

x32

48,

9Fa

ult:

Air

mas

s flo

w m

eter

se

nsor

1) F

ault

in w

iring

or s

enso

r def

ectiv

e. P

ossi

ble

shor

t circ

uit o

r ope

n ci

rcui

t in

air m

ass

flow

m

eter

sen

sor

1) C

heck

ope

ratio

n us

ing

EC

U d

iagn

ostic

s so

ftwar

e. A

pla

usib

le a

ir m

ass

flow

val

ue m

ust b

e di

spla

yed

in "A

ctua

l Val

ues"

tab.

If re

adin

g fo

r air

mas

s flo

w is

"sho

rt", t

here

is

prob

ably

a s

hort

circ

uit i

n w

iring

.If

read

ing

for a

ir m

ass

flow

is "o

pen"

, the

re is

pr

obab

ly a

n op

en c

ircui

t (w

ire b

reak

) in

wiri

ng.

Fu

rther

mor

e, a

pla

usib

le a

ir m

ass

flow

(>0

kg/h

) m

ust b

e di

spla

yed

whe

n en

gine

idlin

g, w

hich

mus

t in

crea

se a

s re

vs/lo

ad in

crea

ses

1) C

heck

wiri

ng fo

r sho

rt ci

rcui

t/ope

n ci

rcui

t or

repl

ace

air m

ass

flow

sen

sor i

f nec

.

xx

xx

x

xx

xx

334

6Fa

ult:

T se

nsor

1) In

corr

ect i

nsta

llatio

n po

sitio

n of

tem

pera

ture

se

nsor

2) If

faul

t occ

urs

spor

adic

ally,

it m

ay p

ossi

bly

be o

win

g to

ope

ratin

g pr

ofile

1) C

heck

inst

alla

tion

of te

mpe

ratu

re s

enso

r2)

-1)

Adj

ust i

nsta

llatio

n po

sitio

n if

nec.

2) -

1) C

heck

ope

ratio

n us

ing

EC

U d

iagn

ostic

s so

ftwar

e. A

pla

usib

le te

mpe

ratu

re v

alue

mus

t be

disp

laye

d in

"Act

ual V

alue

s" ta

b.If

read

ing

for t

empe

ratu

re is

"sho

rt", t

here

is

prob

ably

a s

hort

circ

uit i

n w

iring

.If

read

ing

for t

empe

ratu

re is

"ope

n", t

here

is

prob

ably

an

open

circ

uit (

wire

bre

ak) i

n w

iring

.

If ne

c., c

heck

pla

usib

ility

of t

empe

ratu

re s

enso

r re

sist

ance

usi

ng m

ultim

eter

(200

to 6

00 o

hms)

.

1) C

heck

wiri

ng fo

r sho

rt ci

rcui

t/ope

n ci

rcui

t or

repl

ace

tem

pera

ture

sen

sor i

f nec

essa

ry

30Fa

ult:

Sens

ors

(diff

eren

tial-

pres

sure

/tem

pera

ture

sen

sor

/ EFS

Sen

sor)

xx

xx

4

HJS ECU Fault List

26


F-A

R®

FBC

CR

TSC

RSC

RT®

No.

Task

No.

Run

.No.

Des

crip

tion

Poss

ible

Cau

se o

f Fau

ltTe

st S

teps

Faul

t Rec

tific

atio

n

xx

xx

x

xx

xx

344

4Fa

ult:

T se

nsor

1) In

corr

ect i

nsta

llatio

n po

sitio

n of

tem

pera

ture

se

nsor

2) If

faul

t occ

urs

spor

adic

ally,

it m

ay p

ossi

bly

be o

win

g to

ope

ratin

g pr

ofile

1) C

heck

inst

alla

tion

of te

mpe

ratu

re s

enso

r2)

-1)

Adj

ust i

nsta

llatio

n po

sitio

n if

nec.

2) -

xx

xx

x

xx

3519

4Ev

ent:

CR

T te

mpe

ratu

re

prof

ile

Effi

cien

cy o

f CR

T fil

ter n

ot w

ithin

opt

imum

ra

nge.

You

may

con

tinue

to o

pera

te th

e ve

hicl

e.->

For

mor

e in

form

atio

n, s

ee "F

ault

Rec

tific

atio

n"Th

e m

otor

mus

t be

run

in th

e re

quire

d t e

mpe

ratu

re ra

nge

(see

Die

sel P

artic

ulat

e Fi

lter U

ser's

Man

ual),

bec

ause

the

parti

cula

te fi

lter m

ay o

ther

wis

e be

ov

erlo

aded

.

xx

xx

x

x35

1521

Even

t: FB

C te

mpe

ratu

re

prof

ile

Inte

rnal

eve

nt o

f EC

UN

o fa

ult

xx

xx

x1)

Diff

eren

tial p

ress

ure

hose

s co

nnec

ted

inco

rrec

tly o

r def

ectiv

e1)

Che

ck d

iffer

entia

l pre

ssur

e ho

se:

- Che

ck c

onne

ctio

ns a

t sen

sor a

nd fi

lter =

> H

i co

nnec

tion

on s

enso

r mus

t be

conn

ecte

d to

filte

r in

let.

=> R

EF

conn

ectio

n m

ust b

e co

nnec

ted

to fi

lter

outle

t- C

heck

hos

e lin

es a

re n

ot b

lock

ed

1) C

onne

ct h

oses

cor

rect

ly a

nd re

plac

e if

n ec.

. Che

ck w

heth

er m

easu

red

valu

es in

di

agno

stic

s so

ftwar

e ar

e pl

ausi

ble

2) F

ilter

def

ectiv

e2)

Che

ck v

alue

s us

ing

EC

U d

iagn

ostic

s so

ftwar

e. A

pl

ausi

ble

back

pres

sure

(>1

mba

r) m

ust b

e di

spla

yed

unde

r "A

ctua

l Val

ues"

whe

n en

gine

idlin

g.

Act

ions

: mea

sure

opa

city

, rem

ove

filte

r in

acc.

w.

inst

alla

tion

inst

ruct

ions

and

vis

ually

insp

ect f

ilter

for

dam

age

2) R

emov

e fil

ter,

chec

k an

d re

plac

e if

nec.

xx

xx

x1)

Diff

eren

tial p

ress

ure

hose

s co

nnec

ted

inco

rrec

tly o

r def

ectiv

e1)

Che

ck d

iffer

entia

l pre

ssur

e ho

se:

- Che

ck c

onne

ctio

ns a

t sen

sor a

nd fi

lter =

> H

i co

nnec

tion

on s

enso

r mus

t be

conn

ecte

d to

filte

r in

let.

=> R

EF

conn

ectio

n m

ust b

e co

nnec

ted

to fi

lter

outle

t- C

heck

hos

e lin

es a

re n

ot b

lock

ed

1) C

onne

ct h

oses

cor

rect

ly a

nd re

plac

e if

n ec.

. Che

ck w

heth

er m

easu

red

valu

es in

di

agno

stic

s so

ftwar

e ar

e pl

ausi

ble

2) F

ilter

def

ectiv

e2)

Che

ck v

alue

s us

ing

EC

U d

iagn

ostic

s so

ftwar

e. A

pl

ausi

ble

back

pres

sure

(>1

mba

r) m

ust b

e di

spla

yed

unde

r "A

ctua

l Val

ues"

whe

n en

gine

idlin

g.

Act

ions

: mea

sure

opa

city

, rem

ove

filte

r in

acc.

w.

inst

alla

tion

inst

ruct

ions

and

vis

ually

insp

ect f

ilter

for

dam

age

2) R

emov

e fil

ter,

chec

k an

d re

plac

e if

nec.

3) E

ngin

e ru

nnin

g de

tect

ion

cabl

e no

t co

nnec

ted

to D

+ bu

t to

term

. 15

3) C

heck

wiri

ng3)

Cha

nge

wiri

ng

xx

xx

x

xx

xx

377

1Fa

ult:

Filte

r pre

ssur

e to

o hi

ghD

iffer

entia

l pre

ssur

e of

filte

r too

hig

hH

ave

filte

r ser

vice

dH

ave

filte

r ser

vice

d

xx

xx

x

xx

xx

387

2Fa

ult:

Filte

r pre

ssur

e hi

ghD

iffer

entia

l pre

ssur

e of

filte

r hig

hVe

hicl

e ca

n co

ntin

ue to

be

oper

ated

, but

ap

poin

tmen

t mus

t be

mad

e fo

r filt

er to

be

serv

iced

. "F

ault

37" m

essa

ge w

ill b

e di

spla

yed

soon

Hav

e fil

ter s

ervi

ced

xx

xx

x

xx

xx

x39

--

Faul

t: Sh

ort c

ircui

tS

hort

circ

uit i

n 5V

sup

ply

of d

iffer

entia

l pr

essu

re s

enso

r or a

ir m

ass

flow

sen

sor o

r di

agno

stic

s ca

ble.

Che

ck e

ntire

wiri

ng fo

r sho

rt ci

rcui

tC

onne

ct w

ires

corr

ectly

and

repl

ace

if ne

c.

3619

3618

Faul

t: Fi

lter d

amag

ed

Faul

t: Fi

lter d

amag

ed

8x

xx

x

1

27

SMF-

AR

®FB

CC

RT

SCR

SCR

T®N

o.Ta

sk N

o.R

un.N

o.D

escr

iptio

nPo

ssib

le C

ause

of F

ault

Test

Ste

psFa

ult R

ectif

icat

ion

xx

xx

x

xx

4125

4Fa

ult:

SCR

faul

tIn

tern

al fa

ult i

n S

CR

dos

ing

pum

pFo

llow

use

r's m

anua

l of S

CR

dos

ing

pum

pFo

llow

inst

ruct

ions

in "S

oftw

are

for S

CR

D

osin

g P

ump"

use

r's m

anua

l

x41

1462

Faul

t: re

gene

ratio

n cr

itica

l

New

rege

nera

tion

requ

est d

ue to

load

de

tect

ion

with

in lo

ckou

t per

iod.

Thi

s in

dica

tes,

th

at th

e pr

evio

us re

gene

ratio

n ha

s no

t bee

n su

cces

sful

.

Che

ck o

f sys

tem

beh

avio

ur w

ith E

CU

dia

gnos

tic

softw

are,

i.e.

hea

ting

pow

er a

nd c

urre

nts

of la

st

rege

nera

tions

.

Rea

d al

l dat

a of

the

HJS

-EC

U; i

f nec

essa

ry,

run

filte

r ser

vice

, rep

lace

hea

ting

mod

ule

and/

or H

JS-E

CU

.

x43

185

Even

t: Fi

lter l

oadi

ngFi

lter m

onito

ring

even

tN

o fa

ult

xx

xx

x

xx

xx

4410 19

9 2Ev

ent:

Filte

r mai

nten

ance

Filte

r req

uire

s se

rvic

ing

Afte

r no

mor

e th

an 5

00 k

m (3

00 m

iles)

/ 6

oper

atin

g ho

urs,

ve

hicl

e m

ust b

e ta

ken

to s

peci

alis

t wor

ksho

p in

or

der t

o ha

ve fi

lter s

ervi

ced

Car

ry o

ut fi

lter s

ervi

ce

xx

xx

x

xx

4519

6Fa

ult:

CR

T pr

essu

re d

rop

too

high

Dow

nwar

d de

viat

ion

(dro

p) o

f hou

rly a

vera

ged

diffe

rent

ial p

ress

ure

not w

ithin

val

id ra

nge

Afte

r no

mor

e th

an 5

00 k

m (3

00 m

iles)

/ 6

oper

atin

g ho

urs,

ve

hicl

e m

ust b

e ta

ken

to s

peci

alis

t wor

ksho

p in

or

der t

o ha

ve fi

lter s

ervi

ced

xx

xx

x

xx

4619

7Fa

ult:

Hig

h C

RT

pres

sure

ris

e to

o hi

gh

Upw

ard

devi

atio

n (r

ise)

of h

ourly

ave

rage

d di

ffere

ntia

l pre

ssur

e no

t with

in v

alid

rang

eVe

hicl

e m

ust b

e ta

ken

to s

peci

alis

t wor

ksho

p w

ithin

6

hour

s in

ord

er to

hav

e di

esel

par

ticul

ate

filte

r che

cked

xx

xx

x

xx

xx

x47

31

Even

t: Lo

gin

Inte

rnal

eve

nt o

f EC

UN

o fa

ult

xx

xx

xx

x48

253

Even

t: A

dBlu

e ta

nk e

mpt

yA

dBlu

e ta

nk e

mpt

y. N

o fa

ult p

rese

ntFi

ll A

dBlu

e ta

nkx

xx

xx

x48

141

Faul

t: O

pera

ting

prof

ile

1) O

pera

ting

prof

ile n

ot e

noug

h to

be

able

to

trigg

er e

lect

ric re

gene

ratio

n. T

his

can

be

prom

oted

by

stop

'n g

o tra

ffic

or b

y on

-boa

rd

supp

ly v

olta

ge b

eing

too

low

1) T

ake

vehi

cle

for r

egen

erat

ion

run.

Whe

n ye

llow

indi

cato

r lam

p fla

shes

, reg

ener

atio

n ru

n m

ust b

e ca

rrie

d ou

t as

desc

ribed

in U

ser's

M

anua

l

xx

xx

x

xx

4925

2Ev

ent:

AdB

lue

tank

on

rese

rve

AdB

lue

tank

leve

l low

. No

faul

t pre

sent

xx

xx

x

x49

142

Even

t:R

egen

erat

ion

supp

ress

ion

EC

U e

vent

. Reg

ener

atio

n su

ppre

ssio

n ha

s be

en a

ctua

ted

by d

river

(fun

ctio

n no

t ava

ilabl

e w

ith a

ll S

MF®

-AR

sys

tem

sN

o fa

ult

xx

xx

x

xx

506

3Ev

ent:

Dos

ing

EC

U e

vent

. Cha

nge

in ta

nk s

enso

r sig

nal

dete

cted

No

faul

tx

xx

xx

xx

516

4Ev

ent:

Dos

ing

EC

U e

vent

. Add

itive

dos

ing

has

been

co

nduc

ted

by E

CU

N

o fa

ult

HJS ECU Fault List

28


F-A

R®

FBC

CR

TSC

RSC

RT®

No.

Task

No.

Run

.No.

Des

crip

tion

Poss

ible

Cau

se o

f Fau

ltTe

st S

teps

Faul

t Rec

tific

atio

n

xx

xx

x1)

Sho

rt ci

rcui

t or o

pen

circ

uit i

n w

iring

of r

ed

faul

t lam

p1)

Che

ck w

ire fr

om E

CU

to re

d fa

ult l

amp

for

cont

inui

ty a

nd s

hort

circ

uit u

sing

mul

timet

er

1) T

est w

ire a

nd re

pair

if ne

c.

2) L

amp

'bul

b' d

efec

tive

2) C

heck

lam

p 'b

ulb'

for c

ontin

uity

usi

ng m

ultim

eter

2) R

epla

ce la

mp

'bul

b' if

nec

.3)

Lam

p 'b

ulb'

def

ectiv

e3)

Che

ck la

mp

'bul

b' fo

r con

tinui

ty u

sing

mul

timet

er3)

Rep

lace

lam

p 'b

ulb'

if n

ec.

4) F

aulty

con

nect

ion

to g

roun

d4)

Che

ck g

roun

d pi

ns/c

onta

cts

xx

xx

x1)

Sho

rt ci

rcui

t or o

pen

circ

uit i

n w

iring

of

yello

w in

dica

tor l

amp

1) C

heck

lam

p te

st fo

llow

ing

syst

em s

tart

(term

. 15

activ

atio

n)1)

Tes

t wire

and

repa

ir if

nec.

2) S

hort

circ

uit o

r ope

n ci

rcui

t in

wiri

ng o

f ye

llow

indi

cato

r lam

p2)

Che

ck w

ire fr

om E

CU

to y

ello

w in

dica

tor l

amp

for

cont

inui

ty a

nd s

hort

circ

uit u

sing

mul

timet

er

2) T

est w

ire a

nd re

pair

if ne

c.

3) L

amp

'bul

b' d

efec

tive

3) C

heck

lam

p 'b

ulb'

3)

Rep

lace

lam

p 'b

ulb'

if n

ec.

xx

xx

x1)

Sho

rt ci

rcui

t or o

pen

circ

uit i

n w

iring

of

yello

w in

dica

tor l

amp

1) C

heck

wire

from

EC

U to

yel

low

indi

cato

r lam

p fo

r co

ntin

uity

and

sho

rt ci

rcui

t usi

ng m

ultim

eter

1)

Tes

t wire

and

repa

ir if

nec.

2) L

amp

'bul

b' d

efec

tive

2) C

heck

lam

p 'b

ulb'

2)

Rep

lace

lam

p 'b

ulb'

if n

ec.

xx

xx

x

xx

xx

567

9Fa

ult:

Tem

pera

ture

hig

hTe

mpe

ratu

re o

f filt

er h

igh

Vehi

cle

can

cont

inue

to b

e op

erat

ed, b

ut

appo

intm

ent m

ust b

e m

ade

for f

ilter

to b

e se

rvic

ed.

"Fau

lt 57

" mes

sage

will

be

disp

laye

d so

onH

ave

filte

r ser

vice

d

xx

xx

xx

xx

x57

710

Faul

t: Te

mpe

ratu

re to

o hi

ghTe

mpe

ratu

re o

f filt

er to

o hi

ghH

ave

filte

r ser

vice

dH

ave

filte

r ser

vice

dx

xx

xx

xx

xx

x58

421

Faul

t:En

gine

runn

ing

dete

ctio

nS

peed

sig

nal o

r D+

sign

al n

ot a

ctiv

e or

pre

ssur

e se

nsor

def

ectiv

eC

heck

wiri

ng,

chec

k pr

essu

re s

enso

rC

onne

ct w

ires

corr

ectly

and

repl

ace

if ne

c.

xx

xx

x

x59

--

Even

t: Lo

adin

g st

able

Filte

r mon

itorin

g ev

ent

No

faul

tx

xx

xx

x60

144,

6Ev

ent:

Reg

ener

atio

n lo

g

Filte

r mon

itorin

g ev

ent:

rege

nera

tion

is/h

as

been

car

ried

out

No

faul

tx

xx

xx

xx

6126

4, 5

Faul

t: C

harg

e-ai

r tem

pera

ture

op

en c

ircui

t/sho

rt c

ircui

t

1) F

ault

in w

iring

or s

enso

r def

ectiv

e. P

ossi

ble

shor

t circ

uit o

r ope

n ci

rcui

t in

wire

to c

harg

e-ai

r tem

pera

ture

sen

sor (

runn

ing

no. 4

= o

pen

circ

uit,

runn

ing

no. 5

= s

hort

circ

uit)

1) C

heck

ope

ratio

n us

ing

EC

U d

iagn

ostic

s so

ftwar

e. A

pla

usib

le c

harg

e-ai

r tem

pera

ture

val

ue

mus

t be

disp

laye

d in

"Act

ual V

alue

s" ta

b w

hile

en

gine

is ru

nnin

g.If

read

ing

for c

harg

e-ai

r tem

pera

ture

is "s

hort"

, th

ere

is p

roba

bly

a sh

ort c

ircui

t in

wiri

ng.

If re

adin

g fo

r cha

rge-

air t

empe

ratu

re is

"ope

n",

ther

e is

pro

babl

y an

ope

n ci

rcui

t (w

ire b

reak

) in

wiri

ng.

1) C

heck

wiri

ng fo

r sho

rt ci

rcui

t/ope

n ci

rcui

t or

repl

ace

sens

or if

nec

.

xx

xx

x

x61

--

Even

t: In

tern

alIn

tern

al e

vent

of E

CU

No

faul

tx

xx

xx

xx

xx

x62

3di

v.Ev

ent:

orde

rIn

tern

al e

vent

of E

CU

No

faul

tx

xx

xx

xx

xx

x63

112

Faul

t: M

issi

ng c

onfig

urat

ion

Faul

t in

uplo

adin

g th

e co

nfig

urat

ion

(par

amet

er fi

le)

Test

the

conf

igur

atio

n (C

FG) i

n th

e sy

stem

be

havi

or, i

t mus

t not

beg

in w

ith "0

".U

ploa

d th

e co

nfig

urat

ion

agai

n.

551

Faul

t: M

IL3

Faul

t: Ye

llow

indi

cato

r lam

p1

54531

Faul

t:R

ed fa

ult l

amp

xx

xx

x

xx

xx

x2 3 4

29

SCR dosing pump Fault ListNo. Description Possible Cause of Fault Test Steps Fault Rectification

102 Software error Internal software error affecting pump – Pump must be replaced

103 Invalid configuration Internal software error affecting pump – Pump must be replaced

104 Missing Origo SCR Dosing Pump Pump speed sensor or speed receiver defective – Pump must be replaced

105 Internal Heater Unable To Defreeze No defrosting possible after 30 min – Inform HJS if fault has occurred repeatedly

106 Internal Heater Shorted Low Internal heater defective – Pump must be replaced

107 Internal Heater Shorted High Internal heater defective – Pump must be replaced

108 Internal Heater Open Load Internal heater defective – Pump must be replaced

109 Internal Heater Urea Frozen No fault: pump is frozen – Pump will defrost during operation, no need for action

110 5 V supply shorted to ground Internal voltage error; can go hand in hand with on-board supply voltage problems –

If this is the only fault that is active: pump must be replaced; otherwise rectify other faults first

111 5 V supply open-circuited Internal voltage error; can go hand in hand with on-board supply voltage problems –


114 Supply voltage low Supply voltage at pump lower than 18 V Check supply voltage and wiring Rectify fault in on-board supply system or supply lead

115 Supply voltage high Supply voltage at pump higher than 32 V Check supply voltage and wiring Rectify fault in on-board supply system or supply lead

116 Bad power supply On-board supply voltage fault: 12-V and 24-V components mixed up

Check whether 24-V pump is connected to 12-V system or vice versa

Install components that match on-board supply voltage

117 Nozzle blocked Blocked AdBlue nozzle or pump Check whether nozzle and hoses to nozzle are clear

In the event of a blockage, flush out and replace components if necessary

119 PCB-Temperature Out Of Range Low Internal sensor fault – Pump must be replaced

120 PCB-Temperature Out Of Range High Internal sensor fault – Pump must be replaced

121 PSU voltage low Internal voltage error; can go hand in hand with on-board supply voltage problems –


122 PSU voltage high Internal voltage error; can go hand in hand with on-board supply voltage problems –


125 Air Valve Shorted High Lead to air valve shorted to ground Check wiring Repair faulty component

126 Air Valve Shorted Low Lead to air valve shorted to 24-V supply Check wiring Repair faulty component

127 Air Valve Open Load Cable break or lead to air valve shorted Check wiring Repair faulty component

128 Blocked return line Return line from pump to tank is blocked. Check that return line and pump are clear (not blocked) Follow flushing procedure

129 Missing Air Or Urea Inadequate AdBlue or compressed air supply

Check whether problems with compressed air supply system in vehicle

Check whether AdBlue lines and connectors are tight

If everything is tight, suction capacity may be affected by soiling or drying-out

Rectify compressed air system fault

Repair leak

Follow flushing procedure

130 Pump Head Temperature Out Of Range Low Internal sensor fault – Pump must be replaced

30


131 Pump Head Temperature Out Of Range High Internal sensor fault – Pump must be replaced

132 IntPS PSU6V Out Of Range Low Internal voltage error; can go hand in hand with on-board supply voltage problems –


133 IntPS PSU6V Out Of Range High Internal voltage error; can go hand in hand with on-board supply voltage problems –


134 Pressure Sensor SCR Dosing Pump Out Of Range Low Internal sensor fault – Pump must be replaced

135 Pressure Sensor SCR Dosing Pump Out Of Range High Internal sensor fault – Pump must be replaced

136 Invalid dataset Internal software error affecting pump - Pump must be replaced

137 Missing Air Inadequate compressed air supply identified during operation

Check compressed air supply system in vehicle and compressed air components of HJS system

Rectify fault in compressed air supply

140 Temperature Upstream SCR Catalyst Out Of Range Low

Short circuit in cable harness, connector or sensor

Fault is indicated when resistance is less than 160 . Check sensor and cable harness for short circuit

Repair faulty component

141 Temperature Upstream SCR Catalyst Out Of Range High

Open circuit in cable harness, connector or sensor

Fault is indicated when resistance is higher than 980 . Check sensor, connector and cable harness for open circuit


142 Temperature Downstream SCR Catalyst Out Of Range Low

Short circuit in cable harness, connector or sensor



143 Temperature Downstream SCR Catalyst Out Of Range High




144 Urea Level Out Of Range Low Short circuit in cable harness, connector or sensor



145 Urea Level Out Of Range High Open circuit in cable harness, connector or sensor



146 Urea Temperature Sensor Out Of Range Low Short circuit in cable harness, connector or sensor



147 Urea Temperature Sensor Out Of Range High




158

HJS-ECU Communication TimeoutRequirement: HJS ECU is fault-free

Open circuit between HJS ECU and pump

System relay is active although terminal 15is inactive

HJS ECU activates system relay although term. 15 is inactive

Use diagnosis for HJS ECU and rectify active faults

Check CAN wiring between HJS ECU and pump for continuity and short circuit

Check system relay

Diagnose HJS ECU

HJS ECU sends MAF value and activates system relay when term. 15 is active (ignition for pump)

Rectify defect in cable harness or connector


159 HJS-ECU Invalid Data HJS ECU defective MAF value greater than 13005 kg/h Replace HJS ECU

31


160 NOx Upstream Timeout

Open circuit between NOx sensor and pump

Defective sensor

Check CAN wiring between NOx sensor and pump for continuity and short circuit

No communication despite fault-free wiring


161 NOx Upstream Heater Short Circuit Internal sensor fault – Replace NOx sensor

162 NOx Upstream Heater Open Wire Internal sensor fault – Replace NOx sensor

163 NOx Upstream NOx Short Circuit Internal sensor fault – Replace NOx sensor

164 NOx Upstream NOx Open Wire Internal sensor fault – Replace NOx sensor

165 NOx Upstream O2 Short Circuit Internal sensor fault – Replace NOx sensor

166 NOx Upstream O2 Open Wire Internal sensor fault – Replace NOx sensor

170 NOx Downstream Timeout

Open circuit between NOx sensor and pump

Defective sensor

Check CAN wiring between NOx sensor and pump for continuity and short circuit

No communication despite fault-free wiring


171 NOx Downstream Heater Short Circuit Internal sensor fault – Replace NOx sensor

172 NOx Downstream Heater Open Wire Internal sensor fault – Replace NOx sensor

173 NOx Downstream NOx Short Circuit Internal sensor fault – Replace NOx sensor

174 NOx Downstream NOx Open Wire Internal sensor fault – Replace NOx sensor

175 NOx Downstream O2 Short Circuit Internal sensor fault – Replace NOx sensor

176 NOx Downstream O2 Open Wire Internal sensor fault – Replace NOx sensor

180 Urea Level Indication Low Low urea level. System is still active – AdBlue must be topped up

181 Urea Level Indication Empty Urea level too low. Dosing has been stopped – AdBlue must be topped up

182 NOx Conversion LowUrea is not dosed correctly

SCR catalyst defect


SCR catalyst may be damaged mechanically or thermal


183 NOx Conversion Too LowUrea is not dosed correctly

SCR catalyst defect


SCR catalyst may be damaged mechanically or thermal


206 Urea Temperature Low No Error. Dosing possible when warmer. – Inform HJS if fault has occurred repeatedly

207 Urea Temperature High No Error. Dosing possible when colder. – Inform HJS if fault has occurred repeatedly

www.hjs.com

Emission Technology GmbH & Co. KG is a medium-sized company based in Menden in central Germany and has many years of experience and expertise in the field of exhaust-gas aftertreatment. Some 500 employees are engaged in the development, production andmarketing of modular systems for reducing pollutant emissions. These innovative environmental protection technologies can be used either as original equipment or for retrofitting in passenger cars, commercial vehicles as well as a wide range of non-road mobile machinery and stationary applications.

In addition to systems for spark-ignition engines, HJS today focuses on solutions for diesel engines – especially for reducing the emissions of soot particles (PM) and nitrogen oxides (NOx). With extensive patents for DPF

® (diesel particulate filter) and SCRT® (SelectiveCatalytic Reduction Technology) systems, HJS sets benchmarks.

technology portfolio for OE and retrofitting

> Diesel Particulate Filters (DPF®) Reduction of soot-particle emissions (PM)

> SCR-Systems Reduction of nitrogen-oxide (NOX) emissions

> SCRT®-Systems Simultaneous reduction of soot-particle (PM) and nitrogen-oxide (NOX) emissions

> Thermal M anagement For DPF®-regeneration and SCR-functionality

> Electronic Control Units and Software Monitoring and controlling of all system functions

A clean future with HJS!See www.hjs.com

27 09 3124

DPF®, SMF®and City-Filter

®- trademarks registered by HJS Emission Technology

© HJS 2017 Last update 05.09.2017 Subject to change without notice.

HJS Emission Technology Dieselweg 12 Phone +49 2373 987-0 [email protected] & Co. KG D-58706 Menden / Germany Fax +49 2373 987-199 www.hjs.com

Documents

ECU Diagnostics Software · (1) for the ECU. > Please refer to the User's Manual for the position of the connector in the vehicle. In the case of the universal system, the 4-pin connector