Denso E13c Truck Engine Owner's Manual

Denso E13c Truck Engine Owner's Manual

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DENSO E13C Truck Engine

DENSO E13C Truck Engine-fig1

Outline

Product Application
  • Application
    • Manufacturer: HINO
    • Engine Model: E13C
    • Destination: General countries
  • System Components Parts Number

    DENSO E13C Truck Engine-fig2

Outline
This Service Manual describes the new common rail system installed on the E13C engine of large Hino trucks. The big­gest difference compared with conventional common rail systems is that it uses an injector with a QR code. The basic construction and operation of the system is about the same as for systems installed on the P11 C engine, so this Service Manual will only give a general outline of the E13C system and describe its unique features. For details on the common rail system, refer to Service Bulletin ECO 01-08 “New Common Rail System (ECD-U2) for H INO” published in December 2001, and Service Manual “Common Rail System for HINO J05D/J08E Type Engine” published in October 2003.

Outline of The Main New Features

Common Rail Specifications and Engine Features

DENSO E13C Truck Engine-fig3DENSO E13C Truck Engine-fig4

System Construction
NOTE
For details on sensors such as the NE sensor and G sensor (sub-NE sensor), refer to Page 3,4 in Service Bulletin 01-08.

DENSO E13C Truck Engine-fig5

Outline of Changes in Main Functional Parts

Only the functional parts with significant changes are described.

Supply Pump
  • Changes
    The items that have changed significantly are shown in the table below.
    ItemCon ventiona I SystemNew SystemReason for Change
    Installat ion methodSaddle typeFlange typeEasier installation
    Driving methodCouplingGearEasier installation
    G sensorMPUMREReduced cost
  • Construction

    DENSO E13C Truck Engine-fig6

  • Operation
    For details on the operation, refer to page 12 – 15 in Service Manual “Common Rail System for H INO J05D/J0BE Type Engine”.
Rail
  • Changes
    The items that have changed significantly are shown in the table below.
    ItemConventional SystemNew SystemReason for Change
    System pressure120 MPa160 MPaImproves performance
    Highest pressure during

    normal use

    130 MPa176 MPaImproves performance
    Pressure limiter valve open-

    ing pressure

    140  5 MPa200     9 MPaTo deal with the system

    pressure

    PC sensor specification180 MPa120 MPaTo deal with the system

    pressure

    Installation positionOutside engine headInside engine headEasier instaIlation
  • Construction

    DENSO E13C Truck Engine-fig7

  • Operation
    For details on construction and operation, refer to page 10 in Service Bulletin 01-08.
Injector
  • Changes
    • Uses a compact and power-saving TWV (Two-Way Valve) for electromagnetic control of the injector.
    • Conventional systems use adjusted resistance to correct the injection volume, but to improve the accuracy of correction, the new system uses a QR (Quick Response) code. The QR code greatly increases the correction points of the injection volume, improving correction accuracy. The properties of the engine cylinders are made more equal than before, which increases fuel efficiency and decreases exhaust gas emissions. The ID code (30 base 16 characters) for injection volume correction information is stamped on the injector head.
  • Construction

    DENSO E13C Truck Engine-fig8DENSO E13C Truck Engine-fig9

  • Operation
    The TWV (solenoid valve) controls the pressure in the chamber by opening and closing the outlet orifice passage, which in turn controls the start and end of injection.
    • When not injecting
      When the solenoid is not energized, the outlet orifice passage is closed by the downward force of the TWV (solenoid valve) spring. From this, the control chamber pressure trying to push down the command piston and the pressure trying to push up the nozzle needle is the same. The differences in the areas receiving pressure and the force of the nozzle spring closes the nozzle needle, so there is no injection.
    • During injection
      When the solenoid is energized, the TMV (solenoid valve) is pulled up by the force of the solenoid, which opens the outlet orifice, discharging the fuel from the control chamber. When fuel is discharged, the pressure in the control chamber is reduced, which pulls up the command piston. This raises the nozzle needle, and injection is started.
    •  End of injection
      As the solenoid continues to be energized, the nozzle reaches its maximum lift point, creating the maximum injection rate. When the energization of the solenoid is turned OFF, the TWV (solenoid valve) lowers, closing the outlet orifice. Because of this, fuel enters the control chamber from the inlet orifice, which increases the pressure. The makes the noz­zle needle close abruptly, stopping the injection.

      DENSO E13C Truck Engine-fig10

Servicing injectors with QR code (Reference)

When replacing the injector or engine ECU, a HINO diagnostic tool must be used to register ID code in the engine ECU.
NOTE
If the ID code of the installed injector is not correctly registered, it could cause engine malfunctions such as rough Idling or noise.

  • QR code location

    DENSO E13C Truck Engine-fig11

  • QR code correction points

    DENSO E13C Truck Engine-fig12

  • When replacing the injector

    DENSO E13C Truck Engine-fig13

  • When replacing the engine ECU

    DENSO E13C Truck Engine-fig14

Sensors (Only sensors that were changed.)
  • G Sensor (Cylinder Recognition Sensor)
    The G sensor is an MRE (electromagnetic resistance element) type. When the hole on the flywheel passes the sensor, the electromagnetic resistance flowing through the sensor changes. This variation in current is amplified by the internal IC circuit, and a signal is output to the engine ECU. A cylinder recognition pulsar is installed to the supply pump camshaft, and a cylinder recognition signal is output. 7 pulses are output for every revolution of the supply pump, or for every 2 revolutions of the engine. Cylinder recognition is inferred by combining the NE signal and the G signal. The irregular 7th pulse is used to recognize the first cylinder.
    • External View and Terminal Positions
      The MRE type differs to the conventional type in that a pulse of constant amplification is generated so that the OUT terminal does not affect engine speed changes when constant amplitude (SV) is applied to t he VCC.

      DENSO E13C Truck Engine-fig15

    • Output Signal
      The OUT terminal outputs the following in synchronization with the pulsar missing teeth (pump camshaft). For each one
      rotation of the pump camshaft, there are 6 pulses at 60° intervals, and 1 extra pulse used for recognition of the number
      one cylinder.

      DENSO E13C Truck Engine-fig16

    • NE/G Sensor wiring diagram

      DENSO E13C Truck Engine-fig17

    • NE/G pulse chart

      DENSO E13C Truck Engine-fig18

  • Accelerator Sensor
    The accelerator sensor is a non-contact type. It is linked to the movement of the accelerator pedal, which rotates the lever, and the voltage of the output terminal changes according to the rotational position of the lever. There are hole el­ements on the sensor. A magnet is installed on the shaft, which moves together with the accelerator pedal, so the mag­netic field changes with the rotation of the shaft. A voltage is generated from these changes in the magnetic field.

    DENSO E13C Truck Engine-fig19

ECU
The ECU has 32 bits, compared to the 16 bits of conventional systems, so processing is faster. As in previous systems, it is integrated with the EDU.

  • ECU External Wiring Diagram
  • ECU Connector Diagram
    NOTE
    For the above details, refer to page 44 – 4 7 in Service Manual “Common Rail System for HINO J05D/J0BE Type Engine”, published in October 2003.

Various Types of Control
NOTE
Refer to page 20 – 24 in Service Bulletin ECD 01-08.

Diagnosis

DTC (Diagnostic Trouble Code) Table
A HINO PC tester can be used at the HINO dealership to display DTCs and perform diagnostic troubleshooting on the significantly changed items. The DTCs (to be dealt with at the HINO dealership) are shown below for reference.

OTCP_CodeDST-1 displayCode explanationReference
31P0047VNT solenoid valve 1 malfunctionVNT solenoid valve 1 is abnormal. There could

be a solenoid valve malfunction, harness open circuit, or ground short.

31P0048VNT solenoid valve 1 malfunctionVNT solenoid valve 1 is abnormal. There could

be a harness +B short.

39P0049Turbo speed overrunAn abnormally high turbo speed is detected.Detected by turbine

rotation sensor

76P0088Abnormally high rail pressureAn abnormally high fuel pressure is detected.
78P0093Fuel leakThere could be a fuel leak. Perform a fuel leak check.Conventional pump cannot pump (fuel

discharge)

88P0096EGR valve seizure malfunctionThe EGR system is abnormalValve is detected through EGR gas temperature to have seized in the fully

closed position

18P0097EGR gas temperature sensor malfunction (LO)Cannot detect the temperature normally. There could be a sensor malfunction or a har-

ness ground short.

18P0098EGR gas temperature sensor malfunction (HI)Cannot detect the temperature normally.

There could be a sensor malfunction, harness open circuit or +B short.

17P0102Air flow sensor malfunction (LO )The air flow sensor is abnormal. There could

be a sensor malfunction, harness open circuit or GND short.

17P0103Air flow sensor malfunction (HI)The air flow sensor is abnormal. There could

be a sensor malfunction or a harness +B short.

37P0108Boost pressure sensor malfunc- lion (HI)Cannot detect the boost pressure normally. There could be a sensor malfunction or har-

ness short.

16P0112Intake air temperature sensor malfunction (LO)Cannot detect the temperature normally. There could be a sensor malfunction or a har-

ness ground short.

Air flow sensor inter- nalsensor
16P0113Intake air temperature sensor malfunction (HI)Cannot detect the temperature normally.

There could be a sensor malfunction, harness open circuit or -+-B short.

Air flow sensor inter- nalsensor
11P0117Coolant temperature sensor mal- function (LO)Cannot detect the temperature normally. There could be a sensor malfunction or a har-

ness ground short.

OTCP_CodeDST-1 displayCode explanationReference
11P0118Coolant temperature sensor mal- function (HI)Cannot detect the temperature normally.

There could be a sensor malfunction, harness open circuit or +B short.

14P0187Fuel temperature sensor mal- function (LO)Cannot detect the temperature normally. There could be a sensor malfunction or a har-

ness ground short.

Leakage tempera- ture
14P0188Fuel temperature sensor mal- function (HI)Cannot detect the temperature normally. There could be a sensor malfunction, harness

open circuit or +B short.

Leakage tempera- ture
67P0191Rail pressure sensor malfunctionCannot detect the rail pressure normally.

There could be a sensor malfunction.

Characteristic

abnormality

67P0192Rail pressure sensor malfunction

(LO)

Cannot detect the rail pressure normally.

There could be a sensor malfunction or har- ness ground short.

67P0193Rail pressure sensor malfunction

(HI)

Cannot detect the rail pressure normally. There could be a sensor malfunction, harness

open circuit or +B short.

59P0200ECU charge circuit fault (HI)The voltage for actuating the injector is too

high. Replace the ECU.

51P0201Injector 1 open circuitThere could be an injector 1 malfunction or

harness open circuit.

52P0202Injector 2 open circuitThere could be an injector 2 malfunction or

harness open circuit.

53P0203Injector 3 open circuitThere could be an injector 3 malfunction or

harness open circuit.

54P0204Injector 4 open circuitThere could be an injector 4 malfunction or

harness open circuit.

55P0205Injector 5 open circuitThere could be an injector 5 malfunction or

harness open circuit.

56P0206Injector 6 open circuitThere could be an injector 6 malfunction or

harness open circuit.

6P0217OverheatingOverheating is detected. Inspect the cooling

system.

7P0219Engine overrunThe engine speed is above the rated value.
34P0234Turbo over boostThe boost pressure is higher than the stan-

dard.

37P0237Boost pressure sensor malfunc- lionCannot detect the intake air pressure normally. There could be a sensor malfunction, harness

open circuit or short.

OTCP_CodeDST-1 displayCode explanationReference
61P0263Cylinder correction error #1The speed variations of the first cylinder are larger than those of the other cylinders. The flow damper could be operating.Conventional prod- uct flow damper operation judgment and new speed vari-

ation judgment

62P0266Cylinder correction error #2The speed variations of the second cylinder are larger than those of the other cylinders. The flow damper could be operating.Conventional prod- uct flow damper operation judgment and new speed vari-

ation judgment

63P0269Cylinder correction error #3The speed variations of the third cylinder are larger than those of the other cylinders. The flow damper could be operating.Conventional prod- uct flow damper operation judgment and new speed vari-

ation judgment

64P0272Cylinder correction error #4The speed variations of the fourth cylinder are larger than those of the other cylinders. The flow damper could be operating.Conventional prod- uct flow damper operation judgment and new speed vari-

ation judgment

65P0275Cylinder correction error #5The speed variations of the fifth cylinder are larger than those of the other cylinders. The flow damper could be operating.Conventional prod- uct flow damper operation judgment and new speed vari-

ation judgment

66P0278Cylinder correction error #6The speed variations of the sixth cylinder are larger than those of the other cylinders. The flow damper could be operating.Conventional prod- uct flow damper operation judgment and new speed vari-

ation judgment

13P0335NE sensor malfunctionCannot detect the pulses from the NE sensor. There could be a sensor malfunction or har- ness abnormality.This code is also output if both the NE and G sensors are

malfunctioning

12P0340G sensor malfunctionCannot detect the pulses from the G sensor. There could be a sensor malfunction or har-

ness abnormality.

88P0401Insufficient EGR rateThe EGR system is abnormal. The EGR rate is lower than the standard value.VaIve is detected through Air flow sen- sor to have seized in the fully closed posi-

tion

OTCP_CodeDST-1 displayCode explanationReference
88P0402Excessive EGR rateThe EGR system is abnormal. The EGR rate is higher than the standard value.VaIve is detected through Air flow sen- sor to have seized in the fully open posi-

tion

81P0489EGR solenoid valve 1 malfunc- lionEGR solenoid valve 1 is abnormal. There could be a solenoid valve malfunction, har-

ness open circuit or ground short.

81P0490EGR solenoid valve 1 malfunc- lionEGR solenoid valve 1 is abnormal. There could be a solenoid valve malfunction or +B

harness short

21P0500Vehicle speed sensor malfunction (LO)Cannot detect the pulses from the vehicle

speed sensor. There could be a sensor mal- function or harness abnormality.

Open circuit
21P0501Vehicle speed sensor malfunction

(HI)

The pulses from the vehicle speed sensor are

abnormal. There could be a sensor malfunc- tion or harness abnormality.

Noise
42P0510Idling switch malfunctionThe idling switch is not functioning normally.

While monitoring the vehicle conditions, check the ON/OFF judgment.

25P0540Pre-heat device malfunctionThe intake heater relay is abnormal. There

could be a relay malfunction or harness abnor- mality.

97P0545Exhaust temperature sensor 1 malfunction (LO)Cannot detect the temperature normally.

There could be a sensor malfunction or a har- ness ground short.

97P0546Exhaust temperature sensor 1 malfunction (HI)Cannot detect the temperature normally.

There could be a sensor malfunction, harness open circuit or +B short.

3P0605Flash ROM abnormalityECU internal malfunction. Please replace the

ECU.

3P0606CPU malfunction (hardware

detection)

ECU internal malfunction. Please replace the

ECU.

3P0907CPU surveillance IC malfunctionECU internal malfunction. Please replace the

ECU.

59P0611ECU charge circuit faultThe voltage for actuating the injector is too

low. Replace the ECU.

45P0617Starter switch malfunctionThe starter switch has shorted. While monitor- ing the vehicle conditions, check the ON/OFF

judgment.

73P0628Supply pump solenoid valve 1 malfunctionThe supply pump solenoid valve 1 has a volt- age abnormality. There could be an open cir-

cuit or ground short.

PCV1, PCV1 &

PCV2 (large)

OTCP_CodeDST-1 displayCode explanationReference
73P0629Supply pump solenoid valve 1

malfunction

The supply pump solenoid valve 1 has a volt-

age abnormality. There could be a +B short.

PCV1; PCV1 &

PCV2 (large)

5P0686Main relay malfunctionThe main relay cannot be switched OFF.

Inspect the relay.

41P0704Clutch switch malfunctionCannot detect the clutch switch normally. While monitoring the vehicle conditions, check

the ON/OFF judgment.

47POSSONeutral switch malfunctionCannot detect the neutral switch normally. While monitoring the vehicle conditions, check

the ON/OFF judgment.

32P1062VNT solenoid valve 2 malfunctionVNT solenoid valve 2 is abnormal. There cold

be a solenoid valve malfunction, harness open circuit, or ground short.

32P1063VNT solenoid valve 2 malfunctionVNT solenoid valve 2 is abnormal. There could be a solenoid valve malfunction or harness +B

short.

33P1067VNT solenoid valve 3 malfunctionVNT solenoid valve 3 is abnormal. There cold

be a solenoid valve malfunction, harness open circuit, or ground short.

33P1068VNT solenoid valve 3 malfunctionVNT solenoid valve 3 is abnormal. There could be a solenoid valve malfunction or harness +B

short.

38P1071Turbo speed sensor malfunction

(HI)

The pulses from the turbine speed sensor are abnormal. There could be a sensor malfunc-

lion or harness abnormality.

38P1072Turbo speed sensor malfunction (LO)Cannot detect the pulses from the turbo speed sensor. There could be a sensor malfunction

or harness abnormality.

23P1132Operation accelerator sensor (LO)Cannot detect the operation accelerator sen- sor normally. Check the sensor voltage. There

could be an open circuit or a ground short.

23P1133Operation accelerator sensor (HI)Cannot detect the operation accelerator sen- sor normally. Check the sensor voltage. There

could be a +B short.

44P1142Idling volume (LO)Cannot detect the idling volume normally.

Check the sensor voltage. There could be an open circuit or a ground short.

44P1143Idling volume (HI)Cannot detect the idling volume normally. Check the sensor voltage. There could be a

+B short.

57P1211Injector common 1 malfunctionThere could be a ground short. Check the

injector and the wiring.

OTCP_CodeDST-1 displayCode explanationReference
57P1212Injector common 1 malfunctionThere could be an open circuit or +B short.

Check the injector and the wiring.

58P1214Injector common 2 malfunctionThere could be a ground short. Check the

injector and the wiring.

58P1215Injector common 2 malfunctionThere could be an open circuit or +B short.

Check the injector and the wiring.

76P1229Supply pump excessive pumpingAn abnormally high fuel pressure is detected.

Inspect the pump system.

77P1266Supply pump pumping faultAn abnormally high fuel pressure is detected. Inspect the pump system.Conventional pumps cannot pump or pressure limiter

operation

82P1402EGR solenoid valve 2 malfunc- tionEGR solenoid valve 2 is abnormal. There could be a solenoid valve malfunction, har-

ness open circuit or ground short.

82P1403EGR solenoid valve 2 malfunc- lionEGR solenoid valve 2 is abnormal. There could be a solenoid valve malfunction or har-

ness +B short.

83P1407EGR solenoid valve 3 malfunc- lionEGR solenoid valve 3 is abnormal. There could be a solenoid valve malfunction, har-

ness open circuit or ground short.

83P1408EGR solenoid valve 3 malfunc- tionEGR solenoid valve 3 is abnormal. There could be a solenoid valve malfunction or har-

ness +B short.

84P1412Pulse EGR solenoid valve mal- funct ionThe pulse EGR solenoid valve is abnormal. There could be a solenoid valve malfunction,

harness open circuit or ground short.

84P1413Pulse EGR solenoid valve mal- funct ionThe pulse EGR solenoid valve is abnormal. There could be a solenoid valve malfunction or

harness +B short.

85P1416EGR cooler overheatOverheating of the EGR cooler is detected.

Inspect the EGR cooler.

19P1417EGR cooler coolant temperature sensor malfunction (LO)Cannot detect the temperature normally. There could be a sensor malfunction or a har-

ness ground short.

19P1418EGR cooler coolant temperature sensor malfunction (HI)Cannot detect the temperature normally.

There could be a sensor malfunction, harness open circuit or +B short.

96P1427Exhaust pressure sensor mal- function (LO)Cannot detect the exhaust pressure normally.

There could be a sensor malfunction, harness open circuit or ground short.

OTCP_CodeDST-1 displayCode explanationReference
96P1428Exhaust pressure sensor mal- function (HI)Cannot detect the exhaust pressure normally.

There could be a sensor malfunction or har- ness +B short.

26P1462Engine retarder 1 malfunctionEngine retarder solenoid valve 1 is abnormal. There could be a solenoid valve malfunction ,

harness open circuit or ground short.

#4 to #6 side retarder
26P1463Engine retarder 1 malfunctionEngine retarder solenoid valve 1 is abnormal. There could be a solenoid valve malfunction or

harness +B short

#4 to #6 side retarder
27P1467Engine retarder 2 malfunctionEngine retarder solenoid valve 2 is abnormal. There could be a solenoid valve malfunction,

harness open circuit or ground short.

#1 to #3 side retarder
27P1468Engine retarder 2 malfunctionEngine retarder solenoid valve 2 is abnormal. There could be a solenoid valve malfunction or

harness +B short

#1 to #3 side retarder
27P1472TIM retarder relay malfunctionThe TIM retarder relay is abnormal. There could be a relay malfunction, harness open cir- cuit or ground short.TIM retarder relay for interlocked cruise control in large and medium sized vehi-

cles

29P1473T/M retarder relay malfunctionThe T/M retarder relay is abnormal. There could be a relay malfunction or harness +B short.T/M retarder relay for interlocked cruise control in large and medium sized vehi-

cles

46P1530Engine stop switch closing mal- funct ionThe engine stop switch is malfunctioning, or the wiring has shorted. While monitoring the vehicle conditions, check the ON/OFF judg-

ment.

43P1565Cruise switch malfunctionThe cruise switch has an ON malfunction. While monitoring the vehicle conditions, check

the ON/OFF judgment.

2P1601QR code malfunctionThe QR code is abnormal. Check the QR

code.

48P1676PCS switch malfunctionCannot detect the PCS switch normally. While

monitoring the vehicle conditions, check the ON/OFF judgment.

28P1681Exhaust brake solenoid valve malfunctionThe exhaust brake solenoid valve is abnom,al. There could be a solenoid valve malfunction,

harness open circuit or ground short.

28P1682Exhaust brake solenoid valve malfunctionThe exhaust brake solenoid valve is abnormal.

There could be a solenoid valve malfunction or harness +B short.

OTCP_CodeDST-1 displayCode explanationReference
91P2002DPF system malfunctionThe DPF system is abnormal. There could be

welding damage or clogging. Perform a DPF system check.

98P2032Exhaust temperature sensor 2 malfunction (LO)Cannot detect the temperature normally. There could be a sensor malfunction or a har-

ness ground short.

98P2033Exhaust temperature sensor 2 malfunction (HI)Cannot detect the temperature normally. There could be a sensor malfunction, harness

open circuit or +B short.

22P2120Malfunction of both accelerator sensorsBoth accelerator sensor systems are malfunc- tioning. There could be a sensor abnormality

or harness abnormality.

22P2121Accelerator sensor 1 malfunctionCannot detect accelerator sensor 1 normally.

Check the sensor voltage.

22P2122Accelerator sensor 1 malfunction (LO)Cannot detect accelerator sensor 1 normally. Check the sensor voltage. There could be an

open circuit or ground short.

22P2123Accelerator sensor 1 malfunction (HI)Cannot detect accelerator sensor 1 normally. Check the sensor voltage. There could be a

+B short.

22P2126Accelerator sensor 2 malfunctionCannot detect accelerator sensor 2 normally.

Check the sensor voltage.

22P2127Accelerator sensor 2 malfunction (LO)Cannot detect accelerator sensor 2 normally. Check the sensor voltage. There could be an

open circuit or ground short.

22P2128Accelerator sensor 2 malfunction (HI)Cannot detect accelerator sensor 2 normally. Check the sensor voltage. There could be a

+B short.

15P2228Atmospheric pressure sensor malfunction (LO)The atmospheric pressure sensor (inside the

ECU) is abnormal. If it occurs frequen tly, the ECU must be repaired or replaced.

15P2229Atmospheric pressure sensor malfunction (HI)The atmospheric pressure sensor (inside the ECU) is abnormal. If it occurs frequen tly, the

ECU must be repaired or replaced.

72P2633Supply pump solenoid valve 2 malfunctionSupply pump solenoid valve 2 has abnormal voltage. There could be an open circuit or

ground short.

PCV2 for large vehi- cles
72P2634Supply pump solenoid valve 2

malfunction

Supply pump solenoid valve 2 has abnormal

voltage. There could be a +B short.

PCV2 for large vehi-

cles

9U0101Communication obstruction

(transmission)

Communication with the transmission ECU is

obstructed.

Abnormal communi-

cation with AT-ECU

OTCP_CodeDST-1 displayCode explanationReference
9U0104Communication obstruction

(cruise)

Communication with the vehicle cruise ECU is

obstructed.

9U0121Communication obstruction

(ABS)

Communication with the ABS ECU is

obstructed.

9U0132Communication obstruction (air

suspension)

Communication with the air suspension ECU

is obstructed.

9U0155Communication obstruction

(meter)

Communication with the meter ECU is

obstructed.

9U1001CAN communication obstruction (vehicle)The communication with the other computers installed in the vehicle is abnormal.CAN communica-

lion bus OFF judg- ment

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