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Service Manual
Eaton Hybrid Drive SystemTRTS2500 August 2012
EH-11NA1206A-PBD
4-Battery PEC Model
4-Battery PEC
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Warnings & Cautions
Warnings and Cautions
Throughout this service manual there are paragraphs that are marked with a title of DANGER,WARNING, or CAUTION. These special paragraphs contain specific safety information and mustbe read, understood, and heeded before continuing the procedure or performing the step(s).
DANGER INDICATES YOU WILL BE SEVERLY INJURED OR KILLED IF DO NOT FOLLOW THEINDICATED PROCEDURE.
! WARNING
WARNING INDICATES AN IMMEDIATE HAZARD, WHICH COULD RESULT INSEVERE PERSONAL INJURY IF YOU DO NOT FOLLOW THE INDICATEDPROCEDURE.
! CAUTIONCAUTION INDICATES VEHICLE OR PROPERTY DAMAGE COULD OCCUR IFYOU DO NOT FOLLOW THE INDICATED PROCEDURE.
Note: NOTE INDICATES ADDITIONAL DETAIL THAT WILL AID IN THE DIAGNOSIS ORREPAIR OF A COMPONENT/SYSTEM.
! WARNINGFollow the specified procedures in the indicated order to avoid personalinjury:
1. IF THE HIGH-VOLTAGE CONES ARE AROUND THE VEHICLE AND THE LOCKOUT ISINSTALLED ON THE PEC, THE ONLY PERSON THAT SHOULD BE ALLOWED TO STARTTHE VEHICLE IS THE PERSON WHO SIGNED THE LOCKOUT TAG.
2. Before working on a vehicle or leaving the cab while the engine is running you should placethe shift lever in “N” set the parking brake, and block the wheels.
3. For safety reasons, always engage the service brakes prior to selecting gear positions from“N.”
4. Before starting a vehicle always be seated in the driver's seat, select “N” on the shift control,and set the parking brakes.
5. When parking the vehicle or leaving the cab you should place the shift lever in “N” and set theparking brake.
6. In vehicles with ePTO, the engine and/or Motor/Generator can start in ePTO mode. Neverperform any maintenance or work on vehicle, while in this mode.
7. 24-volt Battery (+) and (-) must be disconnected prior to any welding on any Hybrid equippedvehicle.
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High-Voltage Warnings & Cautions Warnings & Cautions
! CAUTIONDo not release the parking brake or attempt to select a gear until the airpressure is at the correct level.
! CAUTIONTo avoid damage to the transmission during towing place the shift lever in"N" and lift the drive wheels off the ground or disconnect the driveline.
High-Voltage Warnings & Cautions
• Use CO2 or Dry Chemical Fire Extinguishers.• The high-voltage wiring is covered in orange insulation or convoluted tubing and marked with
warning labels at the connectors.• All Eaton® Hybrid Diesel/Electric vehicles will be marked 'Hybrid' on the outside of the vehicle,
along with the shift label on the dash.• Refer to OEM for specific location of chassis mounted hybrid components.• Do NOT cut into the orange high-voltage cables.• Do NOT cut into or open the PEC.• Do NOT cut into or open the DC/DC converter.• Do NOT cut into or open the Inverter.
Warning: A buffer zone must be set up and high-voltage insulated rubber gloves (class “0” with
leather protectors) are required prior to working on high-voltage. Failure to follow these instructionsmay result in severe personal injury or death.
Warning: The rubber-insulated gloves that must be worn while working on the high-voltagesystem are class “0” with leather protectors. The rubber gloves must be tested before EVERY usefollowing the rubber insulation gloves testing procedure found in the “Insulated Rubber Glove Test”section. Failure to follow these instructions may result in severe personal injury or death.
Warning: Before inspecting or working on any high-voltage cables or components the “High-Voltage Service Shutdown Procedure” should be followed. Failure to follow these instructions mayresult in severe personal injury or death.
Warning: High-voltage cables and wiring are orange and contain a warning label at theconnectors. High-voltage components are marked with a label. High-voltage rubber insulatedgloves (class “0” with leather protectors) must be used when working on any of these components.Failure to follow these instructions may result in severe personal injury or death.
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Table of Contents
Warnings & Cautions . . . . . . . . . . . . . . . . i
Insulated Rubber Glove Testand High-Voltage Work Area . . . . . . . . . 1
High-Voltage Service Shutdownand Power-Up Procedures . . . . . . . . . . . 3
Diagnostic Tools/ Service Publications. 9
Hybrid Diagnostic Procedure . . . . . . . . 11
Hybrid Component & Connector Locations13
Fault Code Retrieval/Clearing. . . . . . . . 17
Fault Code Isolation Procedure Index . 19
Symptom-Driven Diagnostics Index . . 23
Product Diagnostic Mode (PDM) . . . . . 25
Hybrid Lamp andGear Display Descriptions . . . . . . . . . . 27
Power-Up Sequence Test . . . . . . . . . . . 29
Electrical Pretest . . . . . . . . . . . . . . . . . . 31
Hybrid Electrical Pretest . . . . . . . . . . . . 35
Fault Code Isolation Procedures
Fault Code 1 . . . . . . . . . . . . . . . . . . . . . . 41
Fault Code 2 . . . . . . . . . . . . . . . . . . . . . . 47
Fault Code 3 . . . . . . . . . . . . . . . . . . . . . . 53
Fault Code 4 . . . . . . . . . . . . . . . . . . . . . . 61
Fault Code 5 . . . . . . . . . . . . . . . . . . . . . . 67
Fault Code 6 . . . . . . . . . . . . . . . . . . . . . . 75
Fault Code 7 . . . . . . . . . . . . . . . . . . . . . . 77
Fault Code 8 . . . . . . . . . . . . . . . . . . . . . . 79
Fault Code 9 . . . . . . . . . . . . . . . . . . . . . . 83
Fault Code 10 . . . . . . . . . . . . . . . . . . . . . 87
Fault Code 11 . . . . . . . . . . . . . . . . . . . . . 91
Fault Code 12 . . . . . . . . . . . . . . . . . . . . . 93
Fault Code 14 . . . . . . . . . . . . . . . . . . . . . 95
Fault Code 16 . . . . . . . . . . . . . . . . . . . . . 99
Fault Code 17 . . . . . . . . . . . . . . . . . . . . 105
Fault Code 18 . . . . . . . . . . . . . . . . . . . . 111
Fault Code 19 . . . . . . . . . . . . . . . . . . . . 115
Fault Code 22 . . . . . . . . . . . . . . . . . . . . 119
Fault Code 24 . . . . . . . . . . . . . . . . . . . . 123
Fault Code 26 . . . . . . . . . . . . . . . . . . . . 127
Fault Code 27 . . . . . . . . . . . . . . . . . . . . 131
Fault Code 32 . . . . . . . . . . . . . . . . . . . . 135
Fault Code 33 . . . . . . . . . . . . . . . . . . . . 139
Fault Code 34 . . . . . . . . . . . . . . . . . . . . 143
Fault Code 35 . . . . . . . . . . . . . . . . . . . . 147
Fault Code 36 . . . . . . . . . . . . . . . . . . . . 153
Fault Code 37 . . . . . . . . . . . . . . . . . . . . 155
Fault Code 38 . . . . . . . . . . . . . . . . . . . . 161
Fault Code 39 . . . . . . . . . . . . . . . . . . . . 167
Fault Code 40 . . . . . . . . . . . . . . . . . . . . 173
Fault Code 48 . . . . . . . . . . . . . . . . . . . . 179
Fault Code 49 . . . . . . . . . . . . . . . . . . . . 183
Fault Code 50 . . . . . . . . . . . . . . . . . . . . 185
Fault Code 51 . . . . . . . . . . . . . . . . . . . . 187
Fault Code 52 . . . . . . . . . . . . . . . . . . . . 191
Fault Code 56 . . . . . . . . . . . . . . . . . . . . 197
Fault Code 58 . . . . . . . . . . . . . . . . . . . . 201
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Table of Contents
Fault Code Isolation Procedures (Continued)
Fault Code 59 . . . . . . . . . . . . . . . . . . . . 205
Fault Code 60 . . . . . . . . . . . . . . . . . . . . 211
Fault Code 61 . . . . . . . . . . . . . . . . . . . . 215
Fault Code 63 . . . . . . . . . . . . . . . . . . . . 219
Fault Code 64 . . . . . . . . . . . . . . . . . . . . 223
Fault Code 65 . . . . . . . . . . . . . . . . . . . . 227
Fault Code 66 . . . . . . . . . . . . . . . . . . . . 233
Fault Code 67 . . . . . . . . . . . . . . . . . . . . 237
Fault Code 68 . . . . . . . . . . . . . . . . . . . . 243
Fault Code 70 . . . . . . . . . . . . . . . . . . . . 247
Fault Code 71 . . . . . . . . . . . . . . . . . . . . 249
Fault Code 72 . . . . . . . . . . . . . . . . . . . . 253
Fault Code 73 . . . . . . . . . . . . . . . . . . . . 257
Fault Code 74 . . . . . . . . . . . . . . . . . . . . 261
Fault Code 75 . . . . . . . . . . . . . . . . . . . . 263
Fault Code 76 . . . . . . . . . . . . . . . . . . . . 265
Fault Code 78 . . . . . . . . . . . . . . . . . . . . 269
Fault Code 82 . . . . . . . . . . . . . . . . . . . . 273
Fault Code 83 . . . . . . . . . . . . . . . . . . . . 279
Fault Code 84 . . . . . . . . . . . . . . . . . . . . 285
Fault Code 85 . . . . . . . . . . . . . . . . . . . . 293
Fault Code 88 . . . . . . . . . . . . . . . . . . . . 299
Fault Code 89 . . . . . . . . . . . . . . . . . . . . 303
Fault Code 95 . . . . . . . . . . . . . . . . . . . . 309
Fault Code 101 . . . . . . . . . . . . . . . . . . . 315
Fault Code 103 . . . . . . . . . . . . . . . . . . . 319
Fault Code 105 . . . . . . . . . . . . . . . . . . . 325
Fault Code 107 . . . . . . . . . . . . . . . . . . . 331
Fault Code 108 . . . . . . . . . . . . . . . . . . . 347
Fault Code 110 . . . . . . . . . . . . . . . . . . . 353
Fault Code 111 . . . . . . . . . . . . . . . . . . . 357
Fault Code 112 . . . . . . . . . . . . . . . . . . . 363
Fault Code 113 . . . . . . . . . . . . . . . . . . . 369
Fault Code 114 . . . . . . . . . . . . . . . . . . . 375
Fault Code 115 . . . . . . . . . . . . . . . . . . . 381
Fault Code 116 . . . . . . . . . . . . . . . . . . . 387
Fault Code 116 . . . . . . . . . . . . . . . . . . . 395
Fault Code 117 . . . . . . . . . . . . . . . . . . . 405
Fault Code 166 . . . . . . . . . . . . . . . . . . . 411
Front Box Test . . . . . . . . . . . . . . . . . . . 413
Engine Crank Test . . . . . . . . . . . . . . . . 419
Hybrid Performance Test. . . . . . . . . . . 423
Gear Engagement Test . . . . . . . . . . . . 427
Wiring Diagrams. . . . . . . . . . . . . . . . . . 431
Connector Pin Description . . . . . . . . . 435
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Insulated Rubber Glove Test and High-Voltage Work Area
Insulated Rubber Glove Test
! WARNING
The rubber-insulated gloves that must be worn while working on the high-voltage system are class “0” with leather protectors. The rubber glovesshould be tested before EVERY use following the rubber insulation glovestesting procedure found in the “Diagnostic Tools” section. Failure to followthese instructions may result in severe personal injury or death.
• The insulated rubber gloves that must be worn while working on the high-voltage system areclass “0” rated. They must be inspected before each use and must always be worn inconjunction with the leather outer glove. Any hole in the insulated rubber glove is a potentialentry point for high-voltage.
• Roll the glove up from the open end until the lower portion of the glove begins to balloon fromthe resulting air pressure. If the glove leaks any air it must not be used.
• The gloves should not be used if they exhibit any signs of wear and tear.• The leather gloves must always be worn over the rubber insulating gloves in order to protect
them.• The rubber insulating gloves must be class “0” and meet all of the American Safety Testing
Materials Standards.
High-Voltage Work Area Requirements
! WARNINGA buffer zone must be set up and high-voltage insulated rubber gloves(class “0” with leather protectors) are required prior to working on any high-voltage. Failure to follow these instructions may result in severe personalinjury or death.
The buffer zone is required only when working on the high-voltage DC or AC systems and is calledout both in the “High-Voltage Service Shutdown Procedure” and the individual repair procedures.
• Position the vehicle in the service bay.• Position four orange cones around the corners of the vehicle to mark off a 1m (3 ft.) perimeter
around the vehicle.• Do not allow any unauthorized personnel into the buffer zone during repairs involving high-
voltage. Only personnel trained for service on the high-voltage system are to be permitted in
the buffer zone.
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Insulated Rubber Glove Test Insulated Rubber Glove Test and High-Volt-
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High-Voltage Service Shutdown and Power-Up Procedures
Warning: A buffer zone must be set up and high-voltage insulated rubber gloves (class “0” withleather protectors) are required prior to working on high-voltage. Failure to follow these instructionsmay result in severe personal injury or death.
Warning: The rubber-insulated gloves that must be worn while working on the high-voltagesystem are class “0” with leather protectors. The rubber gloves must be tested before EVERY usefollowing the rubber insulation gloves testing procedure found in the “Insulated Rubber Glove Test”section. Failure to follow these instructions may result in severe personal injury or death.
Warning: Before inspecting or working on any high-voltage cables or components the “High-
Voltage Service Shutdown Procedure” must be followed. Failure to follow these instructions mayresult in severe personal injury or death.
Warning: High-voltage rubber insulated gloves (class “0” with leather protectors) must be wornwhen working on any high- voltage cables. The “High-Voltage Service Shutdown Procedure” mustbe followed prior to removing any high-voltage cables. Failure to follow these instructions mayresult in severe personal injury or death.
Warning: High-voltage cables and wiring are orange and contain a warning label at theconnectors. High-voltage components are marked with a label. High-voltage rubber insulatedgloves (class “0” with leather protectors) must be used when working on any of these components.Failure to follow these instructions may result in severe personal injury or death.
Air Filter Cover Wing Nuts
Exhaust Duct
PEC Service Switch Access Panel Covers
Access PanelSecurity Screws
Low-Voltage 19-Pin Connector
Top Cover
Air Filter Cover
High-Voltage DCConnector to Inverter
Air Outlet
Access Panel(On side not shown)
Cooling Pipes
8 Mounting Holes(Mounting hardware supplied by OEM)
Cover Bolts
Lifting Eyes
Cover Security Screws
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High-Voltage Service Shutdown and Power-
4-Battery High-Voltage Service Shutdown Procedure
1. Follow “High-Voltage Work Area” procedure.
2. Locate the red PEC Service Switch on the front of the PEC and push to the “Off” position.
3. Turn ignition key “On”.
4. Allow the system to set for a minimum of 5 minutes to discharge high-voltage.
5. Connect ServiceRanger.
6. Select Vehicle Data Monitor from the main menu.
7. Select J1939 HV Battery.
8. Monitor the J1939 HV Battery (Parameter 520323) voltage until it displays 30 volts or less.
Note: If after 5 minutes J1939 HV Battery does not display 30 volts or less, contact RoadrangerCall Center at 1-800-826-4357.
9. Turn ignition key “Off”.
10. Proceed to repair or troubleshooting step. Perform the 4-Battery PEC Isolation Procedurebefore making any internal repairs to the 4-Battery PEC.
PEC Service Switch
2
5 6 7 8
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High-Voltage Service Shutdown and Power-Up Procedures
4-Battery High-Voltage Isolation Procedure
1. After performing the “High-Voltage Service Shut-Down Procedure”, if removal is necessary,refer to the “4-Battery Power Electronics Carrier (PEC) Removal and Installation” procedure inthe service manual TRSM2000.
2. Using a 13 mm socket, remove the 14 nuts and lock washers used to secure both accesspanels. Using a T-27 Plus bit, remove the two security screws and lock washers used to secure
the access panels. Remove the access panel and gaskets.
3. Put on high voltage “0” rated gloves and leather protectors.
4. Remove the 4-Battery PEC main fuses by lifting up on each handle and gently pulling eachfuse from the socket.
Note: There are two main fuses in the 4-Battery PEC.
AccessPanels
AccessPanelSecurityScrews
Main Fuses
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High-Voltage Service Shutdown and Power-
5. Wearing the high voltage “0” rated gloves and leather protectors, pull the battery connectionsfollowing the sequence in the image below.
6. To complete the 4-Battery PEC High-Voltage Isolation Procedure, it is required to place theaccess covers back on the 4-Battery PEC. Secure access covers with lock washers and nutsto service the 4-Battery PEC.
7. Proceed to repair or troubleshooting step.
1 2 3 4
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High-Voltage Service Shutdown and Power-Up Procedures
4-Battery PEC High-Voltage Service Power-Up Procedure
1. Remove both access covers.
2. Put on high voltage “0” rated gloves and leather protectors.
3. Reinstall battery connections following the sequence in the image below.
4. Wearing the high voltage “0” rated gloves and leather protectors, reinstall the two main fuses.
5. Replace both access panel gaskets and reinstall the access panels. Reinstall the 14 lockwashers and nuts. Torque to 44-53 in-lb (5-6 N•m).
1 2 3 4
Main Fuses
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High-Voltage Service Shutdown and Power-
6. Install the two lock washers and security screws. Torque to 44-53 in-lb (5-6 N•m).
7. Install the 4-Battery PEC to the vehicle using proper equipment and safety procedures.
Note: The weight of the 4-Battery PEC is 513 lbs (230 kg).
8. Using a 17 mm socket, install the eight OEM supplied mounting bolts, lock washers, and flatwashers. Torque fasteners to 43-48 ft-lb (32.5-36.6 N•m).
9. Connect the OEM supplied Low-Voltage 19-Pin Connector onto the 4-Battery PEC.
10. Wearing the high voltage “0” rated gloves and leather protectors, install the High-Voltage DCConnector to the Inverter and lock it into place.
11. Reassemble the cooling pipes.
12. Pull out the red PEC Service Switch to the “On” position.
13. Start vehicle when appropriate.
AccessPanels
AccessPanelSecurityScrews
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Diagnostic Tools/ Service Publications
Eaton Tools
• Visit www.Roadranger.com
SPX/OTC Tools
• Contact SPX / OTC at (800) 328-6657
Tool Description
ServiceRanger version 3 ServiceRanger PC based Diagnostic Tool
Tool Description
J-49818 Eaton Hybrid Tool Safety Kit - Basic PPE (Items listed below can be orderedseparately)
J-48603 High-Voltage Gloves w/leather protectors (1000 volt)
J-48605 Hybrid Safety Cones (set of 4)
Tool Description
J-49819 Eaton Hybrid Tool Safety Kit - Basic Plus PPE (Items listed below can beordered separately)
J-48603 High-Voltage Gloves w/leather protectors (1000 volt)
J-48605 Hybrid Safety Cones (set of 4)
J-48907 Orange Magnetic Sign
J-48608 Hybrid Non-Conductive Safety Pole
J-48908 Glove Bag
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Eaton Tools Diagnostic Tools/ Service Publications
J-48893 - Hybrid PPE / Service Tool Kit (includes J-49819 kit and items from Miscellaneous
Service Tools highlighted with *)
Service Publications
• Visit www.Roadranger.com
Tool Description
Misc. Service Tools Items listed below are ordered separately
J-48624 Nexiq USB-Link Communication Adapter
J-43318-A* Pin Adapter Kit - Interface Harness DiagnosticsJ-48735* Alignment Pins - Hybrid Motor/Gen to Transmission Main Case
J-49111* Clutch Alignment Tool
J-46708* Fluke Digital Multimeter
J-48505 Input Shaft Turning Socket
J-48507 Lifting Fixture - Power Electronics Carrier
J-48502 Jack Adapter Plate - Hybrid Drive Unit
5019 Transmission Jack - Low Lift
5078 Transmission Jack - High LiftJ-48577 Engine/Transmission Stand Adapter Plate - Hybrid Drive Unit
J-29109-A Engine/Transmission Stand - 6000 lb. Rating
TRSM2000 Service Manual (covers external components on transmission and
Hybrid components)
TRSM0110 Service Manual (covers internal transmission repairs only)
TRTS2500 Troubleshooting Guide
TRDR1000 Driver Instructions
TRDR1110 First Responder Guide
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Hybrid Diagnostic Procedure
Hybrid Diagnostic Procedure
Key ON
Retrieve Active Faultswith ServiceRanger.
Active Codes YesGo to "Fault Code Isolation Procedure
Index"
No
Does Gear DisplayShow an "N"
Does Engine Crank
No
Yes
NoGo to "Engine CrankTest"
Yes
If equipped, doesvehicle operatenormal in ePTO
mode?
NoGo to "ePTO Test”
Yes
If a mode other than neutral is selected doestransmission engage a gear? NOTE: ServiceBrake must be applied prior to selecting a
gear.
No
Go to "Gear Engagement Testif solid “N” is displayed
Go to “Front Box Test” isflashing gear number is displayed
Yes
Is vehicle accelerationperformance acceptableNo
Go to "Hybrid
Performance Test"
Yes
Clear faults andoperate vehicle basedon customers
concern
Inactive Faults = Goto "Product
Diagnostic Mode"
Active Faults = Go to"Fault Isolation
Procedure Index"
No Fault = TestComplete
Is Red "Stop Hybrid" orAmber “Check Hybrid”lamp blinking?
Yes
No
Go to Hybrid LampGear Display Description
Go to Hybrid Lamp andGear Display description
Go to “Gear EngagementTest”
Will vehicle movefrom a stop?
Yes
No
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Hybrid Diagnostic Procedure
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Hybrid Component & Connector Locations
Transmission Wiring Connections
Hybrid Control Module (HCM)
Left: 38-Way System ConnectorRight: 38-Way Vehicle Connector
Transmission Electronic Control Unit (TECU)Left: 38-Way Vehicle ConnectorRight: 38-Way System Connector
lectronic Clutch Actuatorop: 3-Way Connectorottom: 8-Way Connector
Output Shaft Speed Sensor
Rail Position Sensor
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Transmission Wiring Connections Hybrid Component & Connector Locations
Gear Position Sensor
High-Voltage 3-Way AC Connector
Motor/GeneratorResolver Connector
Motor/GeneratorTemperature Connector
Input Shaft Speed Sensor
Transmission Diagnostic Port
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Hybrid Component & Connector Locations Component Wiring Connections
Component Wiring Connections
24V DC(-)
High Voltage DC ConnectorTop: DC(-)Bottom: (DC(+)
Test Port Connection(Not used)
OEM Connection
DC/DC Converter
HIgh Voltage 3-Way AC Connector
Low Voltage 40-Way Connector High-Voltage DC Connector to PEC
Inverter
Coolant Ports
24V DC(+)
(-) (+)
Coolant Port Inlet
Coolant Port Outlet
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Component Wiring Connections Hybrid Component & Connector Locations
Air Filter Cover Wing Nuts
Exhaust Duct
PEC Service Switch Access Panel Covers
Access PanelSecurity Screws
Low-Voltage 19-Pin Connector
Top Cover
Air Filter Cover
High-Voltage DCConnector to Inverter
Air Outlet
Access Panel(On side not shown)
Cooling Pipes
8 Mounting Holes
(Mounting hardware supplied by OEM)
Cover Bolts
Lifting Eyes
Power Electronics Carrier (PEC)
Cover Security Screws
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Fault Code Retrieval/Clearing
All Eaton® Hybrid systems require the use of ServiceRanger for all diagnostics. To view fault
codes or clear them follow the procedures below.
View Active and Inactive Faults
1. Connect ServiceRanger to the 9-pin diagnostic connector.
2. Go to the Tools menu and select the “Communication” tab.
3. Select the appropriate communication device for J1587 and J1939.
4. Select “Connect” on the main page.
5. Select the “View Fault Codes” tab.
Note: Initial use requires all steps, however subsequent uses require only steps 4 and 5.
Clear Inactive Faults
1. Connect ServiceRanger to the 9-pin diagnostic connector.
2. Go to the Tools menu and select the “Communication” tab.
3. Select the appropriate communication device for J1587 and J1939.4. Select “Connect” on the main page.
5. Select the “View Fault Codes” tab.
6. Select the “Clear Faults” button.
Note: Initial use requires all steps, however subsequent uses require only steps 4 and 5.
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Fault Code Retrieval/Clearing
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Fault Code Isolation Procedure Index
Index
Fault Code SPN FMI Description Page Number
1 520225 0,6,15 Motor/Generator Current Sensor page 41
2 520226 3 Motor/Generator TemperatureSensor
page 47
3 520227 0 Motor/Generator Temperature page 53
4 520228 0,2, 21-27 Motor/Generator Rotation SpeedSensor
page 61
5 520229 21-29 Motor/Generator AC Cable page 67
6 629 13 No ECU Operation (HCM) page 75
7 629 13 Improper ECU Configuration(HCM)
page 77
8 158 4 Loss of Switched Ignition PowerFault (HCM)
page 79
9 168 14 Weak Battery Voltage (HCM) page 83
10 168 4 Low Battery Voltage (HCM) page 87
11 629 12 No ECU Operation (TECU) page 91
12 629 13 Improper ECU Configuration(TECU)
page 93
14 751 2, 3, 4 Invalid Shifter Range page 95
16 625 2 High Integrity Link (HIL) page 99
17 626 3, 4 Start Enable Relay page 105
18 520200 2, 9 ECA Communication page 111
19 520273 2, 9 CAN ECA Message page 115
22 563 2, 9, 14 J1939 ABS Message (HCM) page 119
24 525 9 J1939 HCM Message (TECU) page 123
26 522 10 Clutch Slip page 127
27 788 7, 14 Clutch Disengagement page 131
32 43 2 Loss of Switched Ignition Power(TECU)
page 135
33 168 4 Low Battery Voltage (TECU) page 139
34 168 14 Weak Battery Voltage (TECU) page 143
35 639 2 J1939 Communication Link page 147
36 639 14 J1939 Engine Message (TECU) page 153
37 610 5 Power Supply (TECU) page 155
38 520243 3, 4, 5, 14 Battery Fan Relay page 161
39 520247 3, 4, 5 Heat Exchanger Relay page 167
40 520248 3, 4, 5, 14 Cooling Pump Relay page 173
48 523 2, 9 J1939 Transmission Message(HCM)
page 179
49 190 2, 9 J1939 Engine Message (HCM) page 183
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Index Fault Code Isolation Procedure Index
50 701 2, 9 J1939 Body Controller Message(HCM)
page 185
51 60 2, 3, 4, 10 Rail Position Sensor page 187
52 59 2, 3, 4 Gear Position Sensor page 191
56 161 2,3,4, 5,10 Input Shaft Speed Sensor page 197
58 191 2, 3, 4, 5 Output Shaft Speed Sensor page 201
59 639 2, 9 J1939 Communication Link(HCM)
page 205
60 625 2, 9 CAN Communication Link (HCM) page 211
61 772 5, 6 Rail Select Motor page 215
63 773 5, 6 Gear Select Motor page 219
64 788, 520198,520199, 524035
0, 12, 13,21-28
ECA page 223
65 520203 2, 5 ECA Speed Sensor page 227
66 520271 3, 4, 14 ECA Battery Voltage page 23367 520274 3, 4, 5 ECA Ignition Voltage page 237
68 520231 12, 13, 14 Grade Sensor page 243
70 188, 518, 539, 544 0, 1, 2, 7 Engine Failed to Respond (HCM) page 247
71 520275 7 Failed to Disengage Gear page 249
72 520277 7 Failed to Select Rail page 253
73 520278 7 Failed to Engage Gear page 257
74 93, 190 7 Engine Failed to Respond(TECU)
page 261
75* 520276 14 Power Down In Gear page 263
76 520250 3, 4, 16,18 High-Voltage Battery PotentialVoltage
page 265
78 520232 6 High-Voltage Battery Current page 269
82 520233 0,16 High-Voltage BatteryTemperature
page 273
83 751 12, 13 Invalid Shifter Range page 279
84 751 13 Shift Control Device NotConfigured
page 285
85 639 12 Shift Control Device Incompatible page 293
88 520223 2, 9 Inverter CAN Message (HCM) page 299
89 520234 2, 9 BCU CAN Message (HCM) page 303
95 520249 3, 4 24-volt Cranking Relay page 309
101 520238 0, 22-31 High-Voltage Battery page 315
103 520265 22-26 Battery Control UnitCommunication
page 319
105 520240 22-30 Battery Control Unit page 325
107 520242 1 High-Voltage Battery LeakDetection
page 331
108 520268 3, 4 Battery Control Unit PowerSupply
page 347
Fault Code SPN FMI Description Page Number
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Fault Code Isolation Procedure Index Index
110 520220 21-29 Inverter page 353
111 520260 12 - 28 Inverter Communication page 357
112 520221 3, 4 Inverter Voltage page 363
113 520222 6, 14 Inverter Current page 369
114 520261 3, 4 Inverter Power Supply page 375
115 520223 0 Inverter Temperature page 381
116 521210, 521211,521212
3, 4, 5 High-Voltage Relays page 387
116 520224 10, 14, 20 High-Voltage Relays page 395
117 520251 3, 14, 29 BCU Relay Cut Request page 405
Fault Code SPN FMI Description Page Number
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Index Fault Code Isolation Procedure Index
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Symptom-Driven Diagnostics Index
Index
Symptom Isolation Procedure PageNumber
Power-up no crank and Gear Display shows a“-”
Front Box Test page 413
Power-up no crank and Gear Display shows a“N”
Engine Crank Test page 419
Power-up no crank and Gear Display shows “--”, “**”, or blank
Power Up Sequence Test page 29
Power-up vehicle cranks and Gear Displayshows “--”, “**”, or blank
Refer to OEM for gear display issue
Vehicle acceleration performance is notacceptable
Hybrid Performance Test page 423
Transmission will not engage a gear fromneutral and warning tone sounds (solid “N” ingear display)
Gear Engagement Test page 427
Transmission will not move from a stop (solidgear number in gear display)
Gear Engagement Test page 427
Transmission will not engage a gear fromneutral (flashing gear number in gear display)
Front Box Test page 413
Red “Service” lamp on the push button shiftcontrol is on/blinking
Fault Code Retrieval and Clearing page 17
Amber “Check Hybrid” lamp on the dash is on Fault Code Retrieval and Clearing page 17
Red “Stop Hybrid” lamp on the dash is on Fault Code Retrieval and Clearing page 17
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Symptom-Driven Diagnostics Index
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Product Diagnostic Mode (PDM)
Product Diagnostic Mode (PDM) is used to help diagnose inactive codes that may have been setduring normal driving. This diagnostic mode increases the sensitivity of the fault sensingcapabilities.
This procedure tests loose, degraded, and intermittent connections. Use the active fault isolation
procedure to guide you to the wiring and connectors that are associated with the inactive faultcodes. Flex the wiring harness and connectors and attempt to recreate the fault after activating(PDM).
PDM is only to be used by a trained service technician in an authorized dealer.
To enter PDM mode
Note: The vehicle will not start in Product Diagnostic Mode (PDM). You must turn vehicle key“OFF” and allow the system to power down to exit PDM.
1. Vehicle must be stationary, engine must not be running, vehicle parking brake must be set.
2. Connect ServiceRanger to the 9-pin diagnostic connector.
3. Select the “View Fault Codes” screen.
4. Perform two key clicks of the ignition switch starting in the “ON” position and ending in the“ON” position
Note: An “88” may show up in the dash at key on, which is a normal power-up test of the display.
5. The gear display will flash a solid “PD” (Product Diagnostic Mode) and the mode will beactivated.
6. Flex the wiring harness and connectors and attempt to recreate the fault.
7. If a fault becomes active during PDM, ServiceRanger will display the fault with a status ofactive.
8. If a fault is detected, exit PDM mode and perform the corresponding “Fault IsolationProcedure” page 11.
Note: Active codes set during PDM mode will not be stored as inactive.
9. To exit PDM mode, power the system down by turning the key to the “OFF” position.
PDM will only work with the following inactive codes
9, 10, 14, 16, 17, 18, 19, 22, 24, 32, 33, 34, 35, 36, 38, 39, 40, 48, 49, 50, 51, 52, 56, 58, 59, 60,
61, 63, 76, 87, 88, 89, 95
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Product Diagnostic Mode (PDM) is used to help diagnose inactive codes that may have
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Hybrid Lamp and Gear Display Descriptions
All Eaton® Hybrid systems use a combination of three lamps to indicate failures of differentoperating systems and the ability of the vehicle to drive. These lamps include the red “Service”lamp, amber “Check Hybrid” lamp, and the red “Stop Hybrid” lamp. The details for each lamp areincluded below.
Red “Service” Lamp
1. This lamp is located on the Push Button Shift Control and reads “SERVICE.”
2. This lamp is turned on and off by the Transmission Electronic Control Unit (TECU) forAutomated Transmissions faults over the High Integrity Link (HIL).
3. This lamp also comes on momentarily at key on then goes out as part of the TECU self-test.
Amber “Check Hybrid” Lamp
1. This lamp is located near the middle of the dash. The lamp is amber and contains wordingbelow stating “Check Hybrid.”
2. This lamp is turned on and off indirectly by the Hybrid Control Module (HCM) and directly bythe Body Controller over J1939.
3. This lamp is turned on when a Hybrid system fault is active.
4. When the amber lamp is on, the vehicle can still be driven, however, the vehicle may operatewithout Hybrid electric assist.
Red “Stop Hybrid” Lamp
1. This lamp is located near the middle of the dash. The lamp is red and contains wording belowstating “Stop Hybrid.”
2. This lamp is turned on and off indirectly by the Hybrid Control Module (HCM) and directly bythe Body Controller over J1939.
3. This lamp is turned on when a Hybrid system fault is active.
4. When the red lamp is on, the vehicle should not be driven. Have the vehicle towed or trailered
to the OEM truck dealership.Blinking amber “Check Hybrid” Lamp
1. The majority of vehicles have a red stop switch on the front of the Power Electronics Carrier(PEC). If this switch is pushed in, the amber “Check Hybrid” lamp will blink. To reset, pull theswitch out and turn the key off for 2 minutes. If the lamp remains on, go to the “HybridDiagnostic Procedure on page 11 and start with step 3 “Retrieve Active Faults withServiceRanger”. You should have an active Fault Code 76 FMI 4, or Fault Code 116, FMI 10.Continue to the diagnostic test for the fault that is currently active.
“ST” in Gear Display
1. A “ST” in the gear display indicates a driver trigger Snapshot was recorded. Snapshot is adiagnostic tool that is used to capture specific data at the time of a fault. It is triggered through
two different means listed below.a. Fault code triggered - Specific faults will trigger the HCM or TECU to capture a Snapshot
file for later retrieval. This method will not display and “ST” in the gear display.b. Driver triggered - If the driver chooses to capture a Snapshot of an event he needs to
decide if he wants TECU or HCM data. To capture a TECU Snapshot select, “Low” andthe up button twice. To capture a HCM Snapshot select, “Drive” or “Low” and the up buttonand the down button.
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Hybrid Lamp and Gear Display Descriptions
“PD” in Gear Display
1. A “PD” in the gear display indicates the TECU and HCM are in a special diagnostic modecalled Product Diagnostic Mode (PDM). For more details on the mode and its operation seethe Product Diagnostic Mode on page 25.
“CA” in Gear Display
1. A “CA” in the gear display indicates the HCM is detecting a clutch abuse situation. If thevehicle detects a clutch abuse situation it will first tone the Push Button Shift Control and flasha “CA” in the gear display. If the clutch abuse situation continues, the Hybrid system will onlyallow an electric only launch in addition to continuing the tone and the “CA”. If the clutch abusecontinues, while driving the Hybrid system will open the clutch once vehicle speed is below5mph and allow the clutch to cool.
“OS” in Gear Display
1. A “OS” in the gear display indicates the HCM is detecting a motor overspeed situation. Thevehicle will upshift in Drive and Low automatically, however, if the user is in Manual theyperform the upshift unless the vehicle is close to the motor overspeed. If the vehicle isdescending a long steep grade in top gear, the driver may see an “OS” indicating he needs todepress the service brake pedal to slow the vehicle. The HCM will normally shift the vehicle or
reduce torque to prevent the motor from going overspeed.
“F” in Gear Display
1. A “F” in the gear display indicates the TECU has detected an active fault. This fault can beaccessed with ServiceRanger. See the Fault Code Isolation Procedure Index starting onpage 19.
“-” in Gear Display
1. A “-” in the gear display indicates the transmission is stuck in gear. See the Symptom DrivenDiagnostic Index on page 23.
“**” in Gear Display
1. A “**” in the gear display indicates the gear display has power but no communication on thedata link. See the Symptom Driven Diagnostic Index on page 23.
“- -” in Gear Display
1. A “- -” in the gear display indicates the gear display has power, and there is no communicationpresent on the data link, or the TECU isn’t communicating with the display. See the SymptomDriven Diagnostic Index on page 23.
Blank Gear Display
1. A Blank gear display indicates the display has lost power, or the TECU isn’t communicatingwith the gear display. See the Symptom Driven Diagnostic Index on page 23.
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Power-Up Sequence Test
Overview
This test must be performed only if you experience a “vehicle won’t crank” with a “- -”, “**”, or blankgear display. You must perform the Electrical Pretest prior to this procedure.
Possible Causes
• TECU Power Supply
• TECU
Fallback Mode
There is no fallback for this concern and the vehicle will not crank if the TECU or power supplyharness has failed.
Required Tools
• Basic Hand Tools
• Battery Load Tester• Eaton® Test Adapter Kit J-43318
• Digital Volt/Ohm Meter J-46708
STEP A
Procedure Condition Action
1. Perform the Electrical Pretest
2. Is concern still present afterthe Electrical Pretest.
Yes Replace the TECU. Return to theDiagnostic Procedure.
No Test Complete. Return to theDiagnostic Procedure.
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Overview Power-Up Sequence Test
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Electrical Pretest
Overview
This test must be performed prior to diagnosing select Hybrid faults. This test verifies the quality ofthe standard battery system and the main power and ground supplies to the Hybrid ControlModule (HCM), Transmission Electronic Control Unit (TECU), and Electronic Clutch Actuator
(ECA).Note: This test will be called out in the procedures where it is required.
Possible Causes
• Low-voltage can be caused by the following:
• Low batteries
• Charging system
• Power harness connections or fuses to TECU, HCM, or ECA
Fallback Mode When Fault is Set
A weak power supply can cause many issues such as shift performance, power-up or failure tocrank.
Required Tools
• Basic Hand Tools• Battery Load Tester• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
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Electrical Pretest Wiring Schematic Electrical Pretest
Electrical Pretest Wiring Schematic
ABC
ECA - 3-Way Connector
H
Battery
38
Plus (+)
B
HCM
HCM Power (Vehicle)
36
ECA
ECA PowerC
ECA Ground
Neg (-)
Clutch Ignition (System)
Front View(HCM - Vehicle Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
ECA -Pack 8-Way Connector
E
A B C D
H G F
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
HCM Ground (Vehicle)
TECU
TECU Ground 36
35
38
TECU Ignition
TECU Power
13
Front View (TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
35HCM Ignition (Vehicle)
Ignition Relay
87
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Electrical Pretest Electrical Pretest Procedures
Electrical Pretest Procedures
Electrical Pretest Procedures Continued
STEP A
Procedure Condition Action
1. Key off
2. Inspect starter/battery andin line fuse holderconnections on ElectricClutch Actuator (ECA),Hybrid Control Module(HCM), and TransmissionElectronic Control Unit(TECU) for integrity.
Note: ECA, HCM, and TECUuse a 30 amp fuse. Referto OEM for locations
3. Measure voltage across
batteries.
If voltage is 23 to 25 volts on a
24-volt system
Proceed with battery load test.
Repair or replace batteries asrequired. Go to STEP B
If voltage is outside of range Repair or replace batteries andcharging system as required.Repeat this step.
STEP B
Procedure Condition Action
1. Key on.2. Connect ServiceRanger to
9-pin diagnostic connectorin the cab.
3. Select the “Data Monitor”option and view thefollowing parameters underthe Hybrid (clutch actuator)list.
If PID 132 is within 0.6 volts ofbattery voltage and PID 160reads “1”
Go to STEP C
a. PID 132 “Clutch ActuatorBattery Voltage.”
b. PID 160 “Clutch Actuator
Ignition Switch Status.”
If either voltage is out of range Repair main power or ignitionsupply to the ECA. Repeat thisstep.
Note: If the clutch parameterscan not be viewed onServiceRanger youmust check the powersupply to the ECA witha voltmeter
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Electrical Pretest Procedures Electrical Pretest
Electrical Pretest Procedures Continued
Electrical Pretest Procedures Continued
STEP C
Procedure Condition Action
1. Select the “Data Monitor”
option and view thefollowing parameters underthe Hybrid (Hybrid ControlModule) list.
a. PID 165 “BatteryPotential Voltage”
b. PID 166 “IgnitionSwitch Status.”
If PID 165 is within 0.6 volts ofbattery voltage and PID 166reads “1”
Go to STEP D
Note: If the Battery PotentialVoltage or IgnitionSwitch Status can notbe viewed on
ServiceRanger youmust check the powersupply to the HCM witha voltmeter.
If either voltage is out of range Repair the main power orignition supply to the HCM.Repeat this step.
STEP D
Procedure Condition Action
1. Select the “Data Monitor”option and view thefollowing parameters underthe Hybrid (Transmission)list.
a. PID 168 “BatteryPotential Voltage.”
b. PID 158 “BatteryPotential VoltageSwitched.”
If PID 168 is within 0.6 volts ofbattery voltage and PID 158 iswithin 0.6 volts of ignitionvoltage
Test complete. Return to theFault or Symptom procedurethat directed you to this step.
Note: If the Battery PotentialVoltage or BatteryPotential VoltageSwitched can not beviewed onServiceRanger youmust check the powersupply to the TECUwith a voltmeter.
If either voltage is out of range Repair main power or ignitionsupply to the TECU. Repeat thisstep.
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Hybrid Electrical Pretest
Overview
This test must be performed prior to diagnosing select Hybrid faults. This test verifies the powersupply for the Inverter and Battery Control Unit (BCU).
Note: You must perform the Electrical Pretest before the Hybrid Electrical Pretest.
Note: This test will be called out in the procedures where it is required.
Possible Causes
• Low-voltage can be caused by the following:
• Power harness connections from Inverter or BCU.
Fallback Mode When Fault is Set
Loss of ignition power will cause the Hybrid system to be inoperable. The vehicle will run underdiesel power only.
Required Tools• Basic Hand Tools• High-Voltage Gloves J-48603• Battery Load Tester• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708• ServiceRanger
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Hybrid Electrical Pretest Wiring Schematic Hybrid Electrical Pretest
Hybrid Electrical Pretest Wiring Schematic
Inverter
Chassis Ground 1
Deutsch 19 - Way Mating Connector View(PEC - Low Voltage Connector)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
6
7
6
PEC
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View(Inverter - Low Voltage Connector)
7
9
14
25GND-BC2
Relay Box Enable
Inverter Enable
Chassis Ground 2
HCM(Pin 2)
DC/DC Converter4-Way OEM Connector
4 3
1 2
DC/DCConverter
4
Ground
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Relay Box Enable 2
GND_BC
24
15
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Hybrid Electrical Pretest Hybrid Electrical Pretest Procedures
Hybrid Electrical Pretest Procedures
STEP A
Procedure Condition Action
1. Perform the Electrical
Pretest then continue tostep two.
2. Key off.
! WARNINGFollow “Hybrid ShutdownProcedure” found at front ofbook, to avoid shock, burn, ordeath from improperly handledhigh-voltage.
3. Disconnect the Inverter 40-
way connector.
4. Measure resistance frompin 6 to battery negativeand then from pin 7 tobattery negative.
If resistance is 0 to 0.3 ohmsfrom pin 6 to battery negativeand from pin 7 to batterynegative
Go to STEP B
If resistance is outside of range Repair the Inverter groundharness. Repeat this step.
STEP B
Procedure Condition Action
1. Connect a multi meter tothe Inverter 40-wayconnector pin 9 and pin 6.
2. Key on.
3. Observe multi metervoltage reading.
If voltage is 23 to 25 volts Go to STEP C
If voltage is outside of range Repair the harness from theHCM. Repeat this step.
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Hybrid Electrical Pretest Hybrid Electrical Pretest Procedures
STEP E
Procedure Condition Action
1. Key off.
2. Reconnect PEC 19-wayconnector.
3. Disconnect DC/DCConverter 4-way connector.
4. Measure resistance fromDC/DC Converter 4-wayconnector pin 4 to batterynegative.
If resistance between pin 4 andbattery negative is 0 to 0.3ohms
Test Complete. Reconnect the4-way connector. Return toFault Code Isolation ProcedureIndex page 19.
If resistance is outside of range Repair the ground harness fromthe DC/DC Converter to batterynegative. Repeat this step.
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Hybrid Electrical Pretest Procedures Hybrid Electrical Pretest
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Fault Code 1 Isolation Procedures
Motor/Generator Current Sensor Fault
SA 239
SPN 520225
FMI 0, 6, 15
Overview
The high-voltage Motor/Generator assembly is connected to the Inverter assembly through an AChigh-voltage cable that contains three separate cables. During operation the Inverter monitors theamperage in the AC cables through a current sensor, which is mounted inside the Inverter. Theinductive sensor produces an output based on amperage present in the cables.
Conditions to Run Fault
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 6 is set when Inverter detects current input from the Motor/Generator greater than 100amps for 150 ms
• FMI 0 is set when the Inverter detects current input from the Motor/Generator greater than 200amps for 0.3 ms.
• FMI 15 is set when the sensor offset is out of range at initial check.
Possible Causes
• FMI 0,6
• Inverter
• Motor/Generator
• AC Cable• FMI 15
- Inverter
Fallback Mode When Fault is Set
When Fault Code 1 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display.• Fault is stored in Hybrid Control Module (HCM) memory.• Electric Motor/Generator assist and regen are disabled, however, the high-voltage relays will
remain powered.• HCM continues to control the Hybrid vehicle in a diesel only mode.
• Transmission defaults start gear to 1st.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 1 Isolation Procedures
Required Tools
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed theLock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
• Basic Hand Tools• High-Voltage Gloves J-48603
• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.
Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 1 Isolation Procedures Connector Views
Connector Views
High-Voltage AC Harness Connector View (Amphenol Connector)
W U
V
E D
F
W
V
U
W
V
U
Inverter Motor/
Generator
Phase 1
Phase 2
Phase 3
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
High-Voltage AC Motor/Gen Connector View (Amphenol Connector)
U
V
W
F
E D
Phase 1
Phase 2
Phase 3
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Fault Procedures Fault Code 1 Isolation Procedures
Fault Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Follow “Hybrid Shutdown
Procedure” page 3, to
avoid shock, burn, or death
from improperly handled
high-voltage.
4. Remove the AC cable fromthe Motor/Generator andInverter
5. Measure resistance of eachcircuit in the AC high-voltagecable:
• U-U
• V-V
• W-W
If resistance for each circuit isless than 1 ohm
Go to STEP B
If resistance is outside of range Replace the AC high-voltagecable. Go to STEP V
If FMI 15 is active Replace the Inverter. Go toSTEP V
STEP B
Procedure Condition Action
1. Measure resistance of eachcircuit to ground in the AChigh-voltage cable.
If resistance between each circuitand ground is 5M ohms or greater
Go to STEP C
If resistance is outside of range Replace the AC high-voltagecable. Go to STEP V
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Fault Code 1 Isolation Procedures Fault Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Measure the resistancebetween the following AChigh-voltage cable pins:
If resistance of each phase is 5Mor greater
Go to STEP D
• U-U
• V-V
• W-W
If resistance is outside of range Replace the AC high-voltagecable. Go to STEP V
STEP D
Procedure Condition Action
1. Measure resistance of eachMotor/Generator phase atthe following pins:
If resistance of each phase is lessthan 10 ohms
Replace the Inverter. Go toSTEP V
• U-U
• V-V
• W-W
If resistance is outside of range Replace the Motor/Generator. Goto STEP V
STEP V
Procedure Condition Action1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. Go to FaultCode Retrieval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. Go to FaultCode Retrieval/Clearing onpage 17
If no codes Test complete.
If code 1 appears Return to STEP A to finderror in testing.
If code other than 1 appears Go to Fault Code IsolationProcedure Index on page 19
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Fault Procedures Fault Code 1 Isolation Procedures
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Fault Code 2 Isolation Procedures
Motor/Generator Temperature Sensor Fault
SA 239
SPN 520226
FMI 3
Overview
The Motor/Generator temperature sensor is a thermistor located inside the Motor/Generator thatchanges in value based on the temperature. The Inverter supplies a 5 volt reference voltage to thesensor and measures the volt drop in the circuit. When the Motor/Generator temperature is warmthe sensor resistance is low and the Inverter detects a low-voltage (0.2 volts equals 280°C or536°F). When the Motor/Generator is cold the sensor resistance is high and the Inverter detects ahigh-voltage (4.1 volts equals 0°C or 32°F).
Conditions to Run Fault
• The inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 3 is set when the sensor voltage is greater than 4.1 volts for 10 seconds, while the
Inverter temperature is over 35° C or 95°F, or if the sensor output voltage is less than 0.2
volts for 10 seconds.
Possible Causes
• FMI 3
- Motor/Generator- Short/open temperature sensor wires between the Motor/Generator and theInverter
- Inverter
Fallback Mode When Fault is Set
When Fault Code 2 is set the following conditions will occur:• The amber “Check Hybrid” lamp will display• Fault is stored in Hybrid Control Module (HCM) memory• High-voltage Motor/Generator assist is available, but at a reduced amount
Conditions to Clear Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 2 Isolation Procedures
Required Tools
• Basic Hand Tools
• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
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Fault Code 2 Isolation Procedures Connector Views
Connector Views
36
37
2
1
Inverter Motor/GeneratorTemperature Sensor
TM Ground
TM
Temp Sensor
Temp Sensor
OTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Location
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)
Terminal Side - Harness ConnectorTemperature Sensor
(Deutsch 2-pin connector)
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Fault Code Procedures Fault Code 2 Isolation Procedures
Fault Code Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Follow “Hybrid Shutdown
Procedure” found at front
of book, to avoid shock,
burn, or death from
improperly handled high-
voltage.
4. Disconnect the TemperatureSensor connector at theMotor/Generator.
5. Measure resistance at theMotor/Generator 2-wayTemperature Sensorconnector from pin 1 to pin 2.
If resistance is 0.8K ohms to301.7K ohms
Go to STEP B
If resistance is outside of range Replace the Motor/Generator.Go to STEP V
WARNING
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Fault Code 2 Isolation Procedures Fault Code Procedures
STEP B
Procedure Condition Action
1. Key Off.
2. Disconnect the Inverter40-way connector.
3. Reconnect the Motor/ Generator 2-way temperaturesensor connector.
4. Measure resistance at thefollowing:
a. Inverter 40-wayconnector pin 37 to pin36.
b. Inverter 40-wayconnector pin 37 to
ground.
If resistance is 0.8K - 301.7Kohms between pin 37 and pin 36and resistance between pin 37and ground is 10K ohms orgreater
Replace the Inverter. Go toSTEP V.
If resistance is outside of range Repair the open or short toground in the harness betweenthe Inverter 40-way connectorand the Motor/Generator 2-wayconnector. Go to STEP V.
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectors andthe negative battery cable.
3. Key on.
4. Clear codes. See Fault CodeRetrieval/Clearing on page 17
5. Drive the vehicle and attempt torecreate the code
6. Check for codes. See FaultCode Retrieval/Clearing onpage 17
If no codes Test complete.
If code 2 appears Return to STEP A to find the errorin testing.
If code other than 2 appears Go to Fault Code IsolationProcedure Index page 19
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Fault Code Procedures Fault Code 2 Isolation Procedures
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Fault Code 3 Isolation Procedures
Motor/Generator Temperature Fault
SA 239
SPN 520227
FMI 0
Overview
The Motor/Generator temperature is measured through a thermistor style sensor, which is locatedinternal to the unit. The sensor changes value based on the temperature. The Inverter supplies a 5volt reference voltage to the sensor and measures the volt drop in the circuit. When the Motor/ Generator temperature is warm the sensor resistance is low and the Inverter detects a low-voltage(0.2 volts equals 280°C or 536°F). When the Motor/Generator is cold the sensor resistance is high
and the Inverter detects a high-voltage (4.1 volts equals 0°C or 32°F).
Conditions to Run Fault
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 0 is set when the temperature sensor value is greater than 185°C or 365°F for 1 second.
Possible Causes
• FMI 0
- Motor/Generator
- Inverter
- Liquid cooling system (low coolant, no coolant flow, coolant pump, radiator,radiator fan, reservoir)
Fallback Mode When Fault is Set
When Fault Code 3 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in Hybrid Control Module (HCM) memory• Electric Motor/Generator assist and regen are disabled, however, the high-voltage relays will
remain powered• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Fault Code 3 Isolation Procedures Connector Views
Connector Views
36
37
2
1
Inverter Motor/GeneratorTemperature Sensor
TM Ground
TM
Temp Sensor
Temp Sensor
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)
Terminal Side - Harness ConnectorTemperature Sensor
(Deutsch 2-pin connector)
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Fault Isolation Procedures Fault Code 3 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the 9-pin diagnostic connector.
2. Follow “Hybrid ShutdownProcedure” found at front ofbook, to avoid shock, burn, ordeath from improperly
handled high-voltage.3. Key on
4. Select the Data Monitoroption and view PID 113“Motor/GeneratorTemperature” in the “PowerElectronics” list.
5. Observe PID 113 again after20 minutes
If PID 113 “Motor/GeneratorTemperature” dropped from thefirst reading
Go to STEP B
If PID 113 “Motor/GeneratorTemperature” remained the same
Go to STEP H
STEP B
Procedure Condition Action
1. Key off
2. Observe the coolant levelafter the system has cooleddown to ensure if is filled tothe proper level
If coolant is within therecommended limits
Go to STEP C
If coolant is below therecommended limits Refer to the OEM for coolant typeand fill procedures. Check forsource of coolant leak. Whenrefilling the system it should bepressurized or vacuum bleed ofair to ensure the coolant will flowproperly during normal operation.
WARNING
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Fault Isolation Procedures Fault Code 3 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 3 appears Return to STEP A to finderror in testing.
If code other than 3 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 4 Isolation Procedures
Motor/Generator Rotation Speed Sensor Fault
SA 239
SPN 520228
FMI 0, 2, 21-27
Overview
The Motor/Generator Rotation Speed Sensor is mounted to the back of the Motor/Generatoraround the input shaft. The sensor is a two piece design with the rotor being mounted to the inputshaft and the sensing ring being mounted to the motor housing. The sensing ring is supplied withlow-voltage during operation. When the rotor turns it induces a voltage fluctuation into the sensingring, which is then converted into a digital signal for Motor/Generator RPM. Voltage output and
frequency is low at idle and increases with RPM.
Conditions to Run Fault
• The Inverters ignition voltage is greater than 7 volts and less than 32 volts.
• FMI 2 will not run if there is an active Transmission Input Shaft Speed Sensor fault.
Conditions to Set Fault
• FMI 0 is set when the Motor/Generator speed exceeds the normal allowable range.• FMI 2 is set when the Motor/Generator speed is different than Transmission Input Shaft Speed
by more than 100 RPM for at least 10 seconds.• FMI 21 is set when a resolver signal line short to 24-volt or ground is detected.• FMI 22,24,25 are set when the combination of the analog-to-digital converter signals is a
mismatch
• FMI 27 is set when the Inverter detects and error in the initial check• FMI 23 is set when there is an analog-to-digital converter output error signal for 100ms
• FMI 26 is set when the rotation sensor speed is greater than 6000 min-1 for 10 ms
Possible Causes
• FMI 0
- Long extended grades may require intermittent use of the service brakes to slowthe vehicle
• FMI 21
- Inverter
- Resolver Harness between the Motor/Generator and Inverter• FMI 22,24,25,27
- Inverter• FMI 2,23,26
- Inverter
- Motor/Generator
- Resolver Harness between the Motor/Generator and Inverter
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Fault Isolation Procedures Fault Code 4 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Follow “Hybrid ShutdownProcedure” found at front ofbook, to avoid shock, burn, or
death from improperlyhandled high-voltage.
4. What FMI’s are present. If FMI 22,24,25, or 27 are listed Replace the Inverter. Go toSTEP V
If FMI 2,23, or 26 are listed Go to STEP B
If FMI 21 is listed Go to STEP D
STEP B
Procedure Condition Action1. Disconnect the 40-way low-
voltage connector at theInverter.
2. Measure Resolver resistanceat the 40-pin harnessconnector between thefollowing pins:
• 30 - 40
• 28 - 38
• 29 - 39
If resistance for the following pinsare:
• Pin 30-40 is 10.5 to
8.6 ohms• Pin 28-38 is 34 to 28ohms
• Pin 29-39 is 27 to 23ohms
If FMI 2 is active contact Eaton at1-800-826-HELP (4357). If FMI26 or 23 are active replace theInverter. Go to STEP V
If resistance is outside of rangefor any of the readings
Go to STEP C
WARNING
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Fault Code 4 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Disconnect the 6-way Motor/
Generator resolverconnector.
2. Measure the Resolverresistance at the 6-pinharness connector betweenthe following pins:
• 3-4
• 1-2
• 5-6
Note: An auto-ranging digitalvolt/ ohm meter must beused.
If resistance for the following pinsare:
• Pin 3-4 is 10.5 to 8.6ohms
• Pin 1-2 is 34 to 28
ohms• Pin 5-6 is 27 to 23
ohms
Repair the open harnessbetween the Inverter 40-pinconnector and the Motor/ Generator 6-pin Resolverconnector. Go to STEP V
If resistance is outside of range Replace the Motor/Generator.Go to STEP V
STEP D
Procedure Condition Action
1. Disconnect the 40-way
connector at the inverter2. Use an ohm meter to
measure a short to bothground and vehicle battery24 volt on the following pins
• 28
• 29
• 38
• 39
Note: An auto-ranging digitalvolt/ ohm meter must beused.
If there is continuity at any of thefollowing pins:
• Pin 28
• Pin 29
• Pin 38
• Pin 39
Repair resolver vehicle harnessbetween the Inverter and Motor/ Generator. Go to STEP V
If meter reads Open or OL Replace the Inverter. Go toSTEP V
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Fault Code 5 Isolation Procedures
Motor/Generator AC Cable Fault
SA 239
SPN 520229
FMI 21-29
Overview
The Motor/Generator AC cables are connected from the Motor/Generator to the Inverter. These
cables carry up to 500 volts AC 3 phase when the vehicle is in operation.
Conditions to Run Fault
• The Inverters ignition voltage is greater than 7 volts and less than 32 volts.• FMI 25-27 require the Motor/Generator RPM to be greater than 500 RPM.• FMI 28 requires the Motor/Generator RPM to be less than 500 RPM.
• FMI 29 requires the Motor/Generator RPM to be less than 50 RPM.
Conditions to Set Fault
• FMI 21 is set when the AC interlock circuit is open.• FMI 22,23,24 are set when the 2 phase motor current is more than 360 amps for 0.9 ms.• FMI 25,26,27 are set when the Inverter detects a single open wire and motor current is less
than 8 amps for 200ms at speeds >= 500 RPM and current command from the Inverter is > 20amps.
• FMI 28 is set when Motor/Generator current is less than 8A for 200ms at Speed < |500RPM|and current command > 20A(rms).
• FMI 29 is set during initialization, the Inverter checks if the AC cable is connected between the
Motor and Inverter by sending out 20A for 200ms and checking the feedback.
Possible Causes
• FMI 21
- AC Cable Interlock• FMI 22,23,24
- Inverter
- Motor/Generator
- AC Cable• FMI 25,26,27,28,29
- Motor/Generator
- AC Cable
Fallback Mode When Fault is Set
When Fault Code 5 is set the following conditions will occur:
• The red “Stop Hybrid” lamp will display.• Fault is stored in Hybrid Control Module (HCM) memory.• Inverter shuts high-voltage system off.• HCM continues to control the Hybrid vehicle in a diesel only mode.
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Fault Code 5 Isolation Procedures Connector Views
Connector Views
High-Voltage AC Harness Connector View (Amphenol Connector)
W U
V
E D
F
W
V
U
W
V
U
Inverter Motor/ Generator
Phase 1
Phase 2
Phase 3
OTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Location
High-Voltage AC Motor/Gen Connector View (Amphenol Connector)
U
V
WF
E D
Phase 1
Phase 2
Phase 3
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Fault Isolation Procedures Fault Code 12 Isolation Procedures
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
If code 12 is active Replace the Transmission ECU(only if the fault code is active).
If code 12 is inactive Test complete.
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Fault Code 14 Isolation Procedures
STEP D
Procedure Condition Action
1. Disconnect the TECU
Vehicle Harness 38-wayconnector
2. Check continuity between:
• 38-way connectorpin 17 and 4-pinconnector pin 1
• 38-way connectorpin 31 and 4-pinconnector pin 2
If continuity is okay Replace the TECU. Go toSTEP V
If an open is found Repair or replace theHarness. Go to STEP V
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 14 appears Return to STEP A to finderror in testing.
If code other than 14 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 16 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key on and observe the redpush button Service lamp.
If the red Service lamp turns on Go to STEP C
If the red Service lamp does notturn on
Go to STEP B
STEP B
Procedure Condition Action
1. Disconnect Shift Control30-way connector.
2. Key on.
3. Measure voltage on 30-wayconnector pins J3 and C1
If voltage is within 0.6 volts ofbattery voltage
Go to STEP C
If out of range Go to STEP D
STEP C
Procedure Condition Action
1. Key off.
2. Disconnect the 30-way PushButton Shift ControlConnector.
3. Key on.
4. Connect Voltmeter leads topins F1 and F2.
If the voltage is 0.10 volts AC orgreater
ReplacePush Button Shift Control (Only ifFault Code is Active). Go toSTEP V
Note: Make sure the volt/ohmmeter is on the properscale (around 10 voltsAC).
If the voltage is out of range Go to STEP F
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Fault Isolation Procedures Fault Code 16 Isolation Procedures
STEP D
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect Vehicle Harness38-way connector.
Note: On Peterbilt units,disconnect Gear Display.
4. Measure resistance between:
• Shift Control 30-wayconnector pin J3 andVehicle Harness38-way connectorpin 25.
If resistance between pins J3 and25 is 0 to 0.3 ohms.
Go to STEP E
If any of the above conditions arenot met
Repair harness between the ShiftControl and Transmission ECU.Go to STEP V
STEP E
Procedure Condition Action
1. Key off.
2. Measure the resistance
between:
• Shift Control30-way connectorpin C1 and VehicleHarness 38-wayconnector pin 31.
• Shift Control30-way connectorpin C1 and ground.
If resistance between pins C1and 31 is 0 to 0.3 ohms andresistance between pin C1 andground is 10K ohms or greater
Replace Transmission ECU (Onlyif Fault Code is Active). Go toSTEP V
If any of the above conditions arenot met
Repair harness between theTransmission ECU and ShiftControl. Go to STEP V
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Connector Views Fault Code 17 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Connector Views
Front Harness View(TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECU
30
86
8785
4
32
85
86
Start EnableRelay
Start Enable Minus
Start Enable Plus
Typical Relay Switch
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Connector Views Fault Code 22 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
ABSHCM
2 J1939 LowJ1939 Low
Front Harness View(HCM - Vehicle Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
3 J1939 HighJ1939 High
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 24 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Perform Electrical Pretest If no issues found during theElectrical Pretest
Go to STEP B
If issue was repaired during theElectrical Pretest
Go to STEP V
STEP B
Procedure Condition Action1. Key off.
2. Disconnect negative batterycable.
3. Disconnect HCM VehicleHarness 38-way connector.
4. Measure resistance betweenHCM Vehicle Harness38-way connector pin 2 and3.
If resistance between pin 2 and 3is between 50-70 ohms
Replace HCM. Go to STEP V
Note: Make sure the volt/ohm
meter is on the properscale (around 200 ohmscale).
If resistance is outside of range Repair J1939 Data link Harness.
Go to STEP V
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Fault Code 27 Isolation Procedures
Clutch Disengagement Fault
SA 239
SPN 788
FMI 7, 14
Overview
The mechanical clutch assembly is controlled through the Electric Clutch Actuator (ECA) that ismounted on the clutch housing. The Hybrid Control Module (HCM) controls the ECA position andmonitors several variables to determine if their is a slip concern in the clutch when it is in the
closed position.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
• The ECA ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 7 is set when the set when engine torque is greater than 400 Nm, engine torquecommanded is less than 0 for 0.3 seconds and the clutch position commanded is open for 1second with the gear position confirmed in neutral. Or, if the clutch input speed is greater than300 RPM, the clutch output speed is greater than 300 RPM, the clutch is commanded open for1 second, and the selected gear is neutral with everything above being true for 10 seconds.
• FMI 14 is set when the HCM has commanded the ECA to disengage the clutch and the inputshaft speed is greater than 315 RPM for more than 11 seconds with the transmission inneutral and the engine running.
Possible Causes
• FMI 7
- Clutch Assembly
- ECA• FMI 14
- Clutch Assembly
- Cross-shafts
Fallback Mode When Fault is Set
When Fault Code 27 is set the following conditions will occur:
• The red “Stop Hybrid” lamp will display for FMI 7.• The amber “Check Hybrid” lamp will display for FMI 14.• Fault is stored in HCM memory.• If this fault occurs while driving, the vehicle will operate and the transmission will shift to
neutral once the vehicle comes to a stop.
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Fault Isolation Procedures Fault Code 27 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• ServiceRanger
Note: No Schematic for this Code.
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
2. If fault code 64 is listed If fault code 27 FMI 7 or 14 arelisted with an active fault code 64
Go to procedure for fault code 64on page 223
If fault code 27 FMI 7 is listed withno active fault code 64
Go to STEP B
If fault code 27 FMI 14 is listedwith no active fault code 64
Go to STEP C
STEP B
Procedure Condition Action
1. Key on.
2. Start engine.
3. Launch vehicle and driveuntil 6th gear is obtained.Then slow down to a stop.
4. Repeat the launch 5 times.
5. Is FMI 7 active If FMI 7 is active Replace the Clutch. SeeCLMT0365 for installationprocedure. Go to STEP V
If FMI 7 is not active Test is complete. Go to STEP V
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Fault Code 27 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Remove Electric ClutchActuator from transmissionhousing.
3. Attempt to rotate the cross-shaft and yoke assembly byhand.
If the cross-shaft assemblyrotates by hand from the releasebearing to the transmission case
Replace the Clutch. SeeCLMT0365 for installationprocedure. Go to STEP V
If the cross-shaft assembly doesnot rotate by hand
Replace the cross-shaft,bushings, and grease. RepeatSTEP C
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 27 appears Return to STEP A to finderror in testing.
If code other than 27 appears Go to Fault Code IsolationProcedure page 19
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Connector Views Fault Code 32 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Connector Views
TECU
30
86
8785
87
86
85
30
35Ignition
Typical Relay Switch
Ignition Relay
Ground
VehicleIgnition
24V Truck Battery
2 4 V
P l u s
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Front View(TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
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Fault Code 32 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Perform Electrical Pretest If code 32 is active afterperforming Electrical Pretest
Replace TECU (only if fault codeis active). Go to STEP V
If code 32 is inactive afterperforming the Electrical Pretest
Clear Codes. Go to STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 32 appears Return to STEP A to find error intesting.
If code other than 32 appears Go to Fault Code IsolationProcedure page 19
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Connector Views Fault Code 33 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Connector Views
TECU 24V Truck Battery
24V Plus38TECU Power
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
36TECU Ground
Front View(TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
Ground
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Fault Code 33 Isolation Procedures Isolation Procedures
Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Perform Electrical Pretest. If code 33 is active afterperforming the Electrical Pretest
Replace TECU (only if Fault Codeis active). Go to STEP V
If code 33 is inactive afterperforming the Electrical Pretest
Clear codes. Go to STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 33 appears Return to STEP A to find error intesting.
If code other than 33 appears Go to Fault Code IsolationProcedure page 19
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Isolation Procedures Fault Code 33 Isolation Procedures
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Fault Code 34 Isolation Procedures
Weak Battery Voltage Fault (TECU)
SA 3
SPN 168
MID 130
PID 168
FMI 14
Overview
The Transmission Electronic Control Unit (TECU) is mounted to the transmission and it contains allof the software to control the transmission operation, however, the Hybrid Control Module (HCM)controls the operation of the TECU during normal “Hybrid Mode” operation. The HCM mainbattery power is a 24-volt feed that is fused and runs through the HCM 38-way vehicle connector
with the main ground wire returning to the battery negative terminal.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.
• The TECU System Battery Voltage Low Fault is not active.
Conditions to Set Fault
• FMI 14 is set when the TECU battery voltage drops below 9 volts for 10 seconds.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 14 has several areas that may cause this fault.
- Power supply to TECU
- Low batteries or bad main power connection
- Charging system
- TECU
Fallback Mode When Fault is Set
When Fault Code 34 is set the following conditions will occur:
• Fault is stored in TECU memory.• TECU switches to “AutoShift Fallback” mode.• If this fault occurs while moving, it causes a 1-speed fallback.
• If the vehicle is stopped, the starting gear and reverse can be engaged.
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Connector Views Fault Code 34 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Connector Views
TECU 24V Truck Battery
24V Plus38TECU Power
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
36TECU Ground
Front View(TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
Ground
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Fault Code 34 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Perform Electrical Pretest. If code 34 is active afterperforming the Electrical Pretest
Replace TECU (only if Fault Codeis active). Go to STEP V
If code 34 is inactive afterperforming the Electrical Pretest
Clear codes. Go to STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 34 appears Return to STEP A to find error intesting.
If code other than 34 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 34 Isolation Procedures
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Connector Views Fault Code 35 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Connector Views
Front Harness View (TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECU
D
9 Pin DiagnosticConnector
3J1939 High TECU C
2J1939 Low TECU
J1939 High
J1939 Low
9 Pin Diagnostic Connector
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 35 Isolation Procedures Isolation Procedures
Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key on.
3. Select the “VehicleComponents” screen andview the various modulesthat are reporting on theJ1939 link
If TECU is not reporting onJ1939, but the HCM is listed
Go to STEP B
If the HCM and TECU are notreporting on J1939
Go to STEP C
STEP B
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect TECU Vehicle
Harness 38-way connector.
4. Measure resistancebetween TECU VehicleHarness 38-way connectorpin 2 and 3.
5. Make sure the volt/ohmmeter is on the proper scale(around 200 ohm scale).
If resistance between pin 2 and3 is between 50-70 ohms
Replace TECU. Go to STEP V
If resistance is outside of range Repair the J1939 Data linkHarness. Go to STEP V
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Isolation Procedures Fault Code 35 Isolation Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Measure resistancebetween the diagnosticconnector 9-way pins Cand D.
If resistance between pin C andD is between 50-70 ohms
Go to STEP D
If resistance is 70 ohms orgreater
One or more of the terminatingresistors on the J1939 data linkharness is missing or out ofrange, or there is an open in thelink. Go to STEP V
If resistance is 50 ohms or less There is an additionalterminating resistor present.Repair the OEM J1939 data linkharness. Go to STEP V
STEP D
Procedure Condition Action
1. Key off.
2. Measure the resistancebetween the following9-way diagnostic connector
pins:• C to ground
• D to ground
If resistance between pin C toground and D to ground areboth 10K ohms or greater
Attempt to communicate withanother vehicle to ensureServiceRanger is working. IfServiceRanger fails tocommunicate with anothervehicle, call 1-800-826-HELP(4357).
If resistance is outside of range Repair J1939 Data link Harnessfor a short to ground. Go toSTEP V
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Fault Code 35 Isolation Procedures Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 35 appears Return to STEP A to find error intesting.
If code other than 35 appears Go to Fault Code IsolationProcedure page 19
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Isolation Procedures Fault Code 35 Isolation Procedures
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Fault Code 36 Isolation Procedures
J1939 Engine Message Faults
SA 3
SPN 639
MID 130
SID 231
FMI 14
Overview
J1939 is a high-speed twisted pair 250K data link with one 120 ohm resistor at each end of thelink. The Transmission Electronic Control Unit (TECU) is connected to the J1939 data link at the38-way connector. This link is used to transmit information to the Hybrid Control Module (HCM) aswell as communicate or receive data from the other modules on the network like the engine Engine
Control Module (ECM).
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU Battery Voltage Low fault is not active.
• The TECU J1939 data link fault is not active.
Conditions to Set Fault
• FMI 14 is set when the TECU fails to receive engine ECM data like engine torque for 5
seconds or greater, and it is still communicating with other modules on J1939.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) onpage 25.
Possible Causes
• FMI 14
- J1939 data link
- ECM
Fallback Mode When Fault is Set
When Fault Code 36 is set the following conditions will occur:
• The red “Service” lamp will display and an “F” will flash in the gear display.• Fault is stored in TECU memory.• If the fault occurs while moving, the TECU will go into “AutoShift Fallback” Mode.• Once the vehicle stops, start and reverse gears can be selected and the transmission will
operate in AutoSelect mode.
• If the fault occurs at power-up, the vehicle will crank.
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Connector Views Fault Code 36 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
If code 36 is active Concern is either:1. Engine ECM2. data link from Engine ECM toJ1939 data link backbone. Referto OEM for repair procedure.
If code 36 is inactive Test complete.
Front View (TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECU
Engine ECM
3J1939 High TECU
2J1939 Low TECU
(refer to OEM engine wiringdiagram for pin outs)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 37 Isolation Procedures
Power Supply Fault (TECU)
SA 3
SPN 610
MID 130
SID 251
FMI 5
Overview
The Transmission Electronic Control Unit (TECU) is mounted to the transmission and it contains allof the software to control the transmission operation, however, the Hybrid Control Module (HCM)controls the operation of the TECU during normal “Hybrid Mode” operation. The TECU mainbattery power is a 24-volt feed that is fused and runs through the TECU 38-way vehicle connector
with the main ground wire returning to the battery negative terminal.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU will only run this test if the electric shifter is being cycled from “N” to gear.
Note: Changing the start gear from “N” will allow this test to run.
Conditions to Set Fault
• FMI 5 is set when the TECU power supply resistance is measured before and during an
electric shifter test and the results show a measurement of 0.4 ohms or greater.
Possible Causes
• FMI 5
- Power supply to TECU
- Low batteries or bad main power connection
- Broken or corroded battery interconnect straps may also be the cause of high
resistance readings
Fallback Mode When Fault is Set
When Fault Code 37 is set the following conditions will occur:
• Fault is stored in TECU memory.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Connector Views Fault Code 37 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Connector Views
Front View(TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECU24V Battery
Negative (-)
38TECU Power Positive (+)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
36TECU Ground
4-Pin Diagnostics Port
4-way
B - Service Bat. +C - Service Bat. -A - Service Ignition +
B A
DC
4-Pin Diagnostic Port(Located at the left rear
corner of the transmission.)
Warning! - Do Not Load Test at Diagnostic Port
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Fault Code 37 Isolation Procedures Isolation Procedures
Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Perform Electrical Pretest. If code 37 is active afterperforming the Electrical Pretest
Go to STEP B
If code 37 is inactive afterperforming the Electrical Pretest
Clear codes. Go to STEP V
STEP B
Procedure Condition Action
1. Locate diagnostic port ontransmission harness
2. Key on.
3. Measure voltage betweenpins C and the batterynegative post
If voltage between pin C andbattery negative post is 0.7 voltsor less
Go to STEP C
If voltage is outside of range Repair battery ground supply totransmission ECU. Go to STEP V
STEP C
Procedure Condition Action
1. Locate diagnostic port onTransmission Harness.
2. Key on.
3. Measure voltage betweenpins B and pin C.
If voltage between pins B and C iswithin 0.6 volts of battery voltage
Go to STEP D
If voltage is outside of range Repair battery power supply toTransmission ECU. Fuse may beblown. Repeat test.
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Isolation Procedures Fault Code 37 Isolation Procedures
STEP D
Procedure Condition Action
1. Key on.
2. Measure voltage between pinA and pin C.
If voltage between pins A and C iswithin 0.6 volts of battery voltage
Go to STEP E
If voltage is outside of range Repair Ignition power supply toECU. Fuse may be blown. Repeattest.
STEP E
Procedure Condition Action
1. Key off.2. Disconnect negative battery
cable.
3. Disconnect the VehicleHarness 38-way.
4. Inspect main power 38-wayconnector terminals pin 36and 38, in-line fuse holder,and power supplyconnections for integrity andcorrosion.
If no problem found Go to STEP V
If problem is found Repair power/ground path for the
main power supply. Go to STEP V
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Fault Code 37 Isolation Procedures Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 37 appears Return to STEP A to find error intesting.
If code other than 37 appears Go to Fault Code IsolationProcedure page 19
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Isolation Procedures Fault Code 37 Isolation Procedures
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Fault Code 38 Isolation Procedures
Battery Fan Relay Fault
SA 239
SPN 520243
FMI 3, 4, 5, 14
Overview
The Battery Fan Relay is a normally open relay that is connected to the Hybrid Control Module(HCM) on the control side. When the HCM wants to turn on the relay it powers the control circuit,which closes the relay contacts. The relay powers the Battery Fan located in the Power Electronics
Carrier (PEC), which provides the cooling for the high-voltage batteries.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 3 is set when the HCM detects a short to battery in the in the coil circuit of the battery fanrelay.
• FMI 4 is set when the HCM detects a short to ground in the coil circuit of the battery fan relay.• FMI 5 is set when the HCM detects an open in the coil circuit of the battery fan relay.• FMI 14 is set when the following conditions are true for 10 minutes; the high-voltage battery
temperature is greater than 55°C, the difference between the minimum and maximum batterytemperatures is less than 1°C, and there are no battery temperature faults from the BatteryControl Module.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 3, 4, 5
- Vehicle harness from HCM to Battery Fan Relay
- Battery Fan Relay
- HCM• FMI 14
- Battery Fan Relay
- Battery Fan
- Plugged Air Filter
- Battery Fan Relay main power supply
Fallback Mode When Fault is Set
When Fault Code 38 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display.
• Fault is stored in HCM memory.
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Connector Views Fault Code 38 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
HCM
30
86
8785
26 86
87
85
30
Battery Fan
Typical Relay Switch
Battery Fan
Relay
24V Truck Battery
2 4 V
P l u s
4Battery Fan Return
PEC
12
Ground14
Battery Fan Supply
Cooling Fan Plus
Cooling Fan Minus
Front Harness View(HCM - Hybrid System Interface Connector)
37 38
35 36
1 67 12
13 22
23 28
29 34
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Harness Connector View(PEC 19 - Way)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
1819
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Fault Code 38 Isolation Procedures Isolation Procedures
Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Follow “Hybrid ShutdownProcedure” found at front ofbook to avoid shock, burn, ordeath from improperly
handled high-voltage.3. Change battery fan relay with
another relay to see if faultreturns
If fault does not return with newrelay
Replace the battery fan relay. Goto STEP V
If fault returns with new relay Go to STEP B
STEP B
Procedure Condition Action
1. What FMIs were listed inStep A?
Note: The Battery Fan Relaymust be wired accordingto Eaton® requirements(shown on previouspage) for this test to workproperly. If wireddifferently, consult OEMfor correct wiringschematic.
If FMI 5 is listed Go to STEP C
If FMI 3 is listed Go to STEP D
If FMI 4 is listed Go to STEP E
If FMI 14 is listed Go toSTEP F
WARNING
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Isolation Procedures Fault Code 38 Isolation Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable
3. Disconnect the HCM harness38-way connector
4. Measure the resistancebetween the HCM SystemHarness 38-way connectorpins 26 and 4.
If the resistance between pins26 and 4 is 40-120 ohms
Replace HCM (Only if Fault Codeis Active). Go to STEP V
If the resistance is outside therange
Repair the Vehicle Harness for anopen circuit. Go to STEP V
STEP D
Procedure Condition Action
1. Key on.
2. Measure voltage betweenHCM System Harness38-way connector pins 26and ground at key on
If voltage between pin 26 andground is 0 volts
Replace the HCM (only is faultcode is active). Go to STEP V
If voltage between pin 26 andground is 24 volts
Repair the short to vbatt on theharness. Go to STEP V
STEP E
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect the HCM harness38-way connector.
4. Measure the resistancebetween HCM SystemHarness 38-way connectorpins 26 and ground
If resistance between pin 26 andground is 10K ohms or greater Replace HCM (Only if Fault Codeis Active). Go to STEP V
If resistance is outside of range Repair the Vehicle Harness for ashort to ground. Go to STEP V
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Fault Code 38 Isolation Procedures Isolation Procedures
STEP F
Procedure Condition Action
1. Key off.
2. Remove and inspect the Airfilter on the PEC inlet and theexhaust screen on the PECoutlet.
If the air filter and screen areclean and free from debris
Go to STEP G
If the air filter is dirty or theexhaust screen is plugged
Replace the Air Filter and cleanthe Exhaust Screen. Go toSTEP V
STEP G
Procedure Condition Action1. Key off.
2. Connect ServiceRanger tothe 9-pin diagnosticconnector in the cab.
3. Key on.
4. Go to Product Tests andselect Battery Fan Relay.
If airflow can be felt from the PECair inlet and exhaust
If Fault Code is Active contactEaton® at 1-800-826-4357.
If airflow can not be felt from thePEC air inlet and exhaust
Go to STEP H
STEP H
Procedure Condition Action
1. Key on.
2. Disconnect the 19-wayconnector at the PEC.
3. Measure voltage at the 19-way connector from pin 12 topin 14.
If voltage between pins 12 and 14is +/- 0.2 volts of battery voltage
Replace the PEC Fan. Go toSTEP V
If voltage between pins 12 and 14is outside of range Repair wiring or relay problem.Refer to OEM.
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Isolation Procedures Fault Code 38 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 38 appears Return to STEP A to find error intesting.
If code other than 38 appears Go to Fault Code IsolationProcedure page 19
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Connector Views Fault Code 39 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
HCM
30
86
8785
35 86
87
85
30
Heat Exchange Fan HSD
Typical Relay Switch
Heat Exchanger Fan Relay
24V Truck Battery
2 4 V
P l u s
37Heat Exchange Fan LSD
Heat Exchanger Fan
A
GroundB
HEF Supply
HEF Plus
HEF Minus
Harness Front View(HCM - Hybrid System Interface Connector)
37 38
35 36
16712
13 22
23 28
29 34
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
HEF Plus
Fuse
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Fault Code 39 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Change heat exchanger fanrelay with another relay andsee if the fault returns
If fault does not return with newrelay
Replace the Heat Exchanger FanRelay. Go to STEP V
If fault returns with new relay Go to STEP B
STEP B
Procedure Condition Action
1. Key on.
2. Connect ServiceRanger tothe 9-pin diagnosticconnector.
3. Select “Configurations” menuand pick the Hybrid ControlModule option.
4. Is there an option for Heat
Exchanger Fan
The Heat Exchanger Fan option
is shown and the vehicle has theHybrid cooling system heatexchanger fan installed
Go to STEP C
The Heat Exchanger Fan optionis shown and the vehicle does nothave the Hybrid cooling systemheat exchanger fan installed
Write down the model number onthe transmission tag and contactEaton at 1-800-826-HELP (4357).
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Fault Isolation Procedures Fault Code 39 Isolation Procedures
STEP C
Procedure Condition Action
1. What FMIs were listed from
Step A?
Note: The heat exchanger fanrelay must be wiredaccording to Eatonrequirements (shown onprevious page) for thistest to work properly. Ifwired differently consultOEM for correct wiringschematic.
If FMI 5 is listed Go to STEP D
If FMI 3 is listed Go to STEP E
If FMI 4 is listed Go to STEP F
STEP D
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable
3. Disconnect the HCM SystemHarness 38-way connector.
4. Measure the resistance
between HCM SystemHarness 38-way connectorpins 35 and 37
If resistance between pins 35 and
37 is 40 - 120 ohms
Replace the HCM (only if fault
code is active). Go to STEP V
If resistance is outside of range Repair the Vehicle Harness for anopen circuit or blown fuse. Go toSTEP V
STEP E
Procedure Condition Action
1. Key on.2. Measure the voltage
between HCM systemharness 38-way connectorpins 35 and ground
If voltage between pin 35 andground is 0 volts
Replace the HCM (only if faultcode is active). Go to STEP V
If voltage between pin 35 andground is 24 volts
Repair the short to vbatt on theharness. Go to STEP V
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Fault Code 39 Isolation Procedures Fault Isolation Procedures
STEP F
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable
3. Disconnect the HCM SystemHarness 38-way connector.
4. Measure the resistancebetween HCM SystemHarness 38-way connectorpins 35 and ground
If resistance between pins 35 andground is 10K ohms or greater
Replace the HCM (only if faultcode is active). Go to STEP V
If resistance is outside of range Repair the Vehicle Harness for ashort to ground. Go to STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault Code
Removal/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 39 appears Return to STEP A to find error intesting.
If code other than 39 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 39 Isolation Procedures
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Fault Code 40 Isolation Procedures
Cooling Pump Relay Fault
SA 239
SPN 520248
FMI 3, 4, 5, 14
Overview
The Cooling Pump Relay is normally an open relay that is connected to the Hybrid Control Module(HCM) on the control side. When the HCM wants to turn on the relay it powers the control circuit,which closes the relay contacts. The relay powers the Cooling Pump that circulates the coolant on
the hybrid liquid system.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 3 is set when the HCM detects a short to battery in the coil circuit of the Cooling PumpRelay.
• FMI 4 is set when the HCM detects a short to ground in the coil circuit of the Cooling PumpRelay.
• FMI 5 is set when the HCM detects an open in the coil circuit of the Cooling Pump Relay.• FMI 14 is set when the following occur for 10 minutes or longer; the Inverter temperature is
greater than 50°C, the difference between the maximum battery temperature and theInverter temperature is greater than 20°C, and there are no battery temperature or motortemperature faults.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) onpage 25.
Possible Causes
• FMI 3,4,5
- Vehicle harness from HCM to Cooling Pump Relay
- Cooling Pump Relay
- HCM• FMI 14
- Cooling Pump Relay
- Cooling Pump
- Cooling Pump Relay main power supply
- Low Coolant, Low Coolant Flow, Plugged Radiator, Fan Operation
Fallback Mode When Fault is Set
When Fault Code is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display.
• Fault is stored in HCM memory.
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Connector Views Fault Code 40 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
HCM
30
86
8785
32 86
87
85
30
Coolant Pump
Typical Relay Switch
Coolant PumpRelay
24V Truck Battery
2 4 V P
l u s
4Coolant Pump Return
Coolant Pump
A
GroundB
Coolant Pump Supply
Coolant Pump Plus
Coolant Pump Minus
Harness Front View(HCM - Hybrid System Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 40 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Follow “Hybrid ShutdownProcedure” found at front ofbook to avoid shock, burn, ordeath from improperly
handled high-voltage.3. Change cooling pump relay
with another relay and see iffault returns
If fault does not return with newrelay
Replace the cooling pump relay.Go to STEP V
If fault returns with new relay Go to STEP B
STEP B
Procedure Condition Action
1. What FMI’s were listed fromStep A?
Note: The Cooling Pump Relaymust be wired accordingto Eaton® requirements(shown on previouspage) for this test to workproperly. If wireddifferently, consult OEMfor correct wiringschematic.
If FMI 5 is listed Go to STEP C
If FMI 3 is listed Go to STEP D
If FMI 4 is listed Go toSTEP E
If FMI 14 is listed Go to STEP F
WARNING
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Fault Code 40 Isolation Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect the HCM SystemHarness 38-way connector.
4. Measure the resistancebetween the HCM SystemHarness 38-way connectorpins 32 and 4
If resistance between 32 and 4 is40-120 ohms
Replace HCM (Only if Fault Codeis Active). Go to STEP V
If resistance is outside of range Repair the Vehicle Harness for anopen circuit. Go to STEP V
STEP D
Procedure Condition Action
1. Key on.
2. Measure voltage betweenHCM system harness 38-wayconnector pin 32 and groundat key on
If voltage between pin 32 andground is 0 volts
Replace the HCM (only if faultcode is active). Go to STEP V
If voltage between pin 32 and
ground is 24 volts
Repair the short to vbatt on the
harness. Go to STEP V
STEP E
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect the HCM systemharness 38-way connector.
4. Measure the resistancebetween the HCM systemharness 38-way connectorpins 32 and ground
If resistance between pin 32 andground is 10K ohms or greater
Replace the HCM (only if faultcode is active). Go to STEP V
If resistance is outside of range Repair the vehicle harness for ashort to ground. Go to STEP V
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Fault Code 40 Isolation Procedures
STEP F
Procedure Condition Action
1. Key off.
2. Note the level of the coolantin the Hybrid Liquid CoolingSystem.
If the coolant is within therecommended limits.
Go to STEP G
If the coolant is below therecommended limits.
Refer to OEM for coolant typeand fill procedure. Go to STEP V
STEP G
Procedure Condition Action
1. Key off.2. Connect ServiceRanger to
the 9-pin diagnosticconnector in the cab.
3. Key on.
4. Go to “Product Tests” andselect Coolant Pump Relay.
5. Listen for the Coolant Pumpto turn on and watch forcoolant flow in the reservoir.
If the coolant pump runs andcoolant is moving through thereservoir.
If Fault Code is Active contactEaton® at 1-800-826-4357.
If the coolant pump does not run Go to STEP H
If the coolant pump does run andcoolant does not flow
Check for kinks or sharp bends inthe coolant lines. If okay contactOEM for concerns with coolantpump.
STEP H
Procedure Condition Action
1. Key on.
2. Disconnect the 2-way
connector at the CoolantPump.
3. Measure voltage at the2-way connector from pin Ato B.
If voltage between pins A and B is+/- 0.2 volts of battery voltage.
Refer to OEM for Coolant Pumpproblem.
If voltage between pins A and B isoutside of range.
Repair wiring or relay problem.Refer to OEM.
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Fault Code 40 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 40 appears Return to STEP A to finderror in testing.
If code other than 40 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 48 Isolation Procedures
J1939 Transmission Message Fault (HCM)
SA 239
SPN 523
FMI 2, 9
Overview
J1939 is a high-speed twisted pair 250K data link with one 120 ohm resistor at each end of thelink. The Hybrid Control Module (HCM) is connected to the J1939 data link at the 38-wayconnector. This link is used to transmit information to the HCM as well as communicate or receive
data from the other modules on the network like the Transmission Electronic Control Unit (TECU).
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
• The J1939 data link communication fault is not active.
Conditions to Set Fault
• FMI 9 is set when the HCM fails to receive TECU data (like current gear) for 30 consecutivemessages or greater, and it is still communicating with other modules on J1939.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 2, 9
- J1939 data link- TECU
Fallback Mode When Fault is Set
When Fault Code 48 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display.• Fault is stored in HCM memory.• The red “Service” lamp may display and a “F” may flash in the gear display due to an active
fault code 24.• The operation mode is changed to “AutoShift Only” mode.• Electric motor/generator assist and regen are disabled, however, the high-voltage relays will
remain powered.• If the fault sets at power-up the engine will not crank.• If the fault sets while driving, the vehicle will shift, however, when the vehicle comes to a stop
the clutch will open and remain in the open position.
• Transmission defaults start gear to 1st.
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Connector Views Fault Code 48 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Harness Front View (TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECUHCM
2 2 J1939 LowJ1939 Low
Harness Front View(HCM - Vehicle Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
3 J1939 High3J1939 High
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 48 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Key off.
2. Disconnect negative batterycable.
3. Disconnect TECU VehicleHarness 38-way connector.
4. Measure the resistancebetween the TECU VehicleHarness 38-way connectorpin 2 and 3.
If resistance between pin 2 and 3is between 50 to 70 ohms.
Replace TECU. Go to STEP V
Note: Make sure the volt/ohmmeter is on the proper
scale (around 200 ohmscale).
If resistance is outside of range. Repair J1939 Data link Harness.Go to STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative battery
cable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 48 appears Return to STEP A to find
error in testing.If code other than 48 appears Go to Fault Code Isolation
Procedure page 19
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Fault Isolation Procedures Fault Code 48 Isolation Procedures
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Fault Code 49 Isolation Procedures
J1939 Engine Message Fault (HCM)
SA 239
SPN 190
FMI 2, 9
Overview
J1939 is a high-speed twisted pair 250K data link with one 120 ohm resistor at each end of thelink. The Hybrid Control Module (HCM) is connected to the J1939 data link at the 38-wayconnector. This link is used to transmit information to the HCM as well as communicate or receive
data from the other modules on the network like the Engine Control Module (ECM).
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
• The J1939 data link communication fault is not active
Conditions to Set Fault
• FMI 9 is set when the HCM fails to receive Engine ECM data (like engine torque) for 30
consecutive messages or greater, and it is stil l communicating with other modules on J1939.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 9
- J1939 data link from Engine ECM
- ECM
Fallback Mode When Fault is Set
When Fault Code 49 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display.• Fault is stored in HCM memory.• The operation mode will be changed to “AutoShift Only” mode.• Electric motor/generator assist and regen are disabled, however, the high-voltage relays will
remain powered.
• Transmission defaults start gear to 1st.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Connector Views Fault Code 49 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
If code 49 is active Concern is either:1. Engine ECM2. Data link from Engine ECM toJ1939 data link backbone. Referto OEM for repair procedure.
If code 49 is inactive Test complete.
ECM HCM
2 J1939 LowJ1939 Low
Harness Front View(HCM - Vehicle Interface Connector)
37 38
35 36
1 6
7 12
13 22
23 28
29 34
3 J1939 HighJ1939 High
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 50 Isolation Procedures
J1939 Body Controller Message Fault (HCM)
SA 239
SPN 701
FMI 2, 9
Overview
J1939 is a high-speed twisted pair 250K data link with one 120 ohm resistor at each end of thelink. The Hybrid Control Module (HCM) is connected to the J1939 data link at the 38-wayconnector. This link is used to transmit information to the HCM as well as communicate or receive
data from the other modules on the network like the Body Controller.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
• The J1939 data link communication fault is not active.
Conditions to Set Fault
• FMI 2 is set when the HCM is in PDM mode and fails to receive messages from the bodycontroller for 1 second.
• FMI 9 is set when the HCM fails to receive messages from the body controller for seconds.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) onpage 25.
Possible Causes
• FMI 2, 9- J1939 data link
- Body Controller
Fallback Mode When Fault is Set
When Fault Code 50 is set the following conditions will occur:
• No hybrid lamps are lit when this code is active.• Fault is stored in HCM memory
• HCM disables ePTO operation, since parameters like hydraulic demand are unavailable
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
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Connector Views Fault Code 50 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
If code 50 is active Concern is either:
a. Body Controller
b. Data link from BodyController to J1939 datalink backbone.
Refer to OEM for repairprocedure.
If code 50 is inactive Test complete.
Body Controller HCM
2 J1939 LowJ1939 Low
Harness Front View(HCM - Vehicle Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
3 J1939 HighJ1939 High
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 51 Isolation Procedures
Rail Position Sensor Fault
SA 3
SPN 60
MID 130
PID 60
FMI 2, 3, 4, 10
Overview
The Rail Position Sensor is a Hall Effect position sensor that provides feedback on the position ofthe shift finger. The Transmission Electronic Control Unit (TECU) delivers a constant 5 voltreference to one terminal of the Rail Position Sensor. The signal output from sensor provides aregulated voltage signal from 0.5 volts to 4.5 volts. The last terminal provides a ground for the Rail
Position Sensor to the TECU.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• FMI’s 3 and 4 will not be set if the TECU System Battery Voltage Low Fault is active.
• FMI 2 will not set if FMI 3,4 is active.
Conditions to Set Fault
• FMI 2 sets when the transmission controller detects the rail sensor voltage is above 4.5 voltsor below 0.5 volts for 1 second of longer.
• FMI 3 sets when the transmission controller detects the rail sensor supply voltage is 5% abovethe expected supply voltage for 1 second or longer.• FMI 4 set when the transmission controller detects the rail sensor supply voltage is 5% below
the expected supply voltage for 1 second or longer.
• FMI 10 (refer to troubleshooting guide TRTS0930)
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 2, 10
- Transmission Harness
- Rail Position Sensor- TECU
• FMI’s 3, 4
- TECU
Fallback Mode When Fault is Set
When Fault Code 51 is set the following conditions will occur:
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Connector Views Fault Code 51 Isolation Procedures
• The red “Service” lamp will display and an “F” will flash in the gear display.• Fault is stored in TECU memory.• If this fault occurs while moving, the transmission will remain in the current gear and the clutch
will open when the vehicle comes to a stop.
• The operation mode will be changed to “AutoShift Fallback” Mode.
Conditions to Clear the FaultOnly inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Harness Front View (TECU - System Interface Connector)
3738
3536
16
12
1322
2328
2934
7
B
A
C
Rail Position Sensor Pins
TECU
20
18
19
Rail Position Sensor
Hall EffectB C
A
C
A
B
Rail Position Plus
Rail Position Signal
Rail Position Minus
E: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locat
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Fault Code 51 Isolation Procedures Isolation Procedures
Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. What FMI’s are present If FMI 3 or 4 is listed Replace the TECU. Go toSTEP V
If FMI 2, 10 is listed Go to STEP B
STEP B
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect the TransmissionHarness 38-way connector.
4. Measure resistance betweenthe Transmission Harness
38-way connector pins:
• 18 to 19
• 18 to 20
Note: An Auto Ranging DigitalVolt/Ohm Meter must beused.
If pin 18 and 19 resistance is 100to 200 ohms and if pin 18 and 20resistance is 5K to 7K ohms
Go to STEP C
If any of the above conditions arenot met
Go to STEP D
STEP C
Procedure Condition Action
1. Measure resistance betweenTransmission Harness38-way connector pin 18 toground.
If resistance is 10K ohms orgreater
Replace TECU (Only if FaultCode is Active). Go to STEP V
If resistance is less than 10Kohms
Go to STEP D
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Isolation Procedures Fault Code 51 Isolation Procedures
STEP D
Procedure Condition Action
1. Disconnect Transmission
Harness from Rail SelectSensor.
2. Measure resistance betweenRail Select Sensor pins:
• A to C
• A to B
Note: An Auto Ranging DigitalVolt/Ohm Meter must beused.
If pin A and C resistance is 5K to7K and if pin A and B resistanceis 100 to 200 ohms
Replace the transmissionharness. Go to STEP V
If any to the above conditions arenot met
Replace Electric Shifter. Go toSTEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault Code
Removal/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 51 appears Return to STEP A to find error intesting.
If code other than 51 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 52 Isolation Procedures
Gear Position Sensor Fault
SA 3
SPN 59
MID 130
PID 59
FMI 2, 3, 4
Overview
The Rail Position Sensor is a Hall Effect position sensor that provides feedback on the position ofthe shift finger. The Transmission Electronic Control Unit (TECU) delivers a constant 5 voltreference to one terminal of the Rail Position Sensor. The signal output from sensor provides aregulated voltage signal from 0.5 volts to 4.5 volts. The last terminal provides a ground for the Rail
Position Sensor to the TECU.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• FMI 3, 4 will not be set if the TECU System Battery Voltage Low Fault is active.
• FMI 2 will not set if FMI 3, 4 is active.
Conditions to Set Fault
• FMI 2 sets when the transmission controller detects the rail sensor voltage is above 4.5 voltsor below 0.5 volts for 1 second of longer.
• FMI 3 sets when the transmission controller detects the rail sensor supply voltage is 5% abovethe expected supply voltage for 1 second or longer.• FMI 4 set when the transmission controller detects the rail sensor supply voltage is 5% below
the expected supply voltage for 1 second or longer.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 2
- Transmission Harness
- Rail Position Sensor
- TECU• FMI 3,4
- TECU
Fallback Mode When Fault is Set
When Fault Code 51 is set the following conditions will occur:
• The red “Service” lamp will display and an “F” will flash in the gear display.
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Gear Position Sensor Fault Fault Code 52 Isolation Procedures
• Fault is stored in TECU memory.• If this fault occurs while moving, the transmission will remain in the current gear and the clutch
will open when the vehicle comes to a stop.
• The operation mode will be changed to “AutoShift Fallback Mode.”
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
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Fault Code 52 Isolation Procedures Connector Views
Connector Views
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. What FMIs are present. If FMI 3 or 4 is listed. Replace the TECU. Go toSTEP V
If FMI 2 is listed. Go to STEP B
Harness Front View (TECU - System Interface Connector)
3738
3536
16
12
1322
2328
2934
7
B
A
C
Gear Position Sensor Pins
TECU
12
10
11
Rail Position Sensor
Hall EffectB C
A
C
A
B
Gear Position Plus
Gear Position Signal
Gear Position Minus
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Isolation Procedures Fault Code 52 Isolation Procedures
STEP B
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect the TransmissionHarness 38-way connector.
4. Measure resistance betweenthe Transmission Harness38-way connector pins:
• 18 and 19
• 18 and 20
Note: An Auto Ranging DigitalVolt/Ohm Meter must be
used.
If pin 18 and 19 resistance is 100to 200 ohms and if pin 18 and 20resistance is 5K to 7K ohms.
Go to STEP C
If any of the above conditions arenot met.
Go to STEP D
STEP C
Procedure Condition Action
1. Measure resistance betweenTransmission Harness38-way connector pin 18 to
ground.
If resistance is 10K ohms orgreater.
Replace TECU (Only if FaultCode is Active). Go to STEP V
If resistance is less than 10Kohms.
Go to STEP D
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Fault Code 52 Isolation Procedures Fault Isolation Procedures
STEP D
Procedure Condition Action
1. Disconnect Transmission
Harness from Rail SelectSensor.
2. Measure resistance betweenRail Select Sensor pins:
• A and C
• A and B
Note: An Auto Ranging DigitalVolt/Ohm Meter must beused.
If pin A and C resistance is 5K to7K and if pin A and B resistanceis 100 to 200 ohms.
Replace the transmissionharness. Go to STEP V
If any to the above conditions arenot met.
Replace Electric Shifter. Go toSTEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 52 appears Return to STEP A to find error intesting.
If code other than 52 appears Go to Fault Code Isolation
Procedure page 19
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Fault Isolation Procedures Fault Code 52 Isolation Procedures
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Fault Code 56 Isolation Procedures
Input Shaft Speed Sensor Fault
SA 3
SPN 161
MID 130
PID 161
FMI 2, 3, 4, 5, 10
Overview
The Input Shaft Speed Sensor is located on the 6-bolt PTO cover, which is standard on the rightside of the transmission. The sensor is a magnetic pickup that produces an AC voltage as thecountershaft gear teeth moves past the end of the sensor. At idle the speed sensor output is lowand increases as the speed of the countershaft increases.
Conditions to Run Fault
• The Transmission Electronic Control Unit (TECU) ignition voltage is greater than 7 volts andless than 32 volts.
• FMI 10 requires the transmission to be in neutral and the vehicle speed must be within range.• FMI 2 will not set if there is already an active FMI 5 for the Input or Output Shaft Speed
Sensors.
Conditions to Set Fault
• FMI 2 is set when the TECU input shaft speed is compared to the output shaft speed and itproduces an inconsistent reading for 1 second or greater.
• FMI 3 and 4 are set when the TECU detects a short to ground, short to battery, and the inputshaft speed is 0 for 1 second or greater.
• FMI 5 is set when the TECU detects an open circuit and the Input Shaft Speed Sensor is 0 for1 second or greater.
• FMI 10 is set when the TECU detects a 200 RPM or greater speed difference between theinput shaft speed and the raw input shaft speed for 10 ms or greater.
Note: When troubleshooting an inactive code refer to Product Diagnostic Mode (PDM) on
page 25
Possible Causes
• FMI 2,10
- Input Shaft Speed Sensor- TECU
- Transmission Harness
- Damaged Transmission Gearing
- Contamination on the input shaft speed sensor• FMI 3, 4, 5
- Input Shaft Speed Sensor
- TECU
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Connector Views Fault Code 56 Isolation Procedures
- Transmission Harness
Fallback Mode When Fault is Set
When Fault Code 56 is set the following conditions will occur:
• The red “Service” lamp will display and an “F” will flash in the gear display.• Fault is stored in TECU memory.• The operation mode will be changed to “AutoShift Fallback” Mode.• If this fault occurs while moving, the transmission will remain in the current gear and the clutch
will open when the vehicle comes to a stop.• If this fault occurs at power-up, the vehicle will crank but the transmission will not engage a
gear.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Harness Front View (TECU - System Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECU Input ShaftSpeed Sensor
7
8 B
A
A B
Input Shaft Speed Sensor (Connect View)
Input Shaft SpeedSensor High
Input Shaft SpeedSensor Low
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 56 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Disconnect negative batterycable.
4. Disconnect the TransmissionHarness 38-way connector.
5. Measure the resistancebetween the transmissionharness 38-way connectorpins 7 and 8 and pin 7 andground.
If resistance is 2K to 4.5K ohmsand pin 7 to ground is 10K ohmsor greater
Go to STEP B
If resistance is outside of therange
Go to STEP D
STEP B
Procedure Condition Action
1. Key on.2. Measure the voltage from
between the transmissionharness 38-way connectorpin 7 and ground
If voltage is 0 volts Go to STEP C
If voltage is 23-25 volts Repair the short to battery in theOEM harness. Go to STEP V
STEP C
Procedure Condition Action1. Inspect Input Shaft Speed
Sensor for contamination ordamage.
If no problem found Replace Transmission ECU (Onlyif Fault Code is Active). Go toSTEP V
If problem if found or you weresent here from Step D or E
Replace Input Shaft SpeedSensor and inspect thecountershaft gear for damage. Goto STEP V
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Fault Isolation Procedures Fault Code 56 Isolation Procedures
STEP D
Procedure Condition Action
1. Disconnect the Transmission
Harness from Input ShaftSpeed Sensor.
2. Measure resistance betweenInput Shaft Speed Sensorpins A and B.
If resistance is 2K to 4.5K ohms Go to STEP E
If resistance is outside of range Go to STEP C
STEP E
Procedure Condition Action
1. Measure resistance betweenInput Shaft Speed Sensor pinA and ground.
If resistance is 10K ohms orgreater
Replace Transmission Harness.Go to STEP V
If resistance is less than 10Kohms
Go to STEP C
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Verify proper installation ofspeed sensor.
4. Key on.
5. Clear codes. See Fault CodeRemoval/Clearing onpage 17
6. Drive the vehicle and attemptto recreate the code
7. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 56 appears Return to STEP A to find error intesting.
If code other than 56 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 58 Isolation Procedures
Output Shaft Speed Sensor Fault
SA 3
SPN 191
MID 130
PID 191
FMI 2, 3, 4, 5
Overview
The Output Shaft Speed Sensor is located on the rear bearing cover at the 12 o’clock position. Thesensor is a magnetic pickup that produces an AC voltage as the tone wheel teeth moves past theend of the sensor. At idle the speed sensor output is low and it increases as the speed of the
output shaft increases.
Conditions to Run Fault
• The Transmission Electronic Control Unit (TECU) ignition voltage is greater than 7 volts andless than 32 volts.
• FMI 2 will not set if there is already an active FMI 5 for the Input or Output Shaft Speed
Sensors.
Conditions to Set Fault
• FMI 2 is set when the TECU output shaft speed is compared to the input shaft speed and itproduces an inconsistent reading for 1 second or greater.
• FMI 3,4 are set when the TECU detects a short to ground, short to battery, or the output shaftspeed is 0 for 1 second or greater.• FMI 5 is set when the TECU detects an open and the Output Shaft Speed Sensor is 0 for 1
second or greater.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 2
- Output Shaft Speed Sensor
- TECU
- Transmission Harness- Damaged Transmission Gearing
- Contamination on the output shaft speed sensor• FMI 3, 4, 5
- Output Shaft Speed Sensor
- TECU
- Transmission Harness
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Connector Views Fault Code 58 Isolation Procedures
Fallback Mode When Fault is Set
When Fault Code 58 is set the following conditions will occur:
• The red “Service” lamp will display and an “F” will flash in the gear display.• Fault is stored in TECU memory.• The operation mode will be changed to “AutoShift Fallback” mode.• If this fault occurs while moving, the transmission will remain in the current gear and the clutch
will open when the vehicle comes to a stop.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools
• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Harness Front View (TECU - System Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECU Output ShaftSpeed Sensor
23
24 B
A
A B
Output Shaft Speed Sensor (Connect View)
Output Shaft SpeedSensor High
Output Shaft SpeedSensor Low
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 58 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Disconnect negative batterycable.
4. Disconnect the TransmissionHarness 38-way connector.
5. Measure resistance betweenthe Transmission Harness38-way connector pins 23and 24 and 23 and ground.
If resistance is 2K to 4.5K ohmsand pin 23 to ground is 10K ohmsor greater
Go to STEP B
If resistance is outside of therange
Go to STEP D
STEP B
Procedure Condition Action
1. Key on.
2. Measure voltage betweenthe Transmission Harness38-way connector pin 23 andground
If voltage is 0 volts Go to STEP C
If voltage is 23-25 volts Repair the short to battery in theOEM harness. Go to STEP V
STEP C
Procedure Condition Action
1. Inspect Output Shaft SpeedSensor for contamination ordamage.
If no problem found
If problem is found or you weresent here from Step D or E
Replace Transmission ECU (Onlyif Fault Code is Active). Go toSTEP V
Replace OUtput Shaft SpeedSensor and inspect the tonewheel for damage, looseness orcorrosion. Go to STEP V
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Fault Isolation Procedures Fault Code 58 Isolation Procedures
STEP D
Procedure Condition Action
1. Disconnect the Transmission
Harness from the OutputShaft Speed Sensor.
2. Measure resistance betweenOutput Shaft Speed Sensorpins A and B.
If resistance is 2K to 4.5K ohms Go to STEP E
If resistance is outside of range Go to STEP C
STEP E
Procedure Condition Action
1. Measure resistance betweenOutput Shaft Speed Sensorpin A and ground.
If resistance is 10K ohms orgreater
Replace Transmission Harness.Go to STEP V
If resistance is less than 10Kohms
Go to STEP C
STEP V
Procedure Condition Action
1. Key off.2. Reconnect all connectors
and the negative batterycable.
3. Verify proper installation ofspeed sensor.
4. Key on.
5. Clear codes. See Fault CodeRemoval/Clearing onpage 17
6. Drive the vehicle and attemptto recreate the code
7. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 58 appears Return to STEP A to find error intesting.
If code other than 58 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 59 Isolation Procedures
J1939 Communication Link Fault (HCM)
SA 239
SPN 639
FMI 2, 9
Overview
J1939 is a high-speed twisted pair 250K data link with one 120 ohm resistor at each end of thelink. The Hybrid Control Module (HCM) is connected to the J1939 data link at the 38-wayconnector. This link is used to transmit or receive operation information from other modules on the
network like the Transmission Electronic Control Unit (TECU) or Engine Control Module (ECM).
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 2 is set in PDM mode and the HCM loses communication with other modules on theJ1938 data link for 3 consecutive messages.
• FMI 9 is set when the HCM looses communication with all modules on the J1939 data link for
30 consecutive messages or greater.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 2, 9- J1939 data link
- HCM
Fallback Mode When Fault is Set
When Fault Code 59 is set the following conditions will occur:
• The amber “Check Hybrid” and red “Stop Hybrid” lamps will not display, since the lamps aredriven over the J1939 data link.
• Fault is stored in HCM memory.• The operation mode will be changed to “AutoShift Only” mode.• If the fault sets at power-up the engine will not crank.• If the fault sets while driving, the vehicle will shift, however, when the vehicle comes to a stop
the clutch will open and remain open.• Electric motor/generator assist and regen are disabled; however, the high-voltage relays will
remain powered.• You may see a red “Service” lamp, and a “F” will flash in the gear display due to the active fault
code 24,35, or 36.
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Connector Views Fault Code 59 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter• ServiceRanger
Connector Views
HCM
D
Front Harness View(HCM - Vehicle Interface Connector)
37 38
35 36
1 67 12
13 22
23 28
29 34
9 Pin DiagnosticConnector
3J1939 High C
2J1939 Low
J1939 High
J1939 Low
9 Pin Diagnostic Connector
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 59 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key on.
3. Select the “VehicleComponents” screen andview the various modulesthat are reporting on theJ1939 link
If the HCM is not reporting onJ1939 but the TECU is listed
Go to STEP B
If the HCM and TECU are not
reporting on J1939
Go to STEP C
STEP B
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect HCM Vehicle
Harness 38-way connector.4. Measure resistance between
HCM Vehicle Harness38-way connector pin 2 and3.
Note: Make sure the volt/ohmmeter is on the properscale (around 200 ohmscale).
If resistance between pin 2 and 3is between 50-70 ohms
Replace HCM. Go to STEP V
If resistance is outside of range Repair J1939 Data link Harness.Go to STEP V
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Fault Isolation Procedures Fault Code 59 Isolation Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Measure the resistancebetween pins C and D on the9-way diagnostic connector
If resistance between pin C and Dis 50-70 ohms
Go to STEP D
If resistance is 70 ohms orgreater
One or more of the terminatingresistors on the J1939 data linkharness is missing, out of range,or there is an open in the link.Repair the OEM J1939 data linkharness. Go to STEP V
If resistance is 50 ohms or less There is an additional terminatingresistor present. Repair the OEMJ1939 data link harness. Go to
STEP V
STEP D
Procedure Condition Action
1. Key off.
2. Measure resistance betweenpins C and ground on the9-way diagnostic connector
If resistance between pin C andground is 10K ohms or greater
Attempt to communicate withanother vehicle and ensureServiceRanger is working. IfServiceRanger fails to
communicate with anothervehicle, call 1-800-826-HELP(4357).
If resistance is outside of range Repair J1939 Data link Harnessfor a short to ground. Go toSTEP V
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Fault Code 59 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 59 appears Return to STEP A to find error intesting.
If code other than 59 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 59 Isolation Procedures
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Connector Views Fault Code 60 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
HCM H
Harness Front View(HCM - Vehicle Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
9 Pin DiagnosticConnector28CAN High
J
27CAN Low
CAN Low
CAN High
9 Pin Diagnostic Connector
(TerminatingResistor in HCM)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 60 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Measure the resistancebetween one of the following:
• Diagnostic the9-pin connectorpins H and J.
• Pins A and B on the3-way connector.
• Pins 1 and 2 on the2-way connector.
If resistance between pin H and J,A and B, or 1 and 2 is between 50to 70 ohms
Go to STEP B
Note: The 3-way and 2-waydata link connectors arelocated next to the 9-pindiagnostic connector
If resistance is more than 70ohms
One or more of the terminatingresistors on the CAN data linkharness is either missing or out ofrange, or there is an open in thelink. Repair OEM CAN data linkHarness. Go to STEP V
Note: Make sure the volt/ohmmeter is on the proper
scale (around 200 ohmscale).
If resistance is less than 50 ohms There is an additional terminatingresistor present. Repair the OEM
CAN data link Harness. Go to STEP V
STEP B
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect HCM VehicleHarness 38-way connector.
4. Measure resistance betweenHCM Vehicle Harness38-way connector pin 27 and28.
If resistance between pin 27 and28 is between 110-130 ohms
Replace HCM. Go to STEP V
Note: Make sure the volt/ohmmeter is on the properscale (around 200 ohmscale)
If resistance is outside of range Repair the CAN data linkHarness. Go to STEP V
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Fault Isolation Procedures Fault Code 60 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 60 appears Return to STEP A to finderror in testing.
If code other than 60 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 61 Isolation Procedures
Rail Select Motor Fault
SA 3
SPN 772
MID 130
SID 39
FMI 5, 6
Overview
The Electric Shifter contains two electric motors called the Rail and Gear motors. These motorsmove a shift finger between the various rails which engage the shift rails. Power is supplied from
the Transmission Electronic Control Unit (TECU).
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU System Battery Voltage Low Fault is not active• The TECU System Battery Voltage Weak Fault is not active
• The Electric Shifter is not energized and the shift finger is not moving
Conditions to Set Fault
• FMI 5 and 6 are set when the TECU detects 5 continuous open or short conditions on the
Electric Shifter while the motor drive circuit is idle in a 500 ms interval.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
• FMI 5, 6
- Electric Shifter
- TECU
- Transmission Harness
Fallback Mode When Fault is Set
When Fault Code 61 is set the following conditions will occur:
• The red 'Service” lamp will display and an “F” will flash in the gear display.• Fault is stored in TECU memory.• The operation mode will be changed to “AutoShift Fallback” mode.• If this fault occurs while moving, the transmission will remain in the current gear and the clutch
will open when the vehicle comes to a stop.
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Connector Views Fault Code 61 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Harness Front View (TECU - System Interface Connector)
3738
3536
1
612
1322
2328
2934
7
TECU
35
37
Rail Select Motor
Rail Motor Minus
Rail Motor Plus
Harness Front View
(RailS
elect Motor)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
B A
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Fault Code 61 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key Off.
3. Disconnect negative batterycable.
4. Disconnect the TransmissionHarness 38-way connectorfrom the Transmission ECU.
5. Measure resistance betweenthe Transmission Harness38-way connector pins 35and 37
If resistance is 0.3 to 150 ohms Go to STEP B
If resistance is outside of range Go to STEP C
STEP B
Procedure Condition Action
1. Measure resistance between
the Transmission Harness38-way connector pins 35and ground.
If resistance is 10K ohms or
greater
Replace Transmission ECU (Only
if Fault Code is Active). Go toSTEP V
If resistance is less than 10Kohms
Go to STEP C
STEP C
Procedure Condition Action
1. Disconnect 2-way Rail Select
motor connector from theTransmission Harness.
2. Measure resistance betweenRail Select Motor harness2-way connector pins A andB and A to ground.
If resistance between A & B is 0.3to 150 ohms and pin A to groundis 10K ohms or greater
Replace Transmission Harness.Go to STEP V
If resistance is outside of range Replace Electric Shifter. Go toSTEP V
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Fault Code 61 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 61 appears Return to STEP A to finderror in testing.
If code other than 61 appears Go to Fault Code IsolationProcedure page 19
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Connector Views Fault Code 63 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
Harness Front View (TECU - System Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECU
36
38
Gear S
elect Motor
Gear Motor Minus
Gear Motor Plus
Harness Front View(Gear Select Motor)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
B A
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Fault Code 63 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key Off.
3. Disconnect negative batterycable.
4. Disconnect the TransmissionHarness 38-way connectorfrom the Transmission ECU.
If resistance is 0.3 to 150 ohms Go to STEP B
If resistance is outside of range Go to STEP C
STEP B
Procedure Condition Action
1. Measure resistance betweenthe Transmission Harness38-way connector pin 36 andground.
If resistance is 10K ohms orgreater
Replace Transmission ECU (Onlyif Fault Code is Active). Go toSTEP V
If resistance is less than 10K
ohms
Go to STEP C
STEP C
Procedure Condition Action
1. Disconnect 2-way GearSelect Motor connector fromthe Transmission Harness.
2. Measure resistance betweenGear Select Motor harness
2-way connector pins A andB and A to ground.
If resistance between A and B is0.3 to 150 ohms and pin A to
ground is 10K ohms or greater
Replace Transmission Harness.Go to STEP V
If resistance is outside of range Replace Electric Shifter. Go toSTEP V
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Fault Code 64 Isolation Procedures
ECA Fault
SA 239
SPN 788, 520198, 520199, 524035
FMI 0, 12, 13, 21 - 28
Overview
The Electric Clutch Actuator (ECA) controls the position of the clutch assembly. The ECA has amain power 3-way connector that is directly connected to the 24-volt battery and an 8-wayconnector that is connected to inputs like the HCM and the Engine Speed Sensor. The ECAcommunicates with the Hybrid Control Module (HCM) over the proprietary Controller Area
Network (CAN) data link to change position, show faults, or include other operation information.
Conditions to Run Fault
• The ECA ignition voltage is greater than 8.5 volts.
• The ECA Battery Voltage is greater than 7.8 when ignition voltage is greater than 8.5 volts.
Conditions to Set Fault
• FMI 12 is set for various internal ECA failures.• FMI 22-28 can be set for excessive motor current or incorrect shaft position.• FMI 0 is set when the ECA inverter temperature exceeds 130°C.• FMI 13 is set when the ECA can not find the clutch release bearing touch point after three
attempts.
Possible Causes
• FMI 12
- ECA• FMI 21-28
- Excessive debris buildup on/around the ECA.
- Binding cross-shafts.• FMI 0
- MIssing exhaust shield or exhaust to close to ECA
Fallback Mode When Fault is Set
When Fault Code 64 is set the following conditions will occur:
• The red “Stop Hybrid” lamp will display for FMI 12, 21, 22, 23, 24, 26, 27, or 28.• The amber “Check Hybrid” lamp will display for FMI 0, 13, or 25.• Fault is stored in HCM memory.• If the fault occurs while driving, the ECA will either maintain current clutch position or move to
the last position commanded by the HCM.
• If the fault occurs at power-up, the vehicle will not crank.
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Fault Isolation Procedures Fault Code 64 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter• Service Ranger
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
2. What FMI’s are present If FMI 0is listed Check for damaged or missingexhaust shielding by the ECA.Replace or reroute exhaust toreduce internal ECAtemperatures. Go to STEP V
If FMI 12 is listed Replace the ECA. Go to STEP V
If FMI 21-28 are listed Go to STEP B
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Fault Code 64 Isolation Procedures Fault Isolation Procedures
STEP B
Procedure Condition Action
1. Disconnect the 24 volt
battery cables
2. Remove the ECA from theclutch housing.
3. Check the ECA and clutchhousing for debris build-up
4. Rotate the clutch releaseshaft by hand to check forbinding
If no excessive debris is foundand clutch release shaft rotateswithout binding.
Replace ECA. Go to STEP V
If excessive debris is foundaround ECA or inside the clutchhousing or the clutch releaseshaft binds when rotated by hand.
Remove debris build up aroundECA area. Replace / repair clutchrelease shaft and upper bushingas needed for proper shaft
rotation. Go to STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.4. Clear codes. See Fault Code
Removal/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 64 appears Return to STEP A to finderror in testing.
If code other than 64 appears Go to Fault Code Isolation
Procedure page 19
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Fault Isolation Procedures Fault Code 64 Isolation Procedures
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Fault Code 65 Isolation Procedures
ECA Speed Sensor Fault
SA 239
SPN 520203
FMI 2, 5
Overview
The Electric Clutch Actuator (ECA) controls the position of the clutch assembly. The ECA has amain power 3-way connector that is directly connected to the 24-volt battery and an 8-wayconnector that is connected to inputs like the Hybrid Control Module (HCM) and the Engine SpeedSensor. The ECA communicates with the HCM over the proprietary Controller Area Network
(CAN) data link to change position, show faults, or include other operation information.
Conditions to Run Fault
• The ECA ignition voltage is greater than 8.5 volts.
• Fault Code 18 or 87 are active
Conditions to Set Fault
• FMI 2 is set when the HCM detects engine speed at idle, but does not detect ECA enginespeed.
• FMI 5 is set when the ECA detects an open on the ECA speed sensor signal circuit at key on.
Possible Causes
• FMI 2, 5
- ECA Speed Sensor- ECA Speed Sensor harness
- ECA
Fallback Mode When Fault is Set
When Fault Code 65 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display.
• Fault is stored in HCM memory.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
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ECA Speed Sensor Fault Fault Code 65 Isolation Procedures
• ServiceRanger
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Fault Code 65 Isolation Procedures Connector Views
Connector Views
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
2. What FMIs are listed? If FMI 5 is listed Go to STEP B
If FMI 2 is listed Go to STEP C
ECA
2G
2F
Speed Sensor
Eng Speed Sensor (-)
Eng Speed Sensor (+)
B A
ABC
ECA 8-Way Connector
E
A B C D
H G F
ECA 3-Way Connector
A B
ECA Speed Sensor (Connect View)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Isolation Procedures Fault Code 65 Isolation Procedures
STEP B
Procedure Condition Action
1. Check resistance between
ECA 8-way connector pins Fand G
If resistance between ECA 8-way
connector pins F and G is 140 -180 ohms
Go to STEP C
If resistance is out of range Repair the open in the sensor orthe harness from the ECA to thesensor. Go to STEP V
STEP C
Procedure Condition Action
1. Key off.
2. Check resistance betweenECA 8-way connector pins Fand ground
If resistance is 10K or greater Go to STEP D
If resistance is out of range Repair the shor t to ground in thesensor or the harness from theECA to the sensor. Go to STEP V
STEP D
Procedure Condition Action
1. Key on.
2. Measure voltage from theECA 8-way connector pin Gand ground
If voltage is 0 volts at key on andFMI 5 is active
Replace the ECA (only if FaultCode is active). Go to STEP V
If voltage is 0 volts at key on andFMI 2 is active
Go to STEP E
If voltage is greater than 0 volts atkey on
Repair the short to power on theECA speed sensor harness. Goto STEP V
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Fault Code 65 Isolation Procedures Fault Isolation Procedures
STEP E
Procedure Condition Action
1. Key off.
2. Remove the ECA speedsensor and examine thesensor end for signs ofdamage or debris buildup
If the sensor shows no cracks orsigns of metallic debris buildup onthe end
Go to STEP F
If the sensor is damaged or hasdebris buildup
Replace or clean the ECA sensor.Go to STEP V
STEP F
Procedure Condition Action
1. Inspect the engine flywheelto ensure there are nomissing or damaged teeth
If flywheel teeth are all intact andin good condition
Reinstall flywheel sensor until ittouches the flywheel then rotatecounterclockwise 1/2 to 1 fullturn. Tighten jam nut and drivevehicle. If fault returns replace thesensor. Go to STEP V
If flywheel teeth are damaged ormissing
Concern is with the flywheel.Contact your OEM for repairprocedures.
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 65 appears Return to STEP A to finderror in testing.
If code other than 65 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 65 Isolation Procedures
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Fault Code 66 Isolation Procedures
ECA Battery Voltage Fault
SA 239
SPN 520271
FMI 3, 4, 14
Overview
The Electric Clutch Actuator (ECA) controls the position of the clutch assembly. The ECA has amain power 3-way connector that is directly connected to the 24-volt battery positive and negative
terminals.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
• The ECA ignition voltage is greater than 8.5 volts.
Conditions to Set Fault
• FMI 3 is set when the ECA battery voltage is above 17 volts for 10 ms or greater.• FMI 4 is set when the ECA battery voltage is below 8.5 volts for 10 ms or greater.• FMI 14 is set when the ECA battery voltage is below 8.5 volts for 10 ms or greater, but the
HCM reports the battery voltage is within range.
Possible Causes
• FMI 3
- Charging system
- ECA• FMI 4
- ECA power supply harness, connections, and fuse holder
- Low batteries or bad main power connection
- Charging system
- ECA• FMI 14
- ECA power supply harness, connections, and fuse holder
Fallback Mode When Fault is Set
When Fault Code 66 is set the following conditions will occur:
• The red “Stop Hybrid” lamp will display• Fault is stored in HCM memory• If the fault occurs while driving, the ECA will either maintain current clutch position or move to
the last position commanded by the HCM, then the ECA holding device will engage
• If the fault occurs at power-up, the vehicle will not crank
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Connector Views Fault Code 66 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
ECA
1C
Battery
1B
P l u s
( + )
Ground ECA Ground
ECA Power
ABC
ECA 3-Way Connector
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 66 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Perform Electrical Pretest. If FMI 3 or 4 is active afterperforming the Electrical Pretest
Replace the ECA. Go to STEP V
If FMI 14 is active afterperforming the Electrical Pretest
Replace the ECA power harness.Go to STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault Code
Removal/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 66 appears Return to STEP A to finderror in testing.
If code other than 66 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 66 Isolation Procedures
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Fault Code 67 Isolation Procedures
ECA Ignition Voltage Fault
SA 239
SPN 520274
FMI 3, 4, 5
Overview
The Electric Clutch Actuator (ECA) controls the position of the clutch assembly. The ECA has a 8-
way connector that supplies ignition power to the ECA from the Hybrid Control Module (HCM).
Conditions to Run Fault
• The Hybrid Control Module (HCM) ignition voltage is greater than 7 volts and less than 32
volts.
Conditions to Set Fault
• FMI 3 is set when the ECA ignition voltage is shorted to the 24-volt system which is detectedthrough the HCM prior to powering the ignition supply for the ECA.
• FMI 4 is set when the ECA ignition voltage is shorted to ground during key on operation whichis detected by the HCM.
• FMI 5 is set when the ECA ignition voltage is open circuit after the key is on.
Possible Causes
• FMI 3, 4, 5
- ECA ignition supply harness from HCM
- HCM- ECA
Fallback Mode When Fault is Set
When Fault Code 67 is set the following conditions will occur:
• The red “Stop Hybrid” lamp will display• Fault is stored in HCM memory• If the fault occurs while driving, the ECA will either maintain current clutch position or move to
the last position commanded by the HCM, then the ECA holding device will engage
• If the fault occurs at power-up, the vehicle will not crank
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
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Connector Views Fault Code 67 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
HCM
ECA
ECA Ignition (System) 13 2H
1C
Battery
1A
1B
P l u s
( + )
Ground
ECA Ignition
ECA Ground
ECA Power
ECA 8-Way Connector
E
A B C D
H G F
Front Harness View (HCM - Hybrid System Interface Connector)
37 38
35 36
1 67 12
13 22
23 28
29 34
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 67 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMI’s withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. What FMI’s are present If FMI 3 is listed Go to STEP B
If FMI 4 is listed Go to STEP C
If FMI 5 is listed Go to STEP E
STEP B
Procedure Condition Action
1. Key off.
2. Disconnect the ECA 8-wayconnector.
3. Measure voltage on the ECA8-way connector from pin Hto ground.
If voltage is less than 0 volts Replace the HCM. Go to STEP V
If voltage is 23-25 volts Repair the short to battery in theOEM harness. Go to STEP V
STEP C
Procedure Condition Action
1. Key off.
2. Disconnect the ECA 8-wayconnector.
3. Key on.
4. Measure voltage from the
ECA 8-way connector frompin H to ground.
If voltage from H to ground is
23-25 volts
Replace the HCM. Go to STEP V
If voltage is outside of range Go to STEP D
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Fault Isolation Procedures Fault Code 67 Isolation Procedures
STEP D
Procedure Condition Action
1. Key off.
2. Disconnect the HCM 38-waySystem Harness connector.
3. Measure the resistancebetween the HCM SystemHarness 38-way connectorpin 13 and ground
If resistance from pin 13 toground is 10K ohms or greater
Replace the HCM. Go to STEP V
If resistance is outside of range Repair the OEM harness from theECA to the HCM. Go to STEP V
STEP E
Procedure Condition Action
1. Key off.
2. Disconnect the HCM 38-waySystem Harness connector.
3. Measure the resistancebetween the HCM SystemHarness 38-way connectorand the ECA 8-wayconnector on the followingpins:
• HVM pin 13 to ECApin H
If the resistance between pins 13and H is 0-0.3 ohms
Replace the ECA (only if FaultCode is Active). Go to STEP V
If resistance is outside of range Repair the open in the harnessbetween the ECA and HCM. Goto STEP V
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Fault Code 67 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 67 appears Return to STEP A to finderror in testing.
If code other than 67 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 67 Isolation Procedures
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Fault Isolation Procedures Fault Code 68 Isolation Procedures
Required Tools
• Basic Hand Tools
• ServiceRanger
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Key on.
2. Retrieve active fault codesand FMI’s withServiceRanger using the9-pin diagnostic connector.
If FMI 12 is active Go to STEP B
If FMI 13 is active Go to STEP C
If FMI 14 is active Go to STEP D
STEP B
Procedure Condition Action
1. Key on.
2. Using ServiceRanger viewthe Hybrid HCMconfiguration
HSA configuration is set at “HSAEnabled” and Hill Start Assistfeature is not needed
Select “No HSA” from the dropdown box on the right side of thescreen, then save thisconfiguration change by selectingdownload. Go to STEP V
HSA configuration is set at “HSAEnabled” and Hill Start Assistfeature is needed
The HCM must be changed tohardware version 3.7 or highercontaining an internal gradesensor. Contact Eaton for correctHCM part number information.
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Fault Code 68 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Key on.
2. Using ServiceRangercalibrate the grade sensor byselecting the AdvancedProduct functions from themain menu
3. Select Hybrid Control Modulefrom the upper left menu
4. Select Grade SensorCalibration and follow the onscreen instructions
If FMI 13 is not active aftercalibrating
Calibration complete. Go toSTEP V
If FMI 13 is active after calibrating Contact Eaton at 1-800-826-HELP (4357).
STEP D
Procedure Condition Action
1. Key on.
2. Ensure the HCM is properlymounted to the transmission
If HCM is not properly mounted orcap screws are loose
Tighten HCM mounting capscrews. Go to STEP V
If HCM is properly mounted to thetransmission
Replace HCM. Go to STEP V
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Fault Isolation Procedures Fault Code 68 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 8 appears Return to STEP A to finderror in testing.
If code other than 8 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 70 Isolation Procedures
Engine Failed to Respond Fault (HCM)
SA 239
SPN 188, 518, 539, 544
FMI 0, 1, 2, 7
Overview
The HCM communicates with the Engine ECM over the J1939 data link during normal operation to
control the engine torque and speed for transmission shifting.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.• J1939 Communication Link Fault (HCM) not active.
• J1939 Engine Message Fault (HCM) not active.
Conditions to Set Fault
• FMI 7 is set when the HCM commanded engine torque is less than 80% Max Engine Torque,HCM commanded engine torque is greater than 100 ft. lbs., and the difference betweencommanded engine torque and engine torque feedback is greater than 80 lb-ft for more than 1
second. Or, if the engine speed or torque maps are received with an error.
Possible Causes
• FMI 7
- Engine
- Fuel System- Exhaust Back Pressure
- Turbo charger
- Air Intake/Filter Restriction
- Un-reported engine loads
- Incorrect engine configuration settings for transmission assembly
Fallback Mode When Fault is Set
When Fault Code 70 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display.
• Fault is stored in HCM memory.• If the fault is set while driving, the vehicle may experience shifting concerns.
Conditions to Clear Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Isolation Procedures Fault Code 70 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter• ServiceRanger
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key on.
3. Retrieve codes. See FaultCode Removal/Clearing onpage 17
If code 70 is active Contact the OEM because theengine is failing to respond to theHCM’s command during a shift orthe maps were received in error.
If code 70 is not active Test complete.
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Fault Code 71 Isolation Procedures
Failed to Disengage a Gear
SA 3
SPN 520275
MID 130
SID 60
FMI 7
Overview
The Transmission Electronic Control Unit controls the Electric Shifter, which engages the differentrails and gear positions. The Electric Shifter is comprised of two electric motors; one changes the
rail position and the other changes the gear position.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU System Battery Voltage Low Fault is not active.• The TECU System Battery Voltage Weak Fault is not active.• TECU J1939 Communication Link Fault is not active.
• J1939 engine torque is zero ± 5% and J1939 engine speed is within 50 RPM of synchronous.
Conditions to Set Fault
• FMI 7 is set when the Electric Shifter fails three consecutive attempts to disengage a gear.
Possible Causes• FMI 7
- Dragging Clutch
- ECA
- Shift Bar Housing
- Electric Shifter
- Gear Select Sensor
- Yoke, Sliding Clutch, Mainshaft
- TECU
- Torque locked in gear
Fallback Mode When Fault is Set
When Fault Code 71 is set the following conditions will occur:
• Fault is stored in TECU memory• If the fault sets while driving, the vehicle will maintain the current gear and the clutch will open
when the vehicle comes to a stop.
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Failed to Disengage a Gear Fault Code 71 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter• ServiceRanger
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Note: The picture above shows the shift forks in the neutral position.
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Fault Code 71 Isolation Procedures Isolation Procedures
Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key on.
3. Depress “N” on the PushButton Shift Control.
4. Observe Gear Display. If Gear Display shows: “N” Go to STEP V
If Gear Display shows: “71” Go to STEP B
STEP B
Procedure Condition Action
1. Perform the ElectricalPretest.
If no issues found during theElectrical Pretest
Go to STEP C
If issue was repaired during theElectrical Pretest
Repeat STEP A
STEP C
Procedure Condition Action
1. Key off.
2. Remove Electric Shifterfrom Shift Bar Housing tosee what gear position iscurrently engaged.
3. Attempt to move theengaged rail back to neutral
If rails move from the engagedposition to neutral
Go to STEP D
If rails do not move from theengaged position
Attempt to take the torque offthe driveline. If concern is stillpresent, inspect the main casefor a damaged mainshaft,sliding clutch, or fork. Go toSTEP V.
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Isolation Procedures Fault Code 71 Isolation Procedures
STEP D
Procedure Condition Action
1. Key off.
2. Inspect the following:
• Shift blocks arefastened to shiftrails securely
• Electr ic shifter isfree from anyexcessive lubecontaminationbuildup
• Two gears positionscan not beengaged at the
same time
If no problem found Replace the electric shifter. Goto STEP V
If problem is found Repair as required. Go toSTEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectors
and the negative batterycable.
3. Key on.
4. Clear codes. See FaultCode Removal/Clearing onpage 17
5. Drive the vehicle andattempt to recreate thecode
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 72 appears Return to STEP A to find error intesting.
If code other than 72 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 72 Isolation Procedures
Failed to Select Rail Fault
SA 3
SPN 520277
MID 130
SID 59
FMI 7
Overview
The Transmission Electronic Control Unit controls the Electric Shifter, which engages the differentrails and gear positions. The Electric Shifter is comprised of two electric motors; one changes the
rail position and the other changes the gear position.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU System Battery Voltage Low Fault is not active.• The TECU System Battery Voltage Weak Fault is not active.
• This fault may occur at power-up after 15 seconds.
Conditions to Set Fault
• FMI 7 is set when the Electric Shifter fails five consecutive attempts to engage a particular rail
position.
Possible Causes• FMI 7
- Shift Bar Housing
- Electric Shifter
- Rail Select Sensor
- TECU
Fallback Mode When Fault is Set
When Fault Code 72 is set the following conditions will occur:
• Fault is stored in TECU memory
• If the fault sets while driving, the vehicle will continue to select the proper rail position.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Failed to Select Rail Fault Fault Code 72 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter• ServiceRanger
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Note: The picture above shows the shift forks in the neutral position.
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Fault Code 72 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key on.
3. Place Shift Device inNeutral.
4. Depress Service Brake.
5. Observe gear display. If you have an active code 72 Go to STEP B
If Gear Display shows solid
gear
Go to STEP V
STEP B
Procedure Condition Action
1. Perform the ElectricalPretest.
If no issues found during theElectrical Pretest
Go to STEP C
If issue was repaired during theElectrical Pretest
Repeat STEP A
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Fault Isolation Procedures Fault Code 72 Isolation Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Remove Electric Shifterfrom Shift Bar Housing.
3. Inspect the following:
• Shift blocks arefastened to shiftrails securely
• Shift rails move intoeach gear position
• Electr ic shifter isfree from anyexcessive lube
contaminationbuildup
• Two gear positionscan not beengaged at thesame time
If no problem found Replace the Electric Shifter. Goto STEP V
If problem is found Repair as required. Go toSTEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See FaultCode Removal/Clearing onpage 17
5. Drive the vehicle and
attempt to recreate thecode
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 72 appears Return to STEP A to find error intesting.
If code other than 72 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 73 Isolation Procedures
Failed to Engage a Gear Fault
SA 3
SPN 520278
MID 130
SID 58
FMI 7
Overview
The Transmission Electronic Control Unit controls the Electric Shifter, which engages the differentrails and gear positions. The Electric Shifter is comprised of two electric motors; one changes the
rail position and the other changes the gear position.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU System Battery Voltage Low Fault is not active.
• The TECU System Battery Voltage Weak Fault is not active.
Conditions to Set Fault
• FMI 7 is set when the Electric Shifter fails five consecutive attempts to engage a particular
gear position.
Possible Causes
• FMI 7
- Dragging Clutch
- ECA
- Shift Bar Housing
- Electric Shifter
- Gear Select Sensor
- Yoke, Sliding Clutch, Mainshaft
- TECU
Fallback Mode When Fault is Set
When Fault Code 73 is set the following conditions will occur:
• Fault is stored in TECU memory.
• If the fault sets while driving, the vehicle will maintain the current position.
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Failed to Engage a Gear Fault Fault Code 73 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter• ServiceRanger
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Note: The picture above shows the shift forks in the neutral position.
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Fault Code 73 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key on.
3. Place Shift Device inNeutral.
4. Depress Service Brake.
5. Select Drive.
6. Observe gear display. If you have an active code 73 Go to STEP B
If Gear Display shows solidgear
Go to STEP V
STEP B
Procedure Condition Action
1. Perform the ElectricalPretest.
If no issues found during theElectrical Pretest
Go to STEP C
If issue was repaired during the
Electrical Pretest
Repeat STEP A
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Fault Code 74 Isolation Procedures
Engine Failed to Respond Fault (TECU)
SA 3
SPN 93, 190
MID 130
PID 93, 190
FMI 7
Overview
The Transmission Electronic Control Unit (TECU) communicates with the Engine ECM over theJ1939 data link during normal operation, however, engine control is accomplished by the engineEngine Control Module (ECM) during Hybrid mode. The TECU changes the mode to AutoShiftOnly or AutoShift Fallback mode. Then the TECU is directly requesting changes in engine speed
and torque instead of the Hybrid Control Module (HCM).
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• J1939 Communication Link Fault (TECU) not active.• J1939 Engine Message Fault (TECU) not active.• J1939 engine speed is greater than 300 RPM if the TECU is in speed control mode, or greater
than 1000 RPM if the TECU is in torque control mode.
• Desired Engine Speed is less than J1939 engine configuration map speed.
Conditions to Set Fault
• FMI 7 is set when the difference between actual engine percent torque and desired enginepercent torque is greater than 50 for 2 continuous seconds, or when the difference betweendesired engine speed and actual engine speed is greater than 400 RPM for four continuous
seconds.
Possible Causes
• FMI 7
- Engine
- Fuel System
- Exhaust Back Pressure
- Turbo charger
- Air Intake/Filter Restriction
- Un-reported engine loads
- Incorrect engine configuration settings for transmission assembly
Fallback Mode When Fault is Set
When Fault Code 74 is set the following conditions will occur:
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Fault Isolation Procedures Fault Code 74 Isolation Procedures
• Fault is stored in TECU memory.• If the fault sets while driving, the vehicle will remain in the current gear position. Once the
vehicle is stopped, start and reverse gears can be engaged.
• TECU changes to “Autoshift Fallback” mode.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Note: No schematic for this code.
Note: For component location you must refer to the truck OEM's service literature.
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the
9-pin diagnostic connector.2. Key on.
3. Retrieve codes. See FaultCode Removal/Clearing onpage 17
If code 74 is active Contact the OEM because theengine is failing to respond tothe transmissions commandduring a shift.
If code 74 is not active Test complete.
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Fault Code 75 Isolation Procedures
Power Down in Gear Fault
SA 3
SPN 520276
MID 130
SID 60
FMI 14
Overview
The Push Button Shift Control (PBSC) is connected to the Transmission Electronic Control Unit(TECU) over the High Integrity Link (HIL) to communicate driver mode selection and fault status.At power-down the PBSC should be placed in “N” to perform the proper calibration sequence and
to prevent a torque locked transmission.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.
• The PBSC ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 14 is set when the TECU goes into the power-down sequence and a drive mode selection
other than “N” is confirmed.
Possible Causes
• FMI 14
- Driver powered down in Non-neutral mode
Fallback Mode When Fault is Set
When Fault Code 75 is set the following conditions will occur:
• Fault is stored in TECU memory only as an Inactive fault, since it only sets during the power-
down sequence.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
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Isolation Procedures Fault Code 75 Isolation Procedures
• ServiceRanger
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key on.
3. Check for codes. See Fault
Code Removal/Clearing onpage 17
If code 75 is inactive No action necessary, this code
indicates the driver powereddown the system prior toselecting neutral.
Note: Explain to driver, “N”must be selected on thePush Button ShiftControl beforepowering down toprevent a stuck in gearsituation and/ or apower-up no cranksituation.
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Fault Code 76 Isolation Procedures
High Voltage Battery Potential Voltage Fault
SA 239
SPN 520250
FMI 3, 4, 16, 18
Overview
The High-Voltage Batteries are 172 volts each connected in series to produce 340 volts DC. TheBattery Control Unit located in the Relay Box communicates with each battery to determine
temperature, SOC, and voltage. This information is then sent to the Inverter.
Conditions to Run Fault
• The Inverter enable voltage is greater than 7 volts and less than 16 volts.
• The Battery Control Unit ignition voltage is greater than 7 volts and less than 16 volts.
Conditions to Set Fault
• FMI 3 is set when the BCU detects the high-voltage battery is greater than 417 volts for 240ms.
• FMI 16 is set when the BCU detects the high-voltage battery is greater than 408 volts for 240ms.
• FMI 4 is set when the BCU detects the high-voltage battery is less than 211 volts for 240 ms.• FMI 18 is set when the BCU detects the high-voltage battery is less than 240 volts for 240 ms.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) onpage 25.
Possible Causes
• FMI 3, 4
- PEC
- DC cable
- DC interlock loop
- Inverter
- Service switch
- Inertia Switch
Fallback Mode When Fault is Set
When Fault Code 76 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will blink for FMI 4 and display solid for FMI 3, 16, 18• Fault is stored in HCM memory• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
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Warnings and Cautions Fault Code 76 Isolation Procedures
Conditions to Clear Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked with
DANGER High Voltage should beavoided. Service must be
performed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):
Components marked with High
Voltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Isolation Procedures Fault Code 76 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle andattempt to recreate thecode
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 73 appears Return to STEP A to find error intesting.
If code other than 73 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 78 Isolation Procedures
High Voltage Battery Current Fault
SA 239
SPN 520232
FMI 6
Overview
The High-Voltage Batteries are 172 volts each connected in series to produce 340 volts DC. TheBattery Control Unit (BCU) located in the Relay Box communicates with each battery to determine
temperature, SOC, and voltage. This information is then sent to the Inverter.
Conditions to Run Fault
• The Inverter enable voltage is greater than 7 volts and less than 16 volts.
• The Battery Control Unit ignition voltage is greater than 7 volts and less than 16 volts.
Conditions to Set Fault
• FMI 6 is set when the BCU detects high-voltage battery current is greater than 200 amps for 1
second.
Possible Causes
• FMI 6
- PEC
Fallback Mode When Fault is Set
When Fault Code 78 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in Hybrid Control Module (HCM) memory• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
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Warnings and Cautions Fault Code 78 Isolation Procedures
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage are
listed in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-VoltageShutdown Procedure' should be followed. Failure to follow these instructions may result in
severe personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed theLock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.
Components marked withDANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):
Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 78 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the 9-pin diagnostic connector.
2. Key off.
3. Follow the Hybrid ShutdownProcedure on page 3, to
avoid shock, burn, or deathfrom improperly handledhigh-voltage.
4. What Faults are present If Fault Code 78 is listed with anactive Fault Code 113
Go to procedure for Fault Code113, FMI 6 on page 369
If Fault Code 78 is listed with noFault Code 113
Replace the PEC. Go toSTEP V
STEP V
Procedure Condition Action1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See FaultCode Removal/Clearing onpage 17
5. Drive the vehicle andattempt to recreate the
code6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 78 appears Return to STEP A to find error intesting.
If code other than 78 appears Go to Fault Code IsolationProcedure page 19
WARNING
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Fault Isolation Procedures Fault Code 78 Isolation Procedures
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Fault Code 82 Isolation Procedures
High Voltage Battery Temperature Fault
SA 239
SPN 520233
FMI 0, 16
Overview
The High-Voltage Batteries are 172 volts each connected in series to produce 340 volts DC. TheBattery Control Unit located in the Relay Box communicates with each battery to determine
temperature, SOC, and voltage. This information is then sent to the Inverter.
Conditions to Run Fault
• The Inverter enable voltage is greater than 7 volts and less than 16 volts.
• The Battery Control Unit ignition voltage is greater than 7 volts.
Conditions to Set Fault
• FMI 0 is set when the BCU detects high-voltage battery temperature is greater than 70°C for6.4 seconds.
• FMI 16 is set when the BCU detects high-voltage battery temperature is greater than 60°C for
6.4 seconds.
Possible Causes
• FMI 0
- PEC
- Battery Fan- Battery Fan Air Filter
- Battery Fan Relay power supply harness
- Battery Fan Relay
- Battery Fan Exhaust Screen
Fallback Mode When Fault is Set
When Fault Code 82 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory
• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode• Transmission defaults start gear to 1st
Note: The conditions above are only present for FMI 0.
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Warnings and Cautions Fault Code 82 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage are
listed in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at the
connectors, while high-voltage components are marked with a label. High-voltage rubberinsulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killed
if you do not follow the procedure.Components marked with
DANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):
Components marked with High
Voltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 82 Isolation Procedures Connector Views
Connector Views
HCM
30
86
8785
26 86
87
85
30
Battery Fa
n
Typical Relay Switch
Battery Fan Relay
24V Truck Battery
2 4 V
P l u s
4Battery Fan Return
PEC
12
Ground14
Battery Fan Supply
Cooling Fan Plus
Cooling Fan Minus
Harness Front View(HCM - Hybrid System Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
19 - Way Mating Connector View(PEC - Low Voltage Connector)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
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Fault Isolation Procedures Fault Code 82 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Follow “Hybrid ShutdownProcedure” found at front of
book, to avoid shock, burn,or death from improperlyhandled high-voltage.
4. What Faults are present. If Fault Code 82 FMI 0 is listed Go to STEP B
If Fault Code 82 FMI 16 is listed Test complete. FMI 16 requiresno action or replacement.
STEP B
Procedure Condition Action
1. Remove and inspect the Airfilter on the PEC inlet andthe exhaust screen on thePEC outlet.
If the air filter and screen areclean and free from debris
Go to STEP C
If the air filter is dirty or theexhaust screen is plugged
Replace the Air Filter and cleanthe Exhaust Screen. Go toSTEP V
WARNING
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Fault Code 82 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Connect ServiceRanger tothe 9-pin diagnosticconnector in the cab.
3. Key on.
4. Go to “Product Tests” andselect Battery Fan Relay.
5. Check for airflow from thefront and rear air ports inthe PEC.
If airflow can be felt from thePEC air inlet and exhaust
Go to STEP E
If airflow can not be felt from thePEC air inlet and exhaust
Go to STEP D
STEP D
Procedure Condition Action
1. Key on.
2. Disconnect the 19-wayconnector at the PEC.
3. Measure voltage at the19-way connector from pin
12 to pin 14.
If voltage between pins 12 and14 is +/- 0.2 volts of battery
voltage
Replace the PEC. Go toSTEP V
If voltage between pins 12 and14 is outside of range
Repair Battery Fan Relaycircuit. Refer to OEM.
STEP E
Procedure Condition Action
1. Is fault code 105 FMI 29listed active
Fault code 105 FMI 29 is active Replace the PEC. Go to STEP V
Fault code 105 FMI 29 is notactive Using ServiceRanger go to“Advanced Product Functions”menu and select the HCM option.Download the Snapshot file andcontact Eaton at 1-800-826-HELP (4357).
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Fault Isolation Procedures Fault Code 82 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See FaultCode Removal/Clearing onpage 17
5. Drive the vehicle andattempt to recreate thecode
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 82 appears Return to STEP A to find error intesting.
If code other than 82 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 83 Isolation Procedures
Invalid Shift Range
SA 3
SPN 751
SID 18
PID 18
FMI 12, 13
Overview
The Transmission Electronic Control Unit (TECU) is connected to the shift device, which sendsdriver mode selection data. The only compatible shift devices are the Eaton® Push Button ShiftControl (PBSC) and OEM supplied shift lever (if equipped with park). The TECU checks the
vehicle for the type of shift device during the first power-up.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU System Battery Voltage Low Fault is not active.
• The TECU is being powered up for the first time and no shift device has been configured.
Conditions to Set Fault
• Fault Code 83 is set when redundant sensor voltages do not agree.
Possible Causes
• Faulty Sensors• Harness
• TECU
Fallback Mode When Fault is Set
When Fault Code 83 is set the following conditions will occur:
• A “F” will show in the gear display• Fault is stored in TECU memory• TECU changes to “AutoShift” control
• The engine will not crank
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 83 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-VoltageShutdown Procedure' should be followed. Failure to follow these instructions may result in
severe personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed theLock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubberinsulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.
Components marked withDANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible serious
injury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 83 Isolation Procedures Connector Views
Connector Views
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Disconnect the 4-wayconnector to the park pawlactuator.
2. Key on.
3. Check for 24V supply at 4-pin connector at pins 1 and
2.
If voltage between pins 1 and 2is +/- 0.2 volts of battery voltage
Go to STEP B
If voltage is outside the range Go to STEP D
Harness Front View (TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Park PawlActuator
3
1
4
2
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
17
16
15
31
Shift Return (Minus)
Shift Control Input 1
Shift Control (Plus)
Shift Control Input 2
TECU
2
3
4
1
4-Pin Park Pawl ActuatorConnector
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Fault Isolation Procedures Fault Code 83 Isolation Procedures
STEP B
Procedure Condition Action
1. With the actuator/shift lever
in the Neutral positioncheck voltage on pins:
• 3 to ground
• 4 to ground
If voltage is between 2.25V and2.75 V
Go to STEP C
If voltage is outside the range Replace Sensor. Go to STEP V
STEP C
Procedure Condition Action
1. Disconnect the TECUVehicle Harness 38-wayconnector.
2. Check continuity between:
• 38-way connectorpin 15 and 4-pinconnector pin 4
• 38-way connectorpin 16 and 4-pinconnector pin 3
If continuity is okay Replace the TECU. Go toSTEP V
If an open is found Repair or replace theHarness. Go to STEP V
STEP D
Procedure Condition Action
1. Disconnect the TECUVehicle Harness 38-wayconnector.
2. Check continuity between:
• 38-way connector
pin 17 and 4-pinconnector pin 1
• 38-way connectorpin 31 and 4-pinconnector pin 2
If continuity is okay Replace the TECU. Go to
STEP V
If an open is found Repair or replace theHarness. Go to STEP V
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Fault Code 83 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle andattempt to recreate thecode
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 83 appears Return to STEP A to find error intesting.
If code other than 83 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 83 Isolation Procedures
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Fault Code 84 Isolation Procedures
Shift Control Device Not Configured Fault
SA 3
SPN 751
MID 130
SID 18
FMI 13, 14
Overview
The Transmission Electronic Control Unit (TECU) is connected to the shift device, which sendsdriver mode selection data. The only compatible shift device is the Eaton® Push Button ShiftControl (PBSC) and OEM supplied shift lever (if equipped with park). The TECU checks thevehicle for the type of shift device during the first power-up.
Note: This fault code will only be set active.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU System Battery Voltage Low Fault is not active.
• The TECU is being powered up for the first time and no shift device has been configured.
Conditions to Set Fault
• FMI 13 is set when the TECU powers-up the first time and fails to recognize any valid shift
device connected to the vehicle within five seconds.
Possible Causes
• FMI 13• OEM Wiring Harness between TECU and shift control device is disconnected• PBSC• FMI 14• OEM Wiring Harness between TECU and shift control device is disconnected
• Shift Lever
Fallback Mode When Fault is Set
When Fault Code 84 is set the following conditions will occur:
• The “Service” lamp may or may not come on depending on the failure.• Fault is stored in TECU memory.• TECU changes to “AutoShift Fallback” mode.
• The engine will not crank.
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Shift Control Device Not Configured Fault Fault Code 84 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
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Fault Code 84 Isolation Procedures Connector Views
Connector Views
Harness Front View (TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
23282934
7
Harness Front View(Push Button Shift Control 30-Way Connector)
ABCDEFGHJK
1
2
3
A1
A3
K1
K3
TECU PBSC
28
27 F2
F1
31
25 J3
C1
B3
HIL High
HIL Low
Shift Power (Plus)
Shift Return (Minus)
HIL High
HIL Low
Shift Power (Plus)
Shift Return (Minus)
VDash Dimmer
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Shift LeverController
3
1
4
2
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
17
16
15
31
Shift Return (Minus)
Shift Control Input 1
Shift Control (Plus)
Shift Control Input 2
TECU
2
3
4
1
4-Pin Park Pawl ActuatorConnector
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Fault Code 84 Isolation Procedures
STEP D
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect vehicle harness38-way connector.
4. Measure the resistancebetween pin J3 on the shiftcontrol 30-way connectorand the pin 25 on thevehicle harness 38-wayconnector
If resistance between pins J3and pin 25 is 0-0.3 ohms
Go to STEP E
If resistance is out of range Repair the vehicle harness
between the PBSC and thetransmission ECU. Go toSTEP V
STEP E
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect vehicle harness38-way connector.
4. Measure the resistancebetween the following:
• Pin C1 on the shiftcontrol 30-wayconnector and pin31 on the vehicleharness 38-wayconnector
• Pin C1 on the shift
control and ground
If resistance between pins C1and pin 25 is 0-0.3 ohms andresistance between pin C1 andground is 10K ohms or greater
Replace the Transmission ECU(only if fault code is active). Goto STEP V
If resistance is out of range Repair the vehicle harnessbetween the PBSC and thetransmission ECU. Go toSTEP V
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Fault Code 84 Isolation Procedures
STEP F
Procedure Condition Action
1. Key off.
2. Disconnect the shift control30-way connector
3. Key on.
4. Measure the AC voltagebetween pins F1 and F2
If voltage is 0.1 volts AC orgreater
Replace the push button shiftcontrol (PBSC). Go to STEP V
Note: Make sure the meter ison the AC auto featureor set to the AC 10 voltsscale
If voltage is 0.1 volts AC or less Go to STEP G
STEP G
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect vehicle harness38-way connector.
4. Measure the resistancebetween the following:
• Pin F1 on the shiftcontrol 30-wayconnector and pin28 on the vehicleharness 38-wayconnector
• Pin F1 on the shiftcontrol 30-wayconnector andground
If resistance between pins F1and pin 28 is 0-0.3 ohms andresistance between pin F1 andground is 10K ohms or greater
Go to STEP H
If resistance is out of range Repair the vehicle harnessbetween the PBSC and thetransmission ECU. Go toSTEP V
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Fault Code 84 Isolation Procedures
STEP H
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect vehicle harness38-way connector.
4. Measure the resistancebetween the following:
• Pin F2 on the shiftcontrol 30-wayconnector and pin27 on the vehicleharness 38-way
connector• Pin F2 on the shift
control 30-wayconnector andground
If resistance between pins F2and pin 27 is 0-0.3 ohms andresistance between pin F2 andground is 10K ohms or greater
Replace the Transmission ECU.Go to STEP V
If resistance is out of range Repair the vehicle harnessbetween the PBSC and thetransmission ECU. Go toSTEP V
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Fault Code 84 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle andattempt to recreate thecode
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 84 appears Return to STEP A to find error intesting.
If code other than 84 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 85 Isolation Procedures
Shift Control Device Incompatible Fault
SA 3
SPN 639
MID 130
SID 18
FMI 12
Overview
The Transmission Electronic Control Unit (TECU) is connected to the shift device, which sendsdriver mode selection data. The TECU checks the vehicle for the type of PBSC device during the
first power-up to determine, if a compatible model is being used.
Conditions to Run Fault
• The TECU ignition voltage is greater than 7 volts and less than 32 volts.• The TECU System Battery Voltage Low Fault is not active
• The HIL Link Fault is not active.
Conditions to Set Fault
• FMI 12 is set anytime the TECU powers-up and detects a non-compatible shift control device,
or it does not receive a component I.D. ten seconds after power-up.
Possible Causes
• FMI 12
- Shift Control Device
Fallback Mode When Fault is Set
When Fault Code 85 is set the following conditions will occur:
• Fault is stored in TECU memory• TECU changes to “AutoShift Fallback” mode
• The engine will not crank.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit
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Shift Control Device Incompatible Fault Fault Code 85 Isolation Procedures
• Digital Volt/Ohm Meter• ServiceRanger
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Fault Isolation Procedures Fault Code 85 Isolation Procedures
STEP B
Procedure Condition Action
1. View the Hybrid Control
Module selection under theRoadranger Configurationsoption in ServiceRanger.
2. View the SystemConfiguration field for oneof the following options:
• UPG = Used in EH-8E306A-UPGtransmission
• UP = Used in EH-8E306A-UPtransmissions
• CD or U = Used inEH-8E306A-CDand EH-8E306A-Utransmissions
3. Compare the HCM SystemConfigurations selection tothe TECU Push-button Typeselection.
If HCM System Configurationand TECU Push-button Typeare the same
Contact Eaton at 1-800-826-HELP (4357).
If HCM System Configurationand TECU Push-button Typeare different
Install a HCM with the correctconfiguration to match thetransmission tag. Go to STEP V
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Fault Code 85 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See FaultCode Removal/Clearing onpage 17
5. Drive the vehicle andattempt to recreate thecode
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 85 appears Return to STEP A to finderror in testing.
If code other than 85 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 85 Isolation Procedures
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Fault Code 88 Isolation Procedures
Inverter CAN Message Fault (HCM)
SA 239
SPN 520223
FMI 2, 9
Overview
The Inverter communicates with the Battery Control Unit (BCU) located in the Power ElectronicsCarrier (PEC) and the Hybrid Control Module (HCM) on the Controller Area Network (CAN) high-speed proprietary data link. The data link is a two wire twisted pair with two 120 ohm resistors
located in the link.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
• The HCM CAN data link fault is not active.
Conditions to Set Fault
• FMI 9 is set when the HCM has not received a Inverter message for 30 consecutive messagecycles.
• FMI 2 is only active in Product Diagnostic Mode and will set if 3 consecutive Invertermessages are not received by the HCM.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) onpage 25.
Possible Causes
• FMI 9, 2
- Inverter
- CAN data link
Fallback Mode When Fault is Set
When Fault Code 88 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory• Electric motor/generator assist and regen are disabled, however, the high-voltage relays will
remain powered.
• HCM continues to control the Hybrid vehicle in a diesel only mode• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
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Connector Views Fault Code 88 Isolation Procedures
Required Tools
• Basic Hand Tools
• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
27
28
5
4
HCM Inverter
CAN - High (Vehicle)
CAN - Low (Vehicle)
CAN - High
CAN - Low
Harness Front View(HCM - Vehicle Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)
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Fault Code 88 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector
2. Perform Electrical Pretestand Hybrid ElectricalPretest.
If no issues are found during theHybrid Electrical Pretest
Go to STEP B
If issue was repaired during theHybrid Electrical Pretest
Go to STEP V
STEP B
Procedure Condition Action
1. Key off
2. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or death
from improperly handledhigh-voltage
3. Disconnect Inverter 40-wayconnector
4. Measure resistancebetween Inverter 40-wayconnector pins 5 and 4
If resistance between pins 5and 4 is between 50-70 ohms
Replace Inverter. Go toSTEP V
Note: Make sure the volt/ohmmeter is on the properscale (around 200 ohmscale)
If resistance is outside of range Repair CAN data link Harness.Go to STEP V
WARNING
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Fault Isolation Procedures Fault Code 88 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See FaultCode Removal/Clearing onpage 17
5. Drive the vehicle andattempt to recreate thecode
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 88 appears Return to STEP A to find error intesting
If code other than 88 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 89 Isolation Procedures
Battery Control Unit CAN Message Fault (HCM)
SA 239
SPN 520234
FMI 2, 9
Overview
The Hybrid Control Module (HCM) communicate with the Inverter communicates with the BatteryControl Unit (BCU) located in the Power Electronics Carrier (PEC) and the HCM on the ControllerArea Network (CAN) high-speed proprietary data link. The data link is a two wire twisted pair with
two 120 ohm resistors located in the link.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
• The HCM CAN data link fault is not active.
Conditions to Set Fault
• FMI 2 is only active in Product Diagnostic Mode and will set if 3 consecutive BCU messagesare not received by the HCM.
• FMI 9 is set when the HCM has not received a BCU 1 message for 30 consecutive messagecycles.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) onpage 25.
Possible Causes
• FMI 2, 9
- Inverter
- CAN data link from PEC to Inverter
- PEC
Fallback Mode When Faults is Set
When Fault Code 89 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory• Electric motor/generator assist and regen are disabled, however, the high-voltage relays will
remain powered• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 89 Isolation Procedures
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-VoltageShutdown Procedure' should be followed. Failure to follow these instructions may result in
severe personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed theLock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubberinsulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.
Components marked withDANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):
Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 89 Isolation Procedures Connector Views
Connector Views
27
28
5
4
HCM Inverter
CAN - High (Vehicle)
CAN - Low (Vehicle)
CAN - High
CAN - Low
Harness Front View(HCM - Vehicle Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
PEC Harness Connector View (Deutsch 19 - Way)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
35
34
2
1
PEC
CAN - High
CAN - Low
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)
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Fault Isolation Procedures Fault Code 89 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Perform Electrical Pretestand Hybrid ElectricalPretest.
If no issues are found during theHybrid Electrical Pretest
Go to STEP B
If issue was repaired during theHybrid Electrical Pretest
Go to STEP V
STEP B
Procedure Condition Action
1. Key off
2. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or death
from improperly handledhigh-voltage
3. Disconnect PEC 19-wayconnector
4. Measure resistancebetween PEC 19-wayconnector pins 1 and 2
Note: Make sure the volt/ohmmeter is on the properscale (around 200 ohmscale)
If resistance between pin 1 and2 is between 50-70 ohms
Replace the Battery ControlUnit (BCU). Go to STEP V
If resistance is outside of range Go to STEP C
WARNING
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Fault Code 89 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Disconnect Inverter 40-way
connector.
2. Measure resistancebetween:
• Inverter 40-wayconnector pin 35and PEC 19-wayconnector pin 2.
• Inverter 40-wayconnector pin 34and PEC 19-wayconnector 1.
If resistance between pin 35and 2 is between 0-0.2 ohms,and resistance between 34 and1 is between 0-0.2 ohms
Replace Inverter. Go to STEP V
Note: Make sure the volt/ohmmeter is on the properscale (around 200 ohmscale)
If resistance is outside of range Repair CAN data link Harnessbetween Inverter and PEC. Goto STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete.
If code 89 appears Return to STEP A to find error intesting.
If code other than 89 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 89 Isolation Procedures
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Connector Views Fault Code 95 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• Eaton® Test Adapter Kit• Digital Volt/Ohm Meter
• ServiceRanger
Connector Views
HCM
30
86
8785
32 86
87
85
Crank Enable Plus
Harness Front View(HCM - Vehicle Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
Typical Relay Switch
12-Volt
Cranking Relay
24V Truck Battery
2 4 V
P l u s
4Crank Enable Minus
26Crank Enable Latch
AutoShift Start Enable Relay (30)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
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Fault Code 95 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMI’s withServiceRanger using 9-pindiagnostic connector.
2. Swap the 24V crankingrelay with another relay andsee if the fault returns
If the fault does not return withnew relay
Replace 24V cranking relay. Goto STEP V
If the fault returns with newrelay
Go to STEP B
STEP B
Procedure Condition Action
1. What FMIs were listed fromStep A.
If FMI 3 is listed Go to STEP C
Note: The 24-volt CrankingRelay must be wiredaccording to Eaton®Hybrid requirements(shown on previouspage) for this test to
work properly. If wireddifferently, consult OEMfor correct wiringschematic.
If FMI 4 is listed Go to STEP E
STEP C
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect the HCMvehicle harness 38-wayconnector
4. Measure the resistancebetween HCM vehicleharness 38-way connectorpins 32 and 4
If resistance between 32 and 4is 40-120 ohms
Go to STEP D
If resistance is outside of range Repair the vehicle harness foran open circuit. Go to STEP V
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Fault Isolation Procedures Fault Code 95 Isolation Procedures
STEP D
Procedure Condition Action
1. Key on.
2. Measure voltage betweenHCM vehicle harness38-way connector pin 32and ground at key on.
If voltage between pin 32 andground is 5 volts
Replace the HCM (only if faultcode is active).Go to STEP V
If voltage between pin 32 andground is 24 volts
Repair the short to vbatt on theharness. Go toSTEP V
STEP E
Procedure Condition Action
1. Key off.
2. Disconnect negative batterycable.
3. Disconnect the HCMharness 38-way connector.
4. Measure voltage betweenHCM vehicle harness38-way connector pin 32and ground.
If voltage between pin 32 andground is 10K ohms or greater
Replace the HCM (only if faultcode is active).Go to STEP V
If resistance is outside of range Repair the vehicle harness for a
short to ground. Go to STEP V
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Fault Code 95 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 95 appears Return to STEP A to find error intesting.
If code other than 95 appears Go to Fault Code Isolation
Procedure page 19
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Fault Isolation Procedures Fault Code 95 Isolation Procedures
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Fault Code 101 Isolation Procedures
High Voltage Battery Fault
SA 239
SPN 520238
FMI 0, 22 - 31
Overview
The High-Voltage Batteries are 172 volts each connected in series to produce 340 volts DC. TheBattery Control Unit located in the Relay Box communicates with each battery to determine
temperature, SOC, and voltage. This information is then sent to the Inverter.
Conditions to Run Fault
• The Inverter enable voltage is greater than 7 volts and less than 16 volts.
• The Battery Control Unit ignition voltage is greater than 7 volts and less than 16 volts.
Conditions to Set Fault
• FMI 0,22-31 are set for various internal High-Voltage Battery failures.
Possible Causes
• FMI 0, 22-31
- PEC
Fallback Mode When Fault is Set
When Fault Code 101 is set the following conditions will occur:
• The red “Stop Hybrid” lamp will display for FMI 0• The amber “Check Hybrid” lamp will display for FMI 22-29• Fault is stored in HCM memory• Depending on the FMI the Inverter or HCM shuts the high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
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Warnings and Cautions Fault Code 101 Isolation Procedures
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage are
listed in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-VoltageShutdown Procedure' should be followed. Failure to follow these instructions may result in
severe personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed theLock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.
Components marked withDANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible serious
injury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 101 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Follow the “HybridShutdown Procedure”
found at front of book, toavoid shock, burn, or deathfrom improperly handledhigh-voltage.
4. What FMIs are present If Fault Code 101, FMI 27 or 28are listed with an active FaultCode 101 FMI 26
Replace the PEC. Go toSTEP V
If Fault Code 101, FMI 27 or 28are not listed with an activeFault Code 101 FMI 26
Go to STEP B
If Fault Code 101 FMI 22-25 arelisted
Replace the PEC. Go toSTEP V
If Fault Code 101 FMI 29 islisted
Go to STEP C
If Fault Code 101 FMI 30 or 31are listed
Test complete. FMI’s 30 and 31require no action orreplacement.
STEP B
Procedure Condition Action
1. View the Data Monitorparameter PID 133 “BatterySOC”
If PID 133 “Battery SOC” is lessthan 80 percent Replace the PEC. Go toSTEP V
If PID 133 “Battery SOC” isgreater than 80 percent
Contact Eaton at 1-800-826-HELP (4357).
WARNING
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Fault Isolation Procedures Fault Code 101 Isolation Procedures
STEP C
Procedure Condition Action
1. View the Data Monitor
parameter PID 133 “BatterySOC”
If PID 133 “Battery SOC” is
greater than 10 percent
Replace the PEC. Go to
STEP V
If PID 133 “Battery SOC” is lessthan 10 percent
Contact Eaton at 1-800-826-HELP (4357).
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. See FaultCode Removal/Clearing onpage 17
5. Drive the vehicle andattempt to recreate thecode
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete.
If code 101 appears Return to STEP A to find error intesting.
If code other than 101 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 103 Isolation Procedures
Battery Control Unit Communication Fault
SA 239
SPN 520265
FMI 22 - 26
Overview
The High-Voltage Batteries each contain a cell controller that communicates over a twisted pairdata link to the Battery Control Unit (BCU). The Battery Control Unit located in the Relay Boxcommunicates with each battery to determine temperature, SOC, and voltage. This information is
then sent to the Inverter.
Conditions to Run Fault
• The Inverter enable voltage is greater than 7 volts and less than 16 volts.
• The Battery Control Unit ignition voltage is greater than 7 volts and less than 16 volts.
Conditions to Set Fault
• FMI 22 is set when the BCU fails to communicate over the CAN data link for 30 ms.• FMI 23 is set when the BCU fails to receive HCM data over the CAN data link for 2.5 seconds
or greater after communication is established.• FMI 24 is set when the BCU fails to receive Inverter data over the CAN data link for 2.5
seconds or greater after communication is established.• FMI 25 is set when the BCU fails to transmit anything over the data link for 2 seconds.
• FMI 26 is set when the BCU detects an error on initial check.
Possible Causes• FMI 26
- Relay box• FMI 22, 25
- Relay box
- CAN data link between PEC and Inverter• FMI 23
- Relay box
- CAN data link between PEC and HCM• FMI 24
- Relay box
- Inverter- CAN data link between PEC and Inverter
Fallback Mode When Fault is Set
When Fault Code 103 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory
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Warnings and Cautions Fault Code 103 Isolation Procedures
• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage are
listed in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-VoltageShutdown Procedure' should be followed. Failure to follow these instructions may result in
severe personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed theLock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at the
connectors, while high-voltage components are marked with a label. High-voltage rubberinsulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked with
DANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.
Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Isolation Procedures Fault Code 103 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Key off
2. Key on
3. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector
4. Perform Electrical Pretestand Hybrid ElectricalPretest
If no issues are found duringeither Electrical Test
Go to STEP B
If issue was repaired during
either Electrical Test
Go to STEP V
STEP B
Procedure Condition Action
1. Key off
2. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
3. What Faults are present If Fault Code 103 FMI 26 is listed Replace PEC. Go toSTEP V
If Fault Code 103 FMI 22, 23, 24,or 25 are listed with an active faultcode 111
Go to procedure for Fault Code111 on page 357
If fault code 88 or 89 are listed Go to procedure for Fault Code88 on page 299 or 89 on
page 303
WARNING
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Fault Code 103 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectors
and the negative battery
cable
3. Key on
4. Clear codes. See Fault Code
Removal/Clearing on
page 17
5. Drive the vehicle and attempt
to recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete
If code 103 appears Return to STEP A to find error in
testing.
If code other than 103 appears Go to Fault Code Isolation
Procedure page 19
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Fault Isolation Procedures Fault Code 103 Isolation Procedures
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Fault Code 105 Isolation Procedures
Battery Control Unit Fault
SA 239
SPN 520240
FMI 22 - 30
Overview
The High-Voltage Batteries each contain a cell controller that communicates over a twisted pairdata link to the Battery Control Unit (BCU). The Battery Control Unit located in the Relay Boxcommunicates with each battery to determine temperature, State of Charge (SOC), and voltage.
This information is then sent to the Inverter.
Conditions to Run Fault
• The Inverter enable voltage is greater than 7 volts and less than 16 volts.
• The Battery Control Unit ignition voltage is greater than 7 volts and less than 16 volts.
Conditions to Set Fault
• FMI 22-30 are set for various internal Battery Control Unit failures.
Possible Causes
• FMI 22-30
- Relay box
Fallback Mode When Fault is Set
When Fault Code 105 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 105 Isolation Procedures
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should beavoided. Service must be
performed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.
Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 105 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector.
2. Key off.
3. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
4. What FMIs are present If Fault Code 105, FMI 23-29 islisted
Replace PEC. Go to STEP V
If Fault Code 105, FMI 30 is listed Go to STEP B
If Fault Code 105, FMI 22 is listed Key off and back on. If fault is stillpresent at key on, Replace PEC.Go to STEP V
WARNING
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Fault Isolation Procedures Fault Code 105 Isolation Procedures
STEP B
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Disconnect the AC high-voltage connector at theMotor / Generator
3. With the AC cabledisconnected at both ends,measure resistance to cableshielding at all threeterminals. Note: Cableshould be flexed whilemeasuring
If Open or “OL” on meter Replace PEC
If any resistance/continuity isfound
Replace AC High Voltage Cable.Go to STEP V
WARNING
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Fault Code 105 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 105 appears Return to STEP A to find error intesting.
If code other than 105 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 105 Isolation Procedures
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Fault Code 107 Isolation Procedures
High Voltage Battery Leak Detection Fault
SA 239
SPN 520242
FMI 1
Overview
The Battery Control Unit (BCU) continuously monitors the vehicle to detect a high-voltage leak.The circuit is connected to 3 locations on the DC high-voltage line with the opposite end connected
to the chassis through a resistor.
Conditions to Run Fault
• The Inverter enable voltage is greater than 7 volts and less than 16 volts.
• The Battery Control Unit ignition voltage is greater than 7 volts and less than 16 volts.
Conditions to Set Fault
• FMI 1 is set when resistance between high-voltage cable and inverter case is less than 82k
ohms for 1.2 seconds.
Possible Causes
• FMI 1
- High-voltage cable insulation damage
- High-voltage component leaking
Fallback Mode When Fault is Set
When Fault Code 107 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. The
TECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
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Warnings and Cautions Fault Code 107 Isolation Procedures
• ServiceRanger
• Megatest Meter AMB-45
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed theLock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
WARNING
To reduce risk of possible serious
injury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
DANGER
HAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should be
avoided. Service must beperformed by qualified personnel only.
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Fault Code 107 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Key on
2. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector
If fault code 107 is active Go to STEP B
If fault code 107 is inactive Test complete. Go to STEP V
STEP B
Procedure Condition Action
1. Key off
2. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
3. Disconnect the Inverter DC
connector at the PEC
4. Measure the resistance toshield at the DC cableconnector on both thepositive and negativeterminals
If Open or “OL” on meter Go to STEP I
If any resistance/continuity isfound
Go to STEP C
WARNING
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Fault Isolation Procedures Fault Code 107 Isolation Procedures
STEP C
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Disconnect the DCconnector at the Inverter
3. With the DC cabledisconnected at both endsmeasure the resistance tocable shielding at both thepositive and negativeterminals
If Open or “OL” on meter Go to STEP D
If any resistance/continuity isfound
Replace DC high-voltage cablebetween the PEC and Inverter.
Go to STEP V
WARNING
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Fault Code 107 Isolation Procedures Fault Isolation Procedures
STEP D
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Measure the resistance toground at the Inverter DCconnector on both positiveand negative terminals
If Open or “OL” on meter Possible error with testing. Go toSTEP V
If any resistance/continuity isfound
Go to STEP E
STEP E
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Disconnect the AC connectorat the Inverter
3. Measure the resistance toground on all three terminalsat the AC cable
If Open or “OL” on meter Go to STEP F
If any resistance/continuity isfound
Go to STEP G
WARNING
WARNING
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Fault Isolation Procedures Fault Code 107 Isolation Procedures
STEP F
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Measure the resistance toground at all three terminalsat the Inverter AC connector
If Open or “OL” on meter Possible error with testing. Go toSTEP V
If any resistance/continuity isfound
Replace Inverter. Go to STEP V
WARNING
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Fault Code 107 Isolation Procedures Fault Isolation Procedures
STEP G
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Disconnect the AC high-voltage connector at theMotor/Generator
3. With the AC cabledisconnected at both ends,measure resistance to cableshielding at all threeterminals
If Open or “OL” on meter Go to STEP H
If any resistance/continuity isfound
Replace AC High Voltage Cable.Go to STEP V
WARNING
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Fault Isolation Procedures Fault Code 107 Isolation Procedures
STEP H
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Measure the resistance toground at the Motor/ Generator AC connector
If Open or “OL” on meter Possible error with testing. Go to
STEP V
If any resistance/continuity isfound
Replace Motor/Generator. Go toSTEP V
STEP I
Procedure Condition Action
1. Is unit supplied with a DC/DCconverter or APG?
Yes Go to STEP J
No Replace PEC. Go to STEP V
WARNING
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Fault Code 107 Isolation Procedures Fault Isolation Procedures
STEP J
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Disconnect 24V positive andnegative cables from DC/DCconverter
3. Disconnect the PEC to DC/ DC converter DC cable at thePEC
4. Measure the resistance toground at the DC cableconnector on both thepositive and negativeterminals
If Open or “OL” on meter Possible error in testing. Go toSTEP V if vehicle does not havean APG. Go to STEP M if vehicleis equipped with APG
If any resistance/continuity isfound
Go to STEP K
WARNING
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Fault Isolation Procedures Fault Code 107 Isolation Procedures
STEP K
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Disconnect the high-voltageDC cable at the DC/DCconverter
3. With the DC cabledisconnected at both ends,measure resistance to cableshielding at positive andnegative terminals
If Open or “OL” on meter Go to STEP L
If any resistance/continuity isfound
Replace High Voltage DC Cable.Go to STEP V
WARNING
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Fault Code 107 Isolation Procedures Fault Isolation Procedures
STEP L
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Measure the resistance toground at the DC/DCConverter high-voltage DCconnector at both positiveand negative terminals
If Open or “OL” on meter Possible error with testing. Go toSTEP V
If any resistance/continuity isfound
Replace DC/DC Converter. Go toSTEP V
WARNING
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Fault Isolation Procedures Fault Code 107 Isolation Procedures
STEP M
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Disconnect the APG DChigh-voltage cable at thePEC
3. Measure the resistance toground at the DC cableconnector on both thepositive and negativeterminals
If Open or “OL” on meter Replace the PEC. Go to STEP V
If any resistance/continuity isfound
Go to STEP N
WARNING
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Fault Code 107 Isolation Procedures Fault Isolation Procedures
STEP N
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Disconnect the high-voltageDC cable at the APG
3. With the DC cabledisconnected at both endsmeasure the resistance frompositive and negativeterminals to cable shieldingat PEC cable end
If Open or “OL” on meter Go to STEP O
If any resistance/continuity isfound
Replace DC High Voltage Cable.Go to STEP V
WARNING
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Fault Isolation Procedures Fault Code 107 Isolation Procedures
STEP O
Procedure Condition Action
1. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
2. Measure the resistance toground at APG high-voltageDC connector pins 1(+) and4(-)
If Open or “OL” on meter Possible error with testing. Go toSTEP V
If any resistance/continuity isfound
Replace APG. Go to STEP V
WARNING
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Fault Code 107 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectorsand the negative batterycable.
3. Key on.
4. Clear codes. Clear codes.See Fault Code Removal/ Clearing on page 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. Clearcodes. See Fault Code
Removal/Clearing onpage 17
If no codes Test complete.
If code 107 appears Return to STEP A to find error intesting.
If code other than 107 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 107 Isolation Procedures
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Fault Code 108 Isolation Procedures
Battery Control Unit Power Supply Fault
SA 239
SPN 520268
FMI 3, 4
Overview
The High-Voltage Batteries are 172 volts each connected in series to produce 340 volts DC. TheBattery Control Unit located in the Relay Box receives 24-volts ignition power and ground from the
Inverter.
Conditions to Run Fault
• The HCM Inverter enable voltage is greater than 7 volts and less than 16 volts.
Conditions to Set Fault
• FMI 3 is set when the BCU detects the Inverter enable voltage is greater than 16 volts for 1second.
• FMI 4 is set when the BCU detects the Inverter enable voltage is less than 7 volts for 1
second.
Possible Causes
• FMI 4
- Relay Box
- Low-voltage harness from Inverter to PEC
- HCM- Low-voltage harness from HCM to Inverter
- Inverter• FMI 3
- Relay Box
Fallback Mode When Fault is Set
When Fault Code 108 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory
• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 108 Isolation Procedures
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should beavoided. Service must be
performed by qualified personnel only.
WARNING
To reduce risk of possible serious
injury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 108 Isolation Procedures Connector Views
Connector Views
Inverter
Ground BC
VB_B
19 - Way Mating Connector View(PEC - Low Voltage Connector)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
14
15
6
7
PEC
Ground BC
VB_B
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Harness Front View(HCM - Hybrid System Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
HCM
Inverter Enable 2 9 Inverter Enable
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View(Inverter - Low Voltage Connector)
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Fault Isolation Procedures Fault Code 108 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector
2. Key off
3. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
4. What Faults are present If Fault Code 108 FMI 3 or 4 arelisted with an active Fault Code114
Go to procedure for Fault Code114 on page 375
If Fault Code 108 FMI 3 or 4 arelisted with no active Fault Code114
Go to STEP B
STEP B
Procedure Condition Action
1. Disconnect the PEC 19-wayconnector.
2. Connect a multi meter to thePEC 19-way connector pin 6and pin 7.
3. Place multimeter where it canbe viewed, while standingnext to the truck.
4. Key on.
5. Observe multi meter voltagereading.
If voltage between pins 6 and 7 is23 to 25 volts
Replace the Battery Control Unit.Go to STEP V
If voltage between pins 6 and 7 isless than 7 volts
Go to STEP C
WARNING
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Fault Code 108 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Key off.
2. Disconnect the Inverter40-way connector.
3. Measure resistance on thefollowing:
• Inverter 40-wayconnector pin 14 toPEC 19-wayconnector pin 6.
• Inverter 40-wayconnector pin 15 toPEC 19-wayconnector pin 7.
If resistance from pin 14 to pin 6is 0 to 0.3 ohms and resistancefrom pin 15 to pin 7 is 0 to 0.3ohms
Replace the Inverter. Go toSTEP V
If resistance is outside of range Replace the low-voltage harnessfrom the PEC to the Inverter. Goto STEP V
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable.
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete
If code 108 appears Return to STEP A to find error intesting
If code other than 108 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 108 Isolation Procedures
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Fault Code 110 Isolation Procedures
Inverter Fault
SA 239
SPN 520220
FMI 21 - 29
Overview
The Inverter assembly is connected to the high-voltage DC cable from the PEC along with thehigh-voltage AC cable from the Motor/Generator. It inverts the DC to AC voltage to power themotor during electric assist and rectifies the AC back to DC to charge the high-voltage batteriesduring coasting or regenerative braking. The Inverter is also the main controller for the high-voltage system communicating to the Battery Control Module in the PEC along with
communicating to the HCM for overall system operation.
Conditions to Run Fault
• The HCM is powered and ignition voltage is greater than 7 volts and less than 32 volts.
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 21-29 are set due to various internal failures of the Inverter.
Possible Causes
• FMI 21-29
- Inverter
Fallback Mode When Fault is Set
When Fault Code 110 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory• Depending on the internal failure the Inverter may continue to operate with the fault logged, or
shutdown the high- voltage system.• HCM continues to control the Hybrid vehicle in a diesel only mode for most failures.
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 110 Isolation Procedures
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should beavoided. Service must be
performed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with High
Voltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Isolation Procedures Fault Code 110 Isolation Procedures
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Fault Code 111 Isolation Procedures
Inverter Communication Fault
SA 239
SPN 520260
FMI 12, 19, 22- 28
Overview
The Inverter communicates with the Battery Control Unit (BCU) located in the PEC and the HybridControl Module (HCM) on the CAN high-speed proprietary data link. The data link is a two wire
twisted pair with two 120 ohm resistors located in the link.
Conditions to Run Fault
• The HCM is powered and ignition voltage is greater than 7 volts and less than 32 volts.
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 12 or 19 are set when the CAN message does not match or EEPROM check sum erroroccurs at system power up.
• FMI 22 is set when Inverter detects an internal CAN communication failure at power-up.• FMI 23, 24, 25, 27, or 28 are set when the Inverter fails to transmit, receive or obtain any
messages on the CAN data link.
• FMI 26 is set when a specific message sent from the HCM is invalid.
Possible Causes
• FMI 22 - Inverter• FMI 23, 24, or 25
- CAN data link
- Inverter
- Relay Box• FMI 26
- HCM• FMI 27
- Vehicle Harness
- Relay Box
- Inverter
Fallback Mode When Fault is Set
When Fault Code 111 is set the following conditions will occur:
• The amber "Check Hybrid" lamp will display.• Fault is stored in HCM memory.• Electric Motor/Generator assist and regen are disabled, however, the high-voltage relays will
remain powered.
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Warnings and Cautions Fault Code 111 Isolation Procedures
• HCM continues to control the Hybrid vehicle in a diesel only mode.
• Transmission defaults start gear to 1st.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. The
TECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708• ServiceRanger
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage are
listed in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-VoltageShutdown Procedure' should be followed. Failure to follow these instructions may result in
severe personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed theLock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at the
connectors, while high-voltage components are marked with a label. High-voltage rubberinsulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked with
DANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 111 Isolation Procedures Connector Views
Connector Views
27
28
5
4
HCM Inverter
CAN - High (Vehicle)
CAN - Low (Vehicle)
CAN - High
CAN - Low
Harness Front View(HCM - Vehicle Interface Connector)
37 38
35 36
1 67 12
13 22
23 28
29 34
Deutsch 19 - Way Mating Connector View (PEC - Low-Voltage Connector)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
35
34
2
1
PEC
CAN - High
CAN - Low
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)
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Fault Isolation Procedures Fault Code 111 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Key off
2. Key on
3. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector
4. Perform Electrical Pretestand Hybrid Electrical Pretest
If no issues are found duringeither Electrical Test
Go to STEP B
If issue was repaired during eitherElectrical Test
Go to STEP V
STEP B
Procedure Condition Action
1. Key off
2. Follow “Hybrid ShutdownProcedure,” found at front of
book, to avoid shock, burn, ordeath from improperlyhandled high-voltage
3. What FMI’s are present foractive fault 111
If FMI 22 is listed Replace the Inverter. Go toSTEP V
If FMI 26 is listed Replace the HCM. Go to STEP V
If FMI 12, 23, 24, 25, 28 are listed Go to procedure for Fault Code88
If FMI 27 is listed Go to STEP C
If FMI 19 is listed Go to STEP D
WARNING
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Fault Code 111 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Key off
2. Remove 40-pin connector atthe Inverter
3. Check for short to groundand 24-volt at pins 34 and 35
Short found to ground or 24V Replace the Vehicle Harness. Goto STEP V
No short or open circuit foundand there is an active fault 103FMI 26
Replace PEC. Go to STEP V
No short or open circuits found Replace the Inverter. Go toSTEP V
STEP D
Procedure Condition Action
1. Key on
2. Key off and allow the systemto power down for at least 2minutes.
3. Turn key to the on position If fault code 111 FMI 9 is notactive
Test complete. Go to STEP V
If fault code 111 FMI 9 is active Go to STEP E
STEP E
Procedure Condition Action
1. Key off
2. Remove the 40 pin connectorat the Inverter
3. Measure the voltage at Pin 1 If voltage at PIn 1 is 0 Replace the Inverter. Go toSTEP V
If voltage at Pin 1 is the same as
the battery voltage
Replace the HCM. Go to STEP V
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Fault Isolation Procedures Fault Code 111 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete
If code 111 appears Return to STEP A to find error intesting
If code other than 111 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 112 Isolation Procedures
Inverter Voltage Fault
SA 239
SPN 520221
FMI 3, 4
Overview
The Inverter is connected to the Power Electronics Carrier through a high-voltage DC cable, whichsupplies 340 volts from the batteries. During operation, the Inverter monitors the input voltage to
determine an over or under voltage concern.
Conditions to Run Fault
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 4 is set when the Inverter input voltage measured at the capacitor is less than 200 volts for1 second, while the main relays in the Relay Box are on.
• FMI 3 is set when the Inverter input voltage measured at the capacitor is greater than 435 volts
for 0.05 ms.
Possible Causes
• FMI 3,4
- Inverter
- PEC
- DC high-voltage cable
Fallback Mode When Fault is Set
When Fault Code 112 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 112 Isolation Procedures
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should beavoided. Service must be
performed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):
Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 112 Isolation Procedures Connector Views
Connector Views
Inverter
340-Volt Pos (High Voltage)
340-Volt Neg (High Voltage) DC (-)
DC (+)
DC (-)
DC (+)
PEC
High Voltage DC Connector View(Yazaki Connector)
1 2
DC(+) DC(-)
340-Volt Pos (High Voltage)
340-Volt Neg (High Voltage)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
High-Voltage DC Connector to PEC
DC(+) DC(-)
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Fault Isolation Procedures Fault Code 112 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Key off
2. Key on
3. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector
4. Follow the Hybrid Shutdown
Procedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
5. What Faults are present If Fault Code 112 FMI 3 is listed Contact Eaton at 1-800-826-HELP (4357).
If Fault Code 112, FMI 3 is listedwith other active Hybrid FaultCodes beside 112
Go to procedure for active HybridFault Code(s).
If Fault Code 112 FMI 4 is listed Go to STEP B
WARNING
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Fault Code 112 Isolation Procedures Fault Isolation Procedures
STEP B
Procedure Condition Action
1. Key off
2. Disconnect the DC high-voltage connector at theInverter
3. Place the multi-meter on uFoption
4. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or death
from improperly handledhigh-voltage
5. Place the leads into the twoInverter DC high-voltagesockets making sure theprobes touch the terminals
6. Record the measurementafter 2 minutes
If the uF reading is 1104uF-1656uF at 68°F (20°C)
Go to STEP C
If the uF reading is outside1104uF-1656uF at 68°F (20°C)
Replace the Inverter. Go toSTEP V
STEP C
Procedure Condition Action
1. Key off
2. Disconnect the DC high-voltage connector from thePEC
3. Measure the resistance ofeach circuit on the DC cablefrom the PEC connector tothe Inverter connector
If the resistance for each circuit is1 ohm or less
Replace the Inverter. Go toSTEP V
If resistance is out of range Replace the DC High-VoltageCable. Go to STEP V
WARNING
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Fault Isolation Procedures Fault Code 112 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 112 appears Return to STEP A to find error intesting.
If code other than 112 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 113 Isolation Procedures
Inverter Current Fault
SA 239
SPN 520222
FMI 6, 14
Overview
The Inverter is connected to the Power Electronics Carrier (PEC) through a high-voltage DC cablewhich supplies 340 volts from the batteries. During operation, the Inverter monitors the output
current to the Motor/Generator.
Conditions to Run Fault
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 6 is set when the Inverter IGBT current is greater than 800 amps for 0.05 ms or the motorcable is short.
• FMI 14 is set when motor torque commanded is zero and current is reported by the Inverter.
Possible Causes
• FMI 6
- Inverter
- Motor/Generator
- AC high-voltage cables
• FMI 14- Motor/Generator
- AC high-voltage cables
Fallback Mode When Fault is Set
When Fault Code 113 is set the following conditions will occur:
• The red “Stop Hybrid” lamp will display for FMI 6 and a amber Check Hybrid for FMI 14• Fault is stored in HCM memory• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 113 Isolation Procedures
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage are
listed in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at the
connectors, while high-voltage components are marked with a label. High-voltage rubberinsulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should be
avoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible serious
injury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 113 Isolation Procedures Connector Views
Connector Views
High-Voltage AC Harness Connector View (Amphenol Connector)
W
V
U
W
V
U
Inverter Motor/ Generator
Phase 1
Phase 2
Phase 3
Phase 1
Phase 2
Phase 3
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
High-Voltage AC Motor/Gen Connector View (Amphenol Connector)
W U
V
E D
F
U
V
W
F
E D
D
E
D
E
Loose Disconnect
Loose Disconnect
Loose Disconnect
Loose Disconnect
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Fault Isolation Procedures Fault Code 113 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector
2. Key off
3. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
4. What FMI(s) are present If Fault Code 113 FMI 6 is listed Go to STEP B
If Fault Code 113 FMI 14 is listed Go to STEP D
STEP B
Procedure Condition Action
1. Visually inspect the AC cable
for signs of abrasion, cuts, orexposed wiring
2. Remove the AC high-voltagecable at the Motor/Generatorand Inverter
3. Measure the resistancebetween the following AChigh-voltage cable pins:
• U-V
• V-W
• W-U
If resistance between each phaseis 5M or greater
Go to STEP C
An Auto Ranging Digital Volt/OhmMeter must be used If resistance is outside of range Replace the AC High-VoltageHarness. Go to STEP V
WARNING
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Fault Code 113 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Measure the resistance of
each AC high-voltage cablepin to ground
If resistance between each pin
and ground is 5M or greater
Replace the Inverter. Go to
STEP V
If resistance is outside of range Replace the AC High-VoltageCable. Go to STEP V
STEP D
Procedure Condition Action
1. Remove the AC high-voltagecable from the Inverter andMotor/Generator
2. Measure the resistance ofthe AC high-voltage cablefrom the Inverter connectorto the Motor/Generatorconnector on each of thefollowing pins:
• U-U
• V-V
• W-W
If resistance is less than 1 ohmon each circuit
Replace the Motor/Generator. Goto STEP V
Note: An Auto Ranging DigitalVolt/Ohm Meter must beused
If resistance is outside of range Replace the AC High-Voltage
Harness. Go to STEP V
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Fault Isolation Procedures Fault Code 113 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete
If code 113 appears Return to STEP A to find error intesting
If code other than 113 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 114 Isolation Procedures
Inverter Power Supply Fault
SA 239
SPN 520261
FMI 1, 3, 4
Overview
The Inverter assembly uses a 24-volt supply provided from the HCM to power the internal control
board. The HCM provides this ignition power after it completes the power-up self check.
Conditions to Run Fault
• The HCM ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 1 is set when the internal 24v to 12v converter is out of range.• FMI 3 is set when the Inverter ignition voltage is greater than 16 volts (12-volt system) and 32
volts (24-volt system) for 0.5 seconds.• FMI 4 is set when the Inverter ignition voltage is less than 7 volts (12-volt system) and 16 volts
(24-volt system) for 0.1 seconds.
Possible Causes
• FMI 1
- Inverter• FMI 3
- Inverter• FMI 4
- HCM
- Inverter
- Power supply harness from HCM to Inverter
Fallback Mode When Fault is Set
When Fault Code 114 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory• Electric Motor/Generator assist and regeneration are disabled, however, the high-voltage
relays will remain powered• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
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Warnings and Cautions Fault Code 114 Isolation Procedures
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage are
listed in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltagecables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at the
connectors, while high-voltage components are marked with a label. High-voltage rubberinsulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killed
if you do not follow the procedure.Components marked with
DANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible serious
injury (Shock, Burn or Death):Components marked with High
Voltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 114 Isolation Procedures Connector Views
Connector Views
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector
2. Perform Electrical Pretest If no issues found during theElectrical Pretest
Go to STEP B
If issue was repaired during theElectrical Pretest
Test Complete. Go to STEP V
2
7
9
6
HCM Inverter
Inverter Enable
Ground 1
Inverter Enable
Ground 2
Front Harness View(HCM - Hybrid System Interface Connector)
37 38
35 36
16
7 12
13 22
23 28
29 34
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View(Inverter - Low Voltage Connector)
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Fault Isolation Procedures Fault Code 114 Isolation Procedures
STEP B
Procedure Condition Action
1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector
2. Key off
3. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
If FMI 1 is listed Replace the Inverter
4. What FMI’s are present If Fault Code 114 FMI 3 or 4 islisted
Go to STEP C
If Fault Code 114 is not present Test Complete. Go to STEP V
STEP C
Procedure Condition Action
1. Key off
2. Disconnect the Inverter
40-way connector
3. Connect a multi meter to theInverter 40-way connectorpin 9 and pin 6
4. Place multi meter where itcan be viewed while standingnext to the truck
5. Key on
6. Observe multi meter voltagereading
If voltage is 23 to 25 volts (24-voltsystem)
Replace the Inverter. Go toSTEP V
If voltage is greater than 32 volts
(24-volt system)
Repair the vehicle charging
system. Refer to OEM for repairprocedure.
If voltage is outside of range Go to STEP D
WARNING
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Fault Code 114 Isolation Procedures Fault Isolation Procedures
STEP D
Procedure Condition Action
1. Key off
2. Disconnect the negativebattery cable
3. Disconnect the HCM SystemHarness 38-way connector
4. Measure resistance from thefollowing:
• Inverter 40-wayconnector pin 9 toHCM 38-wayconnector pin 2.
• Inverter 40-way
connector pin 6 toground.
If resistance from pin 1 to pin 2 is0 to 0.3 ohms and resistancefrom pin 6 to ground is 0 to OL
Replace the HCM. Go to STEP V
If resistance is outside of range Repair the open in the power orground harness. Go to STEP V
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See FaultCode Removal/Clearing onpage 17
If no codes Test complete
If code 114 appears Return to STEP A to find error intesting
If code other than 114 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 114 Isolation Procedures
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Warnings and Cautions Fault Code 115 Isolation Procedures
• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708• ServiceRanger
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severepersonal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 115 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the 9-pin diagnostic connector
2. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handled
high-voltage
3. Key on
4. Select the Data Monitoroption and view PID 120“Inverter Temperature” in the“Power Electronics” list
5. Observe PID 120 again after20 minutes
If PID 120 “Inverter Temperature”lowered from the first to secondreading
Go to STEP B
If PID 120 “Inverter Temperature”remained constant
Replace the Inverter. Go toSTEP V
STEP B
Procedure Condition Action
1. Key off
2. Observe the coolant levelafter the system has cooledto see if it is filled to theproper level
If the coolant is within therecommend limits
Go to STEP C
If the coolant is below the
recommended limits
Refer to OEM for coolant type
and fill procedure. Go to STEP V
WARNING
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Fault Isolation Procedures Fault Code 115 Isolation Procedures
STEP C
Procedure Condition Action
1. Visually inspect the Hybrid
liquid cooling system radiatorfor debris or obstruction toairflow and inspect thecoolant lines for sharp bends
If the radiator is free of debris and
the coolant lines are not kinked
Go to STEP D
If the radiator is full of debris, theairflow is obstructed, or thecoolant lines are kinked
Repair the concern. Go toSTEP V
STEP D
Procedure Condition Action1. Key on
2. Connect ServiceRanger tothe 9-way connector in thecab
3. Select the Advanced ProductFunctions option and selectthe “Cooling Pump” option.
4. Enable the Cooling Pumpoption
If the coolant pump turns on Go to STEP E
If the coolant pump fails to turn on Go to STEP F
STEP E
Procedure Condition Action
1. Select the Advanced ProductFunctions option and selectthe “Heat Exchanger Fan”option.
2. Enable the Heat ExchangerFan option
If the Heat Exchanger Fan turnson
The system needs to be purgedof air to allow the coolant to flow.
Bleed the air by using a coolantsystem pressurizing tool or avacuum tool. Go to STEP V
If the Heat Exchanger Fan fails toturns on
Go to STEP G
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Fault Code 115 Isolation Procedures Fault Isolation Procedures
STEP F
Procedure Condition Action
1. Key on
2. Disconnect the CoolantPump 2-way connector
3. Select the Advanced ProductFunctions option and selectthe “Cooling Pump” option
4. Enable the Cooling Pumpoption
5. Measure the voltage at the2-way connector from pin Ato B.
If voltage between pins A and B is+/- 0.2 volts of battery voltage
Refer to OEM for Coolant Pumpconcern
If voltage between pins A and B is
outside of range
Refer to OEM for Cooing Pump
power harness repair procedure.
STEP G
Procedure Condition Action
1. Key on
2. Disconnect the HeatExchanger Fan 2-wayconnector
3. Select the Advanced Product
Functions option and selectthe “Heat Exchanger Fan”option
4. Enable the Heat ExchangerFan option
5. Measure the voltage at the2-way connector from pin Ato B.
If voltage between pins A and B is+/- 0.2 volts of battery voltage
Refer to OEM for Heat ExchangerFan concern
If voltage between pins A and B isoutside of range
Refer to OEM for Heat ExchangerFan power harness repairprocedure
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Fault Isolation Procedures Fault Code 115 Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Check for codes. See Fault
Code Removal/Clearing onpage 17
If no codes Test complete
If code 115 appears Return to STEP A to find error intesting
If code other than 115 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 116 Isolation Procedures
High Voltage Relays Fault
SA 239
SPN 521210, 521211, 521212
FMI 3, 4, 5
Overview
The High-Voltage Relays are located inside the Power Electronics Carrier (PEC) in the Relay Boxunit. There is one pre-charge relay on the positive side, an additional relay on the positive, and oneon the negative for a total of three. These relays are normally open when the system is off. The
relays are controlled through the Inverter.
Conditions to Run Fault
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 3 is set when a short is detected to vehicle 24 volt on the control side of a high-voltagerelay.
• FMI 4 is set when a short is detected to ground on the control side of a high-voltage relay.• FMI 5 is set when an open circuit is detected on the control side of a high-voltage relay.
Possible Causes
• FMI 3, 4, 5
- Relay Box
- Inertia Switch- Inverter
- Vehicle wiring between the Inverter and PEC
Fallback Mode When Fault is Set
When Fault Code 116 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will blink for FMI 10• Fault is stored in HCM memory• The hybrid system will be offline
• Transmission defaults to 1st start gear in diesel only mode
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
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Warnings and Cautions Fault Code 116 Isolation Procedures
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should beavoided. Service must be
performed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed by
qualified personnel only.
HAZARDOUS VOLTAGE
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Fault Code 116 Isolation Procedures Connector Views
Connector Views
Inverter
340-Volt Pos (High Voltage)
340-Volt Neg (High Voltage) DC (-)
DC (+)
DC (-)
DC (+)
PEC
340-Volt Pos (High Voltage)
340-Volt Neg (High Voltage)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Mating Connector View (Deutsch 19 - Way)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
1
2
1
2Interlock negative
Interlock positive
Interlock negative
Interlock positive
21
22
17
9
23
32
13
11
33
31
15
19
Precharge Plus
Main Plus Plus
Precharge Minus
Main Minus Minus
Main Plus Minus
Main Minus Plus
Precharge Plus
Main Plus Plus
Precharge Minus
Main Minus Minus
Main Plus Minus
Main Minus Plus
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)
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Fault Isolation Procedures Fault Code 116 Isolation Procedures
Fault Isolation Procedures
STEP A
Procedure Condition Action1. Retrieve active fault codes
and FMIs withServiceRanger using the9-pin diagnostic connector
2. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handled
high-voltage3. What FMI’s are present If Fault Code 116 FMI 3 is listed Go to STEP B
If Fault Code 116 FMI 4 is listed Go to STEP D
If Fault Code 116 FMI 5 is listed Go to STEP F
STEP B
Procedure Condition Action
1. Key off
2. Temporarily remove thelockout bracket and pull the'Service Switch' out
3. Disconnect the PEC 19-pinconnector
4. Measure the followingconnectors according to theSPN:
a. SPN 521210; pins 17and 19 to 24-volt
b. SPN 521211; pins 9 and11 to 24-volt
c. SPN 521212; pins 13and 15 to 24-volt
Any resistance from PECconnector pins to 24-volt
Replace PEC. Go to STEP V
If meter reads OL or Open Circuit Go to STEP C
WARNING
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Fault Code 116 Isolation Procedures Fault Isolation Procedures
STEP C
Procedure Condition Action
1. Key off
2. Connect the PEC 19-pinconnector
3. Disconnect the 40-pinInverter connector
4. Measure the followingconnectors according to theSPN:
a. SPN 521210; pins 21and 31 to 24-volt
b. SPN 521211; pins 22and 32 to 24-volt
c. SPN 521212; pins 23
and 33 to 24-volt
Any resistance from the Inverterconnector pins to 24-volt
Repair vehicle harness. Go toSTEP V
If meter reads OL or Open Circuit Replace the Inverter. Go toSTEP V
STEP D
Procedure Condition Action
1. Key off
2. Disconnect the PEC 19-way
connector3. Temporarily remove the
lockout bracket and pull the“Service Switch” out.
4. Measure the followingconnectors according to theSPN:
a. SPN 521210; pin 17 toground
b. SPN 521211; pin 9 toground
c. SPN 521212; pin 13 to
ground
Any resistance from the PECconnectors to ground
Replace PEC. Go to STEP V
If meter reads OL or Open Circuit Go to STEP E
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Fault Isolation Procedures Fault Code 116 Isolation Procedures
STEP E
Procedure Condition Action
1. Key off
2. Reconnect the PEC 19-wayconnector
3. Disconnect the Inverter40-way connector.
4. Measure the followingconnectors according to theSPN:
a. SPN 521210; pin 21 toground
b. SPN 521211; pin 22 toground
c. SPN 521212; pin 23 to
ground
Any resistance from the Inverterconnectors to ground
Repair vehicle harness. Go toSTEP V
If meter reads OL or Open Circuit Replace the Inverter. Go toSTEP V
STEP F
Procedure Condition Action
1. Key off
2. Disconnect the PEC 19-way
connector3. Ensure the key is in the Off
position
4. Temporarily remove thelockout bracket and pull theService Switch out
5. Measure resistance at thePEC 19-way connectorterminal at the following pins:
• SPN 521210; pins17 to 19
• SPN 521211; pins
9 to 11• SPN 521212; pins
13 to 15
If the resistance between pins 17and 19 is 112-122 ohms and theresistance from pin 9 to 11 and
pin 13 to 15 are each 33-37 ohms
Go to STEP G
If resistance is out of range Reset inertia switch if Pin 13 to 15is open or OL, retest circuit.Replace PEC if circuit is still openafter switch reset or the othercircuits are out of range. Go toSTEP V
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Fault Code 116 Isolation Procedures Fault Isolation Procedures
STEP G
Procedure Condition Action
1. Key off
2. Connect the PEC 19-wayconnector
3. Disconnect the Inverter40-pin connector
4. Ensure the key is in the Offposition
5. Temporarily remove thelockout bracket and pull theService Switch out
6. Measure resistance at theInverter 40-way connector
terminal at the following pins:• SPN 521210; pins
21 to 31
• SPN 521211; pins23 to 33
• SPN 521212; pins22 to 32
If the resistance between pins 21and 31 is 112-122 ohms and theresistance from pin 23 to 33 andpin 22 to 32 are each 33-37 ohms
Replace the Inverter. Go toSTEP V
If resistance is out of range Repair the vehicle harnessbetween the PEC and Inverter.Go to STEP V
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable.
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing on
page 175. Drive the vehicle and attempt
to recreate the code
6. Check for codes. See FaultCode Removal/Clearing on
page 17
If no codes Test complete.
If code 116 appears Return to STEP A to find error intesting.
If code other than 116 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 116 Isolation Procedures
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Fault Code 116 Isolation Procedures
High Voltage Relays Fault
SA 239
SPN 520224
FMI 10, 14, 20, 29, 30
Overview
The High-Voltage Relays are located inside the Power Electronics Carrier (PEC) in the Relay Boxunit. There is one pre-charge relay on the positive side, an additional relay on the positive, and oneon the negative for a total of three. These relays are normally open when the system is off. The
relays are controlled through the Inverter.
Conditions to Run Fault
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 10 is set when inverter capacitor voltage is less than 210 volts after 4 seconds from pre-charge relay being closed or main positive relay is not on.
• FMI 14 is set when the main negative relay is on and the inverter capacitor voltage decrease isless than 10-volts / 5 seconds when initial capacitor voltage was greater than 200 volts andmotor speed is less than 500 RPM.
• FMI 20 is set when the high-voltage DC cable interlock switch is open.• FMI 29 is set when battery voltage is present on the Inverter side of the main relays under
Main Positive Relay open status.• FMI 30 is set when battery voltage is present on the Inverter side of the main relays under
Main Negative Relay open status.
Possible Causes
• FMI 10
- High-voltage fuse
- Red Service Switch
- DC high-voltage cable or interlock
- Inverter
- Inertia switch• FMI 14
- Inverter
- PEC• FMI 20
- DC cable interlock circuit• FMI 29
- Failed Main Positive relay• FMI 30
- Failed Main Negative relay
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High Voltage Relays Fault Fault Code 116 Isolation Procedures
Fallback Mode When Fault is Set
When Fault Code 116 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will be illuminated for FMI 10, 14 and 20. The Red “StopHybrid” lamp will be illuminated for FMI 29 and 30.
• Fault is stored in HCM memory• The hybrid system will be offline
• Transmission defaults start gear to 1st in diesel only mode
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. TheTECU will automatically clear the faults from history after 200 hours and the HCM willautomatically clear the faults from history after 200 hours of the fault staying inactive.
Required Tools
• Basic Hand Tools• High-Voltage Gloves J-48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
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Fault Code 116 Isolation Procedures Warnings and Cautions
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be testedbefore EVERY use following the rubber insulation gloves testing found in this manual.
Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result in
severe personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personalinjury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to followthese instructions may result in severe personal injury or death.
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.Components marked withDANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
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Connector Views Fault Code 116 Isolation Procedures
Connector Views
Inverter
340-Volt Pos (High Voltage)
340-Volt Neg (High Voltage) DC (-)
DC (+)
DC (-)
DC (+)
PEC
340-Volt Pos (High Voltage)
340-Volt Neg (High Voltage)
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Mating Connector View (Deutsch 19 - Way)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
1
2
1
2Interlock negative
Interlock positive
Interlock negative
Interlock positive
21
22
17
9
23
32
13
11
33
31
15
19
Precharge Plus
Main Plus Plus
Precharge Minus
Main Minus Minus
Main Plus Minus
Main Minus Plus
Precharge Plus
Main Plus Plus
Precharge Minus
Main Minus Minus
Main Plus Minus
Main Minus Plus
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)
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Fault Code 116 Isolation Procedures Fault Isolation Procedures
Fault Isolation Procedures
Check to see if the red “Service Switch” on the front of the PEC is pulled out. If the switch ispushed in pull the switch out and turn the ignition key off. After 2 minutes turn the ignition
key on.
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMI’s withServiceRanger using the9-pin diagnostic connector
2. Check to see if the red“Service Switch” on the frontof the PEC is pulled out. Ifthe switch is pushed in pullthe switch out and turn theignition key off. After 2minutes turn the ignition keyon
3. What FMI’s are present If Fault Code 116 FMI 10 is listed Go to STEP B
If Fault Code 116 FMI 14 is listed Go to STEP I
If Fault Code 116 FMI 20 is listed Go to STEP J
If Fault Code 116 FMI 29 or 30 islisted
Go to STEP K
IMPORTANT
WARNING
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Fault Isolation Procedures Fault Code 116 Isolation Procedures
STEP B
Procedure Condition Action
1. Key off
2. Remove the PEC air filtercover
3. Reset the PEC Inertia Switch(see TRSM2000 forprocedures)
4. Key on
5. Retrieve active fault codesand FMI’s withServiceRanger using the9-pin diagnostic connector.
If Fault Code 116 FMI 10 is nowactive
Go to STEP V
If Fault Code 116 FMI 10 is still
listed
Go to STEP C
STEP C
Procedure Condition Action
1. Key on
2. Connect ServiceRanger tothe 9-way diagnosticconnector in the cab
3. Select the “Data Monitor”
option and view BatteryVoltage PID 118 (SPN520250 J1939) from the HVBattery list
if Battery Voltage PID 118 (SPN
520250 J1939) is greater than210 volts
Go to STEP D
if Battery Voltage PID 118 (SPN520250 J1939) is less than 210volts
Check main fuse in the PEC. Iffuse has not failed replace PEC.Go to STEP V
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Fault Code 116 Isolation Procedures Fault Isolation Procedures
STEP D
Procedure Condition Action
1. Key off
2. If the vehicle is not equippedwith a DC/DC Converter orAPG skip to Step E
3. Using high-voltage glovesdisconnect the DC cable forthe DC/DC Converter or APGat the PEC bulkhead and capthe connector and thebulkhead terminal
4. Temporarily remove thelockout bracket and pull theService Switch out.
5. Key on If fault code 116 FMI 10 is activewith the DC/DC Converter andAPG connector disconnected
Go to STEP E
If fault code 116 FMI 10 is notactive with the DC/DC Converterand APG connector disconnected
Replace the Auxiliary Relays inthe PEC. Go to STEP V
STEP E
Procedure Condition Action
1. Key off
2. Disconnect the DC high-voltage cable at the PEC andthe Inverter
3. Measure the of each high-voltage circuit on the cable
Resistance of each circuit is 0 -0.3 ohms
Go to STEP F
If resistance is outside of range Replace the DC High-VoltageCable. Go to STEP V
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Fault Isolation Procedures Fault Code 116 Isolation Procedures
STEP F
Procedure Condition Action
1. Key off
2. Disconnect the PEC 19-wayconnector
3. Ensure the key is in the Offposition
4. Temporarily remove thelockout bracket and pull theService Switch out
5. Measure resistance at thePEC 19-way connectorterminal at the following pins:
• Pins 17 to 19
• Pins 9 to 11• Pins 13 to 15
If the resistance between pins 17
and 19 is 112-122 ohms and theresistance from pin 9 to 11 andpin 13 to 15 are each 33-37 ohms
Go to STEP G
If resistance is out of range Replace PEC. Go to STEP V
STEP G
Procedure Condition Action
1. Key off
2. Connect the PEC 19-way
connector
3. Disconnect the Inverter40-pin connector
4. Inspect the connectors fordamage or corrosion
5. Ensure the key is in the Offposition
6. Temporarily remove thelockout bracket and pull theService Switch out
7. Measure resistance at the
Inverter 40-way connectorterminal at the following pins:
• Pins 21 to 31
• Pins 23 to 33
• Pins 22 to 32
If the resistance between pins 21and 31 is 112-122 ohms and theresistance from pin 23 to 33 andpin 22 to 32 are each 33-37 ohms
Go to STEP H
If resistance is out of range Repair the vehicle harnessbetween the PEC and Inverter.Go to STEP V
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Fault Code 116 Isolation Procedures Fault Isolation Procedures
STEP H
Procedure Condition Action
1. Key off
2. Check for short betweenInverter Pos (+) to Neg (-)
Short from Pos to Neg Replace the Inverter. Go toSTEP V
No continuity Replace PEC. Go to STEP V
STEP I
Procedure Condition Action
1. Connect ServiceRanger tothe 9-way diagnostic
connector in the cab2. Select the “Data Monitor”
option
3. View the followingparameters in the HV-Batterylist:
• Battery PackVoltage PID 118(SPN 520250J1939)
• Battery Voltage PID116 (SPN 520323
J1939)
If the voltage readings on PID116 and PID 118 are within 10volts of each other
Replace PEC. Go to STEP V
If the voltage readings on PID116 and PID 118 are greater than10 volts of each other
Replace the Inverter. Go toSTEP V
STEP J
Procedure Condition Action
1. Key off
2. Disconnect the DC high-voltage cables at the PECbulkhead and at the Inverter
3. Measure the resistancebetween the two low voltageinterlock pins on each end ofthe DC high-voltage cable
If resistance is 0 - 0.3 ohms Replace the Inverter. Go toSTEP V
If resistance is outside of range Replace the DC High-VoltageCable. Go to STEP V
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Fault Isolation Procedures Fault Code 116 Isolation Procedures
STEP K
Procedure Condition Action
1. Key off
2. The PEC main fuse MUSTbe removed before the PECto Inverter high-voltage cableis disconnected from thePEC. Reference Servicemanual TRSM-2000 for themain fuse removal procedure
3. Remove PEC from vehicle Replace PEC. Go to STEP V
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attempt
to recreate the code6. Clear codes. See Fault Code
Removal/Clearing onpage 17
If no codes Test complete
If code 116 appears Return to STEP A to find error intesting
If code other than 116 appears Go to Fault Code IsolationProcedure page 19
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Fault Code 117 Isolation Procedures
Battery Control Unit (BCU) Relay Cut Request Fault
SA 239
SPN 520251
FMI 3, 14, 29
Overview
The High-Voltage Relays are located inside the Power Electronics Carrier (PEC) in the Relay Boxunit. These relays are normally open when the system is off. The relays are controlled through theInverter and monitored through a 5-volt input from the Inverter. If the relays are open the voltage is
around 5 volts and when the relays are closed the voltage is around 1 volt.
Conditions to Run Fault
• The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
• FMI 3 is set when Battery Control Unit (BCU) relay ready CAN flag is active and the relay offsignal is set high for 0.02 seconds.
• FMI 14 is set when the BCU relay cut request is by a different active BCU fault.• FMI 29 is set when the Relay Off signal line is active.
Possible Causes
• FMI 3, 29
- Inverter
- Low-voltage wire harness
Fallback Mode When Fault is Set
When Fault Code 117 is set the following conditions will occur:
• The amber “Check Hybrid” lamp will display• Fault is stored in HCM memory• Inverter shuts high-voltage system off• HCM continues to control the Hybrid vehicle in a diesel only mode
• Transmission defaults start gear to 1st
Conditions to Clear the Fault
The Eaton® service tool ServiceRanger may be used to clear the fault from TECU or HCM history.The TECU and HCM automatically clear the faults from history after 200 hours of the fault stayingInactive.
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Warnings and Cautions Fault Code 117 Isolation Procedures
Required Tools
• Basic Hand Tools• High-Voltage Gloves J48603• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Warnings and Cautions
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior toworking on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage arelisted in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.Failure to follow these instructions may result in severe personal injury or death.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result insevere personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may resultin severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing anyhigh-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at theconnectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to follow
these instructions may result in severe personal injury or death.
WARNING
To reduce risk of possible seriousinjury (Shock, Burn or Death):Components marked with HighVoltage should be avoided.Service must be performed byqualified personnel only.
HAZARDOUS VOLTAGE
DANGERHAZARDOUS VOLTAGEYou will be severly injured or killedif you do not follow the procedure.
Components marked withDANGER High Voltage should beavoided. Service must beperformed by qualified personnel only.
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Fault Code 117 Isolation Procedures Connector Views
Connector Views
Fault Isolation Procedures
STEP A
Procedure Condition Action
1. Retrieve active fault codesand FMIs withServiceRanger using the9-pin diagnostic connector
2. Key off
3. Follow the Hybrid ShutdownProcedure on page 3, toavoid shock, burn, or deathfrom improperly handledhigh-voltage
4. What FMIs are present If FMI 14 is listed Test complete. FMI 14 requiresno action or replacement
If FMI 3 or 29 are listed Go to STEP B
Inverter
Relay Off
Deutsch 19 - Way Mating Connector View (PEC - Low Voltage Connector)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
13
3
5
PEC
Relay Off
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)
WARNING
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Fault Isolation Procedures Fault Code 117 Isolation Procedures
STEP B
Procedure Condition Action
1. View active faults to see if
any of the following are listed:76, 78, 82, 101, 103, 105,107, 108
If any of the faults are listed with
Fault Code 117 FMI 3
Go to test for faults that are active
If none of the faults are listed withFMI 3
Go to STEP C
If none of the faults are listed withFMI 29
Go to STEP D
STEP C
Procedure Condition Action1. Key off
2. Disconnect the PEC 19-wayconnector
3. Disconnect the Inverter40-way connector.
4. Measure the resistance fromthe PEC 19-way connectorpin 5 to the Inverter 40-wayconnector pin 13
If the resistance between pin 5and pin 13 is 0 - 0.3 ohms
Replace Inverter. Go to STEP V
If resistance is outside of range Repair the HCM Low-Voltage
harness between the PEC andInverter. Go to STEP V
STEP D
Procedure Condition Action
1. Key off
2. Remove the 40-pin connectorfrom the Inverter
3. Use an ohm meter tomeasure the resistance frompin 3 to ground at the vehicleharness
If the resistance between pin 3 toground is 0 to 0.3 ohms
Replace Inverter. Go to STEP V
If resistance is outside of range Repair 40-pin vehicle harness.Go to STEP V
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Fault Code 117 Isolation Procedures Fault Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectorsand the negative batterycable
3. Key on
4. Clear codes. See Fault CodeRemoval/Clearing onpage 17
5. Drive the vehicle and attemptto recreate the code
6. Clear codes. See Fault Code
Removal/Clearing onpage 17
If no codes Test complete
If code 117 appears Return to STEP A to find error intesting
If code other than 117 appears Go to Fault Code IsolationProcedure page 19
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Fault Isolation Procedures Fault Code 117 Isolation Procedures
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Fault Code 166 Isolation Procedures
Instrument Cluster Message
SPN 84
FMI 2, 9
Overview
Fault Code 166 is generated from missing park brake message.
See OEM cluster messages for any repairs.
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Instrument Cluster Message Fault Code 166 Isolation Procedures
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Front Box Test
Front Box Test
Overview
This symptom-driven test is performed if a “-” or flashing gear is displayed on the Gear Display,
and there are no active or inactive codes. Turn the key on and watch the Gear Display. If the GearDisplay shows “-” constantly, the Transmission ECU was not able to confirm front box control. If thetransmission displays a flashing gear when a forward or reverse mode is selected, thetransmission is not able to engage the gear position.
Note: This symptom-based test should only be performed if you were sent here from the
Diagnostic Procedure and you have no active fault codes.
Possible Causes
• Low Power to Gear Select Motor• Electric Shifter• Gear Select Sensor
• Yoke / Clutch / Main Shaft• Shift Bar Housing• Dragging Clutch
• Torque Locked in Gear
Fallback Mode When Fault is Set
There is no fallback mode for this symptom, however, the vehicle will either not crank if the “-” is
present or not engage a gear if the flashing gear is present when a non-neutral gear is selected.
Symptoms
• Power-up no crank and the gear display shows “-”
• Transmission will not engage a gear from neutral (flashing gear number is gear display).
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
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Connector Views Front Box Test
Connector Views
Note: The picture above shows the shift forks in the neutral position.
Isolation Procedures
STEP A
Procedure Condition Action
1. You should only perform thissymptom test if you weresent here from the DiagnosticProcedure and you have noactive fault codes
2. Key on3. Depress “N” on the Push
Button Shift Control
4. Observe Gear Display If Gear Display shows: “N” Go to STEP B
If Gear Display shows: “-” Go to STEP C
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Front Box Test Isolation Procedures
STEP B
Procedure Condition Action
1. Depress service brake and
select “D”
2. Observe Gear Display If Gear Display shows a solidgear
Test complete
If Gear Display shows a flashinggear with no arrows
Go to STEP C
STEP C
Procedure Condition Action
1. Key off2. Attempt to remove any type
of torque lock on the vehiclesdrivetrain through one of thefollowing methods:
a. Remove the driveshaftb. Lift the drive wheels off
the groundc. Roll the vehicle in neutral
3. Key on
4. Observe gear display If Gear Display shows a solid “N” Go to STEP B
If Gear Display still shows a solid
“-”
Go to STEP D
STEP D
Procedure Condition Action
1. Perform Electrical Pretest If no issues found during theElectrical Pretest
Go to STEP E
If issue was repaired during theElectrical Pretest
Go to STEP A
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Isolation Procedures Front Box Test
STEP E
Procedure Condition Action
1. Key on
2. Listen for noise from theElectric Shifter calibrating/ actuating then turn the keyoff and listen for the samenoise again
If the Electric Shifter can beheard calibrating/actuating
Go to STEP F
If the Electric Shifter can’t beheard calibrating
Go to STEP F
STEP F
Procedure Condition Action1. Key off
2. Remove Electric Shifter fromShift Bar Housing
3. Inspect the following:
• Shift blocks arefastened to shiftrails securely
• Shift rails move intoeach gear position
• Electr ic shifter is
free from anyexcessive lubecontaminationbuildup
• Two gear positionscan not beengaged at thesame time
If no problem found and you couldnot hear the electric shifteractuation in the previous step
Replace the TECU. Go toSTEP V
If no problem found and you couldhear the electric shifter actuationin the previous step
Replace the Electric Shifter. Go toSTEP V
If problem is found Repair as required. Go to STEP V
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Front Box Test Isolation Procedures
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectors
3. Place Shift Control intoneutral
4. Key on If Gear Display displays a solid“N”
Test complete
If Gear Display does not display asolid “N”
Return to STEP A to finderror in testing
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Isolation Procedures Front Box Test
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Engine Crank Test
Engine Crank Test
Overview
This symptom-driven test is performed if a “N” is displayed on the Gear Display with no active or
inactive codes and the vehicle will not crank.
The Hybrid Control Module (HCM) receives the input to crank from pin 20 on the HCM 38-wayVehicle Connector, which is wired to the key switch. The HCM normally powers the High-VoltageMotor/Generator to start the engine. If the Hybrid system is offline, the HCM will use the standard24-volt starter by energizing the 24-volt Cranking relay. This relay then provides battery power topin 30 of the Start Enable Relay, which then powers the starter solenoid.
Note: This symptom-based test should only be performed if you were sent here from the
Diagnostic Procedure and you have no active fault codes.
Symptom
Vehicle will not crank or there is a solid “N” in the gear display.
Possible Causes
• 24-volt Cranking Relay• Start Enable Relay• OEM Vehicle Harness• Engine Starter• 24-volt batteries
• Key switch input to pin 20 of the HCM
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
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Engine Crank Test Wiring Schematic Engine Crank Test
Engine Crank Test Wiring Schematic
Harness Front View(TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
TECU
HCM
30
86
8785
26
87
86
85
30
32Crank Enable Plus
Start Enable Latch
Harness Front View(HCM - Vehicle Interface Connector)
3738
35 36
1 67 12
13 22
23 28
29 34
Typical Relay Switch
Start EnableRelay
24V Truck Battery
2 4 V
P l u s
4Crank Enable Minus
4Start Enable Minus
87
86
85
30
24V CrankingRelay26Crank Enable Latch
Start Enable Plus 32
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
Starter solenoid
Key Switch
20
Off
Ignition
Crank
Engine Crank Request
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Engine Crank Test
STEP D
Procedure Condition Action
1. Key on
Engine may crank
2. Jumper pin 87 of the startenable relay connector tobattery power
If engine cranks Repair open circuit between pin87 of the start enable relay andbattery. Refer to OEM for repairprocedures.
If engine does not crank Concern is with starter solenoidor power harness to solenoid.Refer to OEM for repairprocedures
STEP E
Procedure Condition Action
1. Key off
2. Disconnect negative batterycable
3. Disconnect HCM vehicleharness 38-way connector
4. Key in start position
5. Measure voltage from HCMvehicle harness 38-wayconnector pin 20 to ground
If voltage is 23-25 volts Replace the HCM. Go to STEP V
If voltage is below 23 volts Repair the OEM vehicle harness.Go to STEP V
STEP V
Procedure Condition Action
1. Key off
2. Reconnect all connectors
3. Place Shift Control intoneutral
4. Key on If engine starts Test complete
If engine does not start Return to STEP A to finderror in testing.
WARNING
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Hybrid Performance Test
Hybrid Performance Test
Overview
The Hybrid System uses a combination of diesel engine and electric power to provide varying
levels of torque during vehicle operation. If the Hybrid system has a fault, or if a hybrid componentis above the optimum operating temperature, the vehicle will reduce the amount of available Motor/ Generator torque.
Note: Some faults codes will affect the amount of torque available from the Motor/Generator andwill be noticeable to the driver.
Note: This symptom-based test should only be performed if you were sent here from the
Diagnostic Procedure and you have no active fault codes.
Symptoms
• Vehicle acceleration performance is not acceptable
Possible Causes
• Hybrid liquid cooling system• PEC air cooling system restriction or poor air flow• Reduce engine power
• Truckload capacity above the rated amount
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
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Isolation Procedures Hybrid Performance Test
Isolation Procedures
STEP A
Procedure Condition Action
1. Key on.
2. Connect ServiceRanger tothe 9-pin diagnosticconnector in the cab andview the following DataMonitor parameters underthe Hybrid (Engine andBrake) list:
• SPN 513 ActualEngine Torque
• SPN 518Requested EngineTorque
If actual torque is equal torequested torque
Go to STEP B
If actual torque is less thanrequested torque
Refer to OEM for engine powerconcern. Go to STEP V
STEP B
Procedure Condition Action
1. Select the “Data Monitor”option and view the followingparameter:
• BatteryTemperature PID115
If Battery temperature is below40°C
Refer to OEM for engine powerconcern. Go to STEP V
If temperature if above 40°Cinspect the battery coolingsystem for the following.
• Plugged intake orexhaust ports
• Restricted orplugged air filter
• Failed batterycooling fan
Refer to the OEM for proceduresand specifications. Makenecessary and go to STEP V
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Isolation Procedures Hybrid Performance Test
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Gear Engagement Test
Gear Engagement Test
Overview
The Hybrid Control Module (HCM) normally commands the different gears shifts which are done
through the Transmission Electronic Control Unit (TECU). The HCM also controls the ElectricClutch Actuator (ECA), which changes the position of the clutch.
Note: This symptom-based test should only be performed if you were sent here from the
Diagnostic Procedure and you have no active fault codes.
Symptoms
• Transmission will not engage a gear from Neutral and warning tone sounds (Solid “N” in GearDisplay).
• Transmission will not engage a gear from Neutral (Flashing Gear in Gear Display). Thissymptom is addressed in the Front Box Symptom test.
• Transmission will not move from a stop (Solid Gear number in Gear Display).
Messages from the Body Controller to the HCM
Messages from the Engine, Chassis, or Body Controller to the TECU
Possible Causes
• Transmission• Service Brake Switch
• Boom/Outrigger switch
Required Tools
• Basic Hand Tools• Eaton® Test Adapter Kit J-43318• Digital Volt/Ohm Meter J-46708
• ServiceRanger
Signal Value Meaning Description
Prohibit Driving 01
Allow DrivingProhibit Driving
Body Controller isrequesting the HCM notallow gear engagementfrom neutral.
Signal Value Meaning DescriptionBrake Switch 0
1Not AppliedApplied
The ECU is confirmingthe current state of theservice brake switch.
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Isolation Procedures Gear Engagement Test
Isolation Procedures
STEP A
Procedure Condition Action1. You should only perform this
symptom test if you weresent here from the DiagnosticProcedure and you have noactive fault codes
2. Depress “N” on the PushButton Shift Control
If “N” is present on the GearDisplay
Go to STEP B
If “N” is not present on the GearDisplay
Refer to the DiagnosticProcedure for the correctsymptom based test to perform
STEP B
Procedure Condition Action
1. Key on
2. Start engine
3. Depress service brake andselect “D”
If gear display shows a “N” and awarning tone sounds
Go to STEP D
If Gear Display shows a flashinggear with no arrows
Go to Front Box Test
If Gear Display shows a solidgear, but vehicle will not move
Go to STEP C
STEP C
Procedure Condition Action
1. Key on.
2. Connect ServiceRanger andview the following DataMonitor parameter PID 154
“Prohibit Driving”
Prohibit Driving reads 0 (AllowDriving)
Contact Eaton at 1-800-826-HELP [4357]
Prohibit Driving reads 1 (ProhibitDriving)
Ensure boom and outriggers arefully retracted. Contact your OEMfor repair procedures. Go toSTEP V
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Gear Engagement Test Isolation Procedures
STEP D
Procedure Condition Action
1. Key on
2. View the following DataMonitor parameter whiledepressing the service brake:
• SPN 597 “ServiceBrake Status”
If the service brake switch statusis depressed when you apply thebrakes
Contact Eaton at 1-800-826-HELP [4357]
If the service brake switch doesnot change status
Repair service brake wiring orswitch. Contact your OEM forrepair procedures. Go to STEP V
STEP V
Procedure Condition Action
1. Key off.
2. Reconnect all connectors.
3. Place Shift Control intoneutral.
4. Key on. If the transmission will engage agear and move from a stop
Test complete.
If the transmission will not
engage a gear or move from astop
Return to STEP A to find
error in testing.
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Isolation Procedures Gear Engagement Test
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Wiring Diagrams
Wiring Diagram with Push Button Shift Controller
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Wiring Diagram with Push Button Shift Controller Wiring Diagrams
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Wiring Diagrams Wiring Diagram with Push Button Shift Con-
Hybrid Transmission ECU System Harness
Gear selectmotor
Rail selectmotor
Electricshifter
A
B
A
B
Rail selectsensor
Gear selectsensor
Input shaftspeed sensor
Output shaftspeed sensor
181920
101112
78
2324
A
B
C
AB
C
3537
3638
B
C
A
17
31
25
D
For Transmission
Diagnostics
4-way
B - Service Bat. +C - Service Bat. -A - Service Ignition +
BCA
Transmission ECU
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Wiring Diagram with Push Button Shift Controller Wiring Diagrams
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Connector Pin Description
Hybrid and Transmission Connector Pins
TECU and HCM Connectors
Please note the location and orientation of the HCM and TECU connectors.
HCM - Vehicle Interface Connector
TECU - Vehicle Interface Connector
HCM - Hybrid System Interface Connector
Terminal Side - Harness Connector(HCM - Vehicle Interface Connector)
37 38
35 36
1 67 12
13 22
23 28
29 34
Terminal Side - Harness Connector (HCM - Hybrid System Interface Connector)
37 38
35 36
1 67 12
13 22
23 28
29 34
Terminal Side - Harness Connector (TECU - Vehicle Interface Connector)
3738
3536
16
12
1322
2328
2934
7
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Hybrid and Transmission Connector Pins Connector Pin Description
The backshell should always face down on the harness connectors.
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Connector Pin Description Hybrid and Transmission Connector Pins
Transmission Controller 38-Way (Vehicle Interface Connector)
Description From Pin # To Pin # AWG
Not Used 1 Plug
J1939 Low (CAN) TECU 2 1939 Backbone B 18 TXL
J1939 High (CAN) TECU 3 1939 Backbone A 18 TXL
Start Enable RelayMinus
TECU 4 AS Start Enable Relay 85 18 TXL
Not Used 5 Plug
Not Used 6 Plug
Not Used 7 Plug
Not Used 8 Plug
Not Used 9 Plug
J1587 Plus TECU 10 Splice into 1587 A 18 TXL
J1587 Minus TECU 11 Splice into 1587 B 18 TXL
Not Used 12 Plug
Not Used 13 Plug
Not Used 14 Plug
Not Used 15 Plug
Not Used 16 Plug
Not Used 17 Plug
Not Used 18 Plug
Not Used 19 Plug
Not Used 20 Plug
Not Used 21 Plug
Not Used 22 Plug
Not Used 23 Plug
Not Used 24 Plug
Shift Control PowerMinus
TECU 25 PBSC J3 18 TXL
Start Enable Latch TECU 26 AS Start Enable Relay 87 18 TXL
HIL Low (ProprietaryCAN)
TECU 27 PBSC F2 18 TXL
HIL High (ProprietaryCAN)
TECU 28 PBSC F1 18 TXL
Not Used 29 Plug
Not Used 30 Plug
Shift Control PowerPlus
TECU 31 PBSC C1 18 TXL
Start Enable RelayPlus
TECU 32 AS Start Enable Relay 86 18 TXL
Not Used 33 Plug
Not Used 34 Plug
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Connector Pin Description Hybrid and Transmission Connector Pins
Hybrid Controller 38-Way (Vehicle Interface Connector)
Description From Pin # To Pin # AWG
Not Used 1 Plug
J1939 Low (CAN) HCM 2 1939 Backbone B 18 TXL
J1939 High (CAN) HCM 3 1939 Backbone A 18 TXL
24V Cranking RelayMinus
HCM 4 24V CrankingRelay
85 Plug
Not Used 5 Plug
Not Used 6 Plug
Not Used 7 Plug
Not Used 8 Plug
Not Used 9 Plug
J1587 Plus HCM 10 Splice into 1587 18 TXL
J1587 Minus HCM 11 Splice into 1587 18 TXL
Not Used 12 Plug
Not Used 13 Plug
Not Used 14 Plug
Not Used 15 Plug
Not Used 16 Plug
Not Used 17 Plug
PTO Signal HCM 18 PTO 18 TXL
Not Used 19 Plug
Engine Crank Request HCM 20 Crank Position onSwitch
18 TXL
Not Used 21 PlugNot Used 22 Plug
Service Lamp HCM 23 4-pin ServiceConnector
D 18 TXL
PTO Request (NonJ1939 BCU)
HCM 24 BCU 18 TXL
Not Used 25 Plug
24V Cranking RelayLatch
HCM 26 24V CrankingRelay
87 18 TXL
CAN Low (ProprietaryCAN)
HCM 27 HEV Backbone B 18 TXL
CAN High (ProprietaryCAN)
HCM 28 HEV Backbone A 18 TXL
Not Used 29 Plug
Not Used 30 Plug
Not Used 31 Plug
24V Cranking RelayPlus
HCM 32 24V CrankingRelay
86 18 TXL
Not Used 33 Plug
Not Used 34 Plug
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Hybrid and Transmission Connector Pins Connector Pin Description
Ignition HCM 35 Fused 10A toIgnition Relay
12 GXL or14SXL
Battery Minus HCM 36 Battery Ground 12 GXL
Not Used 37 Plug
Battery Plus HCM 38 Fused 30A Battery 12 GXL
Description From Pin # To Pin # AWG
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Connector Pin Description Hybrid and Transmission Connector Pins
Hybrid Controller 38-Way (Hybrid System Interface Connector)
Description From Pin # To Pin # AWG
Not Used 1 Plug
Inverter Enable HCM 2 Inverter 9 and 10 18 TXL
Not Used 3 Plug
Coolant Pump &Battery Fan RelayMinus
HCM 4 Coolant PumpRelay & BatteryFan Relay
85 18 TXL
High-Voltage RelayMinus
HCM 5 High-Voltage Relay 4 18 TXL
PTO Power Minus HCM 6 PTO 18 TXL
Not Used 7 Plug
Not Used 8 Plug
Not Used 9 Plug
Not Used 10 Plug
DC/DC ConverterTemperature
HCM 11 DC/DC Converter 3 18 TXL
Not Used 12 Plug
ECA Ignition HCM 13 ECA H 18 TXL
Not Used 14 Plug
Not Used 15 Plug
Not Used 16 Plug
Service Battery Plus 17 Service Port A 18 TXL
Not Used 18 Plug
DC/DC Converter
Feedback Voltage
HCM 19 DC/DC Converter 1 18 TXL
Not Used 20 Plug
Not Used 21 Plug
Not Used 22 Plug
Not used 23 Plug
Not Used 24 Plug
Service Ignition HCM 25 Service Port C 18 TXL
Battery Cooling FanRelay Plus
HCM 26 Battery CoolingFan
86 18 TXL
Not Used 27 Plug
APG Enable HCM 28 APG C 18 TXL
Not Used 29 Plug
Not Used 30 Plug
Service Battery Minus HCM 31 Service Port B 18 TXL
Coolant Pump RelayPlus
HCM 32 Coolant PumpRelay
86 18 TXL
High-Voltage RelayPlus
HCM 33 High-Voltage Relay 3 18 TXL
PTO Power Plus HCM 34 PTO 18 TXL
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Hybrid and Transmission Connector Pins Connector Pin Description
Heat Exchanger Plus HCM 35 HEF Relay 86 12 GXL or14SXL
Not Used 36 Plug
Heat Exchanger Minus HCM 37 HEF Relay 85 18 TXL
Not Used 38 Plug
Description From Pin # To Pin # AWG
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Connector Pin Description Hybrid and Transmission Connector Pins
REZ_Plus Inverter 30 Resolver 4 16 TXL
PRECHRG (-) Inverter 31 PEC 19 16 TXL
Main (+) (-) Inverter 32 PEC 11 16 TXL
Main (-) (-) Inverter 33 PEC 15 16 TXL
CAN High 2 Inverter 34 PEC 1 16 TXL
CAN-Low 2 Inverter 35 PEC 2 16 TXL
TMGND Inverter 36 Temp Sensor 2 16 TXL
TM Inverter 37 Temp Sensor 1 16 TXL
REZS3 Inverter 38 Resolver 1 16 TXL
REZS4 Inverter 39 Resolver 5 16 TXL
REZ_Minus Inverter 40 Resolver 3 16 TXL
Description From Pin # To Pin # AWG
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Hybrid and Transmission Connector Pins Connector Pin Description
Power Electronics Carrier (PEC) Connectors
19-way Connector
Description From Pin # To Pin # AWG
CAN High PEC 1 Inverter 14 18
CAN Low PEC 2 Inverter 28 18
Mating Connector View (Deutsch 19 - Way)
8 9
1
2
3
45
6
7 10
11
12
131415
16
17
18
19
High Voltage DC Connector 1to Inverter (Yazaki Connector)
High Voltage DC Connector 2to APG (Yazaki Connector)
High Voltage DC Connector 3to DCDC (Yazaki Connector)
Low Voltage Deutsch19 - Way Connector
Cautio
n: The PEC 19-way low-voltage connector needs to have the back shell and strain
relief such that the unit will not allow water entry from direct spray.
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Connector Pin Description Hybrid and Transmission Connector Pins
HV Relay (+) PEC 3 HCM 33 18
HV Relay (-) PEC 4 HCM 5 18
RelayOff PEC 5 Inverter 43 18
BCU (+) PEC 6 Inverter 16 18
BCU (-) PEC 7 Inverter 34 18
Main (+) + PEC 9 Inverter 30 18
Main (+) - PEC 11 Inverter 35 18
Main (-) + PEC 13 Inverter 31 18
Main (-) - PEC 15 Inverter 36 18
PreChg + PEC 17 Inverter 29 18
PreChg - PEC 19 Inverter 37 18
Battery Fan Plus PEC 12 Battery Fan Cooling Relay 87 12
Battery Fan Minus PEC 14 Battery Negative - 12
Description From Pin # To Pin # AWG
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Hybrid and Transmission Connector Pins Connector Pin Description
PEC High-Voltage (DC) Connector to Inverter
PEC High-Voltage (DC) Connector to DC/DC Converter
Inverter High-Voltage (AC) Connector
Inverter High-Voltage (DC) Connector
Description From Pin # To Pin # AWG
DC + PEC A Inverter A 15mm²
DC - PEC B Inverter B 15mm²
Loose Disconnect PEC 1 PEC 2 0.8 mm² (18 AWG)
Description From Pin # To Pin # AWG
DC + PEC A DC/DCConverter
A 14 AWG
DC - PEC B DC/DCConverter
B 14 AWG
Loose Disconnect PEC 1 DC/DCConverter
1 0.8 mm² (18 AWG)
Loose Disconnect PEC 2 DC/DCConverter
2 0.8 mm² (18 AWG)
Description From Pin # To Pin # AWG
Phase 1 Inverter A Motor/Gen A 4 AWG
Phase 2 Inverter B Motor/Gen B 4 AWG
Phase 3 Inverter C Motor/Gen C 4 AWG
Description From Pin # To Pin # AWG
DC + Inverter A PEC A 15mm²
DC - Inverter B PEC B 15mm²
Loose Disconnect Inverter 1 Inverter 2 0.8 mm² (18 AWG)
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Connector Pin Description Hybrid and Transmission Connector Pins
Electric Clutch Actuator (ECA) Connectors
ECA 3-Way Connector
ECA 8-Way Connector
Description From Pin # To Pin # AWGIgnition ECA A Not Used Plug
Battery Minus ECA B Chassis Ground Battery - 12
Battery Plus ECA C Fused 50 ampfrom Vbatt
Battery + 12
Description From Pin # To Pin # AWG
CAN High ECA A CAN Backbone A 18
CAN Low ECA B CAN Backbone B 18
CAN - Pass ECA C Not Used Plug
Signal ECA D Not Used Plug
CAN + Pass ECA E Not Used Plug
Engine Flywheel SpeedSensor Plus
ECA F Speed Sensor + A 18
Engine Flywheel SpeedSensor Minus
ECA G Speed Sensor - B 18
ECA Ignition ECA H HCM 13 18
HCM
2827
AB
AB
F G
F G
50 AMP fuse
Battery power (Non-switched power)
run to the Battery
Engine Flywheel Speed Sensor (Eaton Supplied)
A B
C
Terminal Side - Harness Connector Metri-Pack 3-Way Connector
Terminal Side - Harness Connector Metri-Pack 8-Way Connector
13
E F G H
D C B A
A B C
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Hybrid and Transmission Connector Pins Connector Pin Description
Motor/Generator Connectors
Views looking into connectors with wires exiting the opposite side.
Terminal Side - Harness Connector Temperature Sensor
(Deutsch 2-pin connector)
Terminal Side - Harness Connector Resolver
(Deutsch 6-pin connector)
High Voltage ACAmpenol Connector
Temperature SensorConnector
Low Voltage DeutschResolver Connector
Low Voltage Deutsch
Bottom View
Ground StrapBracket
Ground Strap
8/12/2019 Eaton Hybrid Drive System Model TRTS2500
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Connector Pin Description Hybrid and Transmission Connector Pins
Motor/Generator Resolver Connector
Motor/Generator Temperature Sensor Connector
Motor/Generator High-Voltage (AC) Connector
Description From Pin # To Pin # AWG
Resolver Signal 3 Motor/Gen 1 EPS Inverter 38 18
Resolver Signal 2 Motor/Gen 2 EPS Inverter 28 18
Resolver Signal 1 Motor/Gen 3 EPS Inverter 40 Plug
Resolver Signal 4 Motor/Gen 4 EPS Inverter 30 Plug
Resolver - Motor/Gen 5 EPS Inverter 39 Plug
Resolver + Motor/Gen 6 EPS Inverter 29 18
Description From Pin # To Pin # AWG
Motor Temp Motor/Gen 1 EPS Inverter 37 18
Motor Temp Gnd Motor/Gen 2 EPS Inverter 36 18
Description From Pin # To Pin # AWG
Phase 1 Motor/Gen U Inverter U 4 AWG
Phase 2 Motor/Gen V Inverter V 4 AWG
Phase 3 Motor/Gen W Inverter W 4 AWG
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Hybrid and Transmission Connector Pins Connector Pin Description
Typical DC/DC Converter Circuit
Remove the 24-volt battery cables prior to working on the DC/DC converter.
DC(-)
DC(+)
24V DC(+)
24V DC(-)
g o tageYazaki Connector
OEM Connection
Deutsch 4-Way OEM Connector
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Connector Pin Description Hybrid and Transmission Connector Pins
DC/DC Converter 4-Way Deutsch OEM Connector
Converter High-Voltage (DC) Connector
Converter 24-volt Studs
Description From Pin # To Pin # AWG
Ground DC/DC 4 Ground 18
Thermocouple DC/DC 3 HCM 11 18
Not Used DC/DC 2 Not Used Plug
Voltage Feedback DC/DC 1 HCM 19 18
Description From Pin # To Pin # AWG
DC + DC/DC A PEC A 14
DC - DC/DC B PEC B 14
Loose Disconnect DC/DC 1 PEC 1 18
Loose Disconnect DC/DC 2 PEC 2 18
Description From Pin # To Pin # AWG
24volt + DC/DC A Battery PositivePost
A 2
24volt - DC/DC B Battery NegativePost
B 2
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Hybrid and Transmission Connector Pins Connector Pin Description
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