Eaton Transmission TRTS1000 User Manual

Troubleshooting Guide

Eaton Hybrid Drive Systems MY08 TRTS1000 EN-US

October 2015

EH-8E306A-U EH-8E306A-UPG EH-8E306A-UP EH-8E306A-CD EH-8E306A-T EH-6E606B-CD

Table of Contents TRTS1000

Table of Contents

General Information

Warnings & Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . 1

High-Voltage Warnings & Cautions . . . . . . . . . . . . 2

Insulated Rubber Glove Test and High-Voltage

Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Insulated Rubber Glove Test. . . . . . . . . . . . . . . . . . 3

High-Voltage Work Area Requirements . . . . . . . . . 3

High-Voltage Service Shutdown and Power-Up

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

High-Voltage Service Shutdown Procedures . . . . . 5

High-Voltage Service Power-Up Procedure . . . . . . 5

Diagnostic Tools/Service Publications. . . . . . . . . . . . . 6

Eaton Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SPX/OTC To ols. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Service Publications. . . . . . . . . . . . . . . . . . . . . . . . 7

Hybrid Diagnostic Procedure. . . . . . . . . . . . . . . . . . . . 8

Hybrid Component and Connector Locations. . . . . . . . 9

Transmission Wiring Connections . . . . . . . . . . . . . 9

Component Wiring Connections. . . . . . . . . . . . . . 11

Fault Code Retrieval and Clearing. . . . . . . . . . . . . . . . 13

View Active and Inactive Faults . . . . . . . . . . . . . . 13

Clear Inactive Faults. . . . . . . . . . . . . . . . . . . . . . . 13

Fault Code Isolation Procedure Index. . . . . . . . . . . . . 14

Symptom-Driven Diagnostics Index. . . . . . . . . . . . . . 18

Product Diagnostic Mode (PDM). . . . . . . . . . . . . . . . 19

PDM only works with the following Inactive

codes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hybrid Light and Gear Display Descriptions. . . . . . . . 20

Red “Service” Light . . . . . . . . . . . . . . . . . . . . . . . 20

Amber “Check Hybrid” Light . . . . . . . . . . . . . . . . 20

Red “Stop Hybrid” Light. . . . . . . . . . . . . . . . . . . . 20

Blinking Amber “Check Hybrid” Light. . . . . . . . . . 20

“ST” in Gear Display. . . . . . . . . . . . . . . . . . . . . . . 20

“PD” in Gear Display . . . . . . . . . . . . . . . . . . . . . . 20

“CA” in Gear Display . . . . . . . . . . . . . . . . . . . . . . 21

“OS” in Gear Display . . . . . . . . . . . . . . . . . . . . . . 21

“F” in Gear Display. . . . . . . . . . . . . . . . . . . . . . . . 21

Dash “-” in Gear Display. . . . . . . . . . . . . . . . . . . . 21

Double Stars “**” in Gear Display . . . . . . . . . . . . 21

Double Dashes “- -” in Gear Display. . . . . . . . . . . 21

Blank Gear Display. . . . . . . . . . . . . . . . . . . . . . . . 21

Electrical Pretest Procedures

Power-Up Sequence Test. . . . . . . . . . . . . . . . . . . . . . 22

Electrical Pretest . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Hybrid Electrical Pretest. . . . . . . . . . . . . . . . . . . . . . . 29

Fault Isolation Procedures

Fault Code 1 - Motor/Generator Current Sensor. . . . . 33

Fault Code 2 - Motor/Generator Temperature Sensor 38

Fault Code 3 - Motor/Generator Temperature . . . . . . 42

Fault Code 4 - Motor/Generator Rotation Speed

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fault Code 5 - Motor/Generator AC Cable . . . . . . . . . 52

Fault Code 6 - No HCM Operation . . . . . . . . . . . . . . . 57

Fault Code 7 - Improper HCM Configuration . . . . . . . 60

Fault Code 8 - Loss of Switched Ignition Power

(HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Fault Code 9 - Weak Battery Voltage . . . . . . . . . . . . . 66

Fault Code 10 - Low Battery Voltage (HCM). . . . . . . . 69

Fault Code 11 - No TECU Operation. . . . . . . . . . . . . . 72

Fault Code 12 - Improper TECU Configuration. . . . . . 75

Fault Code 14 - Invalid Shifter Range. . . . . . . . . . . . . 78

Fault Code 16 - High Integrity Link (HIL) Test . . . . . . 83

Fault Code 17 - Start Enable Relay. . . . . . . . . . . . . . . 89

Fault Code 18 - ECA Communication. . . . . . . . . . . . . 94

Fault Code 24 - J1939 HCM Message (TECU) . . . . . . 97

Fault Code 26 - Clutch Slip. . . . . . . . . . . . . . . . . . . . 101

Fault Code 27 - Clutch Disengagement . . . . . . . . . . 105

Fault Code 32 - Loss of Switched Ignition Power

(TECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Fault Code 33 - Low Battery Voltage (TECU) . . . . . . 111

Fault Code 34 - Weak Battery Voltage Fault (TECU). 114 Fault Code 35 - J1939 Communication Link (TECU) 117

Fault Code 36 - J1939 Engine Message (TECU). . . . 122

Fault Code 37 - Power Supply (TECU) . . . . . . . . . . . 125

Fault Code 38 - Battery Fan Relay . . . . . . . . . . . . . . 129

Fault Code 39 - Heat Exchanger Relay . . . . . . . . . . . 135

Fault Code 40 - Cooling Pump Relay . . . . . . . . . . . . 140

Fault Code 47 - J1939 ABS Message (HCM) . . . . . . 146

Fault Code 48 - J1939 Transmission Message

(HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

TRTS1000 T able of Contents

Fault Isolation Procedures - continued

Fault Code 49 - J1939 Engine Message (HCM) . . . . 153

Fault Code 50 - J1939 Body Controller Message

(HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Fault Code 51 - Rail Position Sensor . . . . . . . . . . . . 159

Fault Code 52 - Gear Position Sensor . . . . . . . . . . . 164

Fault Code 53 - DC/DC Converter. . . . . . . . . . . . . . . 169

Fault Code 54 - DC/DC Converter Output Voltage . . 172

Fault Code 56 - Input Shaft Speed Sensor. . . . . . . . 177

Fault Code 58 - Output Shaft Speed Sensor. . . . . . . 181

Fault Code 59 - J1939 Communication Link (HCM). 18 5 Fault Code 60 - CAN Communication Link (HCM) . . 190

Fault Code 61 - Rail Select Motor . . . . . . . . . . . . . . 194

Fault Code 63 - Gear Select Motor. . . . . . . . . . . . . . 197

Fault Code 64 - ECA Fault . . . . . . . . . . . . . . . . . . . . 201

Fault Code 65 - ECA Speed Sensor . . . . . . . . . . . . . 204

Fault Code 66 - ECA Battery Voltage . . . . . . . . . . . . 208

Fault Code 67 - ECA Ignition Voltage. . . . . . . . . . . . 211

Fault Code 70 - Engine Failed to Respond (HCM) . . 215

Fault Code 71 - Failed to Disengage a Gear . . . . . . . 218

Fault Code 72 - Failed to Select Rail. . . . . . . . . . . . . 222

Fault Code 73 - Failed to Engage a Gear. . . . . . . . . . 225

Fault Code 74 - Engine Failed to Respond (TECU). . 228

Fault Code 75 - Power Down in Gear. . . . . . . . . . . . 231

Fault Code 76 - High Voltage Battery 1 Potential

Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Fault Code 77 - High Voltage Battery 2 Potential

Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Fault Code 78 - High Voltage Battery 1 Current . . . . 240

Fault Code 79 - High Voltage Battery 2 Current . . . . 243

Fault Code 82 - High Voltage Battery 1 Temperature 246

Fault Code 83 - Invalid Shifter Range. . . . . . . . . . . . 250

Fault Code 84 - Shift Control Device Not Configured 255 Fault Code 85 - Shift Control Device Incompatible. . 261 Fault Code 86 - High Voltage Battery 2 Temperature 265

Fault Code 87 - CAN ECA Message (HCM). . . . . . . . 269

Fault Code 88 - CAN Inverter Message (HCM). . . . . 273

Fault Code 89 - CAN BCU 1 Message (HCM). . . . . . 277

Fault Code 90 - CAN BCU 2 Message (HCM). . . . . . 281

Fault Code 91 - APG Unit 1 CAN . . . . . . . . . . . . . . . 285

Fault Code 95 - 12-Volt Cranking Relay. . . . . . . . . . 289

Fault Code 96 - Accelerator Pedal Offset . . . . . . . . . 293

Fault Code 97 - PTO Engagement . . . . . . . . . . . . . . 296

Fault Code 101 - High Voltage Battery 1 . . . . . . . . . 303

Fault Code 102 - High Voltage Battery 2 . . . . . . . . . 307

Fault Code 103 - High Voltage Battery 1 Control

Unit Communication . . . . . . . . . . . . . . . . . . . . . . . . 311

Fault Code 104 - High Voltage Battery 2 Control

Unit Communication . . . . . . . . . . . . . . . . . . . . . . . . 314

Fault Code 105 - High Voltage Battery 1 Control

Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Fault Code 106 - High Voltage Battery 2 Control

Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

Fault Code 107 - High Voltage Battery Leak

Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Fault Code 108 - High Voltage Battery 1 Control

Unit Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . 334

Fault Code 109 - High Voltage Battery 2 Control

Unit Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . 338

Fault Code 110 - Inverter. . . . . . . . . . . . . . . . . . . . . 342

Fault Code 111 - Inverter Communication. . . . . . . . 345

Fault Code 112 - Inverter Voltage . . . . . . . . . . . . . . 349

Fault Code 113 - Inverter Current . . . . . . . . . . . . . . 353

Fault Code 114 - Inverter Power Supply . . . . . . . . . 358

Fault Code 115 - Inverter Temperature . . . . . . . . . . 362

Fault Code 116 - High Voltage Relays . . . . . . . . . . . 367

Fault Code 117 - BCU Relay Cut Request. . . . . . . . . 374

Fault Code 118 - Auxiliary High-Voltage Relay

Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Fault Code 120 - APG Unit 1 AC Voltage . . . . . . . . . 385

Fault Code 122 - APG UNIT 1 Output . . . . . . . . . . . . 388

Fault Code 123 - APG Unit 1 High Voltage Battery. . 393

Fault Code 125 - APG Unit 1 Over Temperature. . . . 396

Fault Code 126 - APG Unit 1 Configuration . . . . . . . 399

Fault Code 127 - APG Unit 1 Ambient Air

Over Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 402

Fault Code 128 - APG Unit 1 Ambient Air

Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . 405

Fault Code 129 - APG Unit 1 Communication . . . . . 408

Fault Code 131 - APG Unit 1 Configuration Error. . . 412

2015.10.19

Table of Contents TRTS1000

Symptom Procedures

Front Box Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

Engine Crank Test . . . . . . . . . . . . . . . . . . . . . . . . . . 420

Hybrid Performance Test. . . . . . . . . . . . . . . . . . . . . 424

ServiceRanger Test . . . . . . . . . . . . . . . . . . . . . . . . . 427

Gear Engagement Test. . . . . . . . . . . . . . . . . . . . . . . 432

ePTO Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

Appendix

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

Hybrid Tr ansmission ECU System Harness . . . . 445

Connector Pin Descriptions . . . . . . . . . . . . . . . . . . . 446

Hybrid and Transmission Connector Pins . . . . . 446

TECU and HCM Connectors . . . . . . . . . . . . . . . . 446

Transmission Controller 38-Way

(Vehicle Interface Connector). . . . . . . . . . . . . . . 447

Hybrid Controller 38-Way

(Vehicle Interface Connector). . . . . . . . . . . . . . . 448

Hybrid Controller 38-Way

(Hybrid System Interface Connector). . . . . . . . . 449

Inverter connectors . . . . . . . . . . . . . . . . . . . . . . 450

Inverter 56-Way Connector . . . . . . . . . . . . . . . . 451

Power Electronics Carrier (PEC) Connectors . . . 452

PEC 19-Way Connector . . . . . . . . . . . . . . . . . . . 453

PEC High-Voltage (DC) Connector to Inverter . . 453

PEC High-Voltage (DC) Connector to DC/DC

Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453

Inverter High-Voltage (AC) Connector . . . . . . . . 453

Inverter High-Voltage (DC) Connector . . . . . . . . 453

Electric Clutch Actuator (ECA) Connectors. . . . . 454

ECA 3-Way Connector . . . . . . . . . . . . . . . . . . . . 454

ECA 8-Way Connector . . . . . . . . . . . . . . . . . . . . 454

Motor/Generator Connectors . . . . . . . . . . . . . . . 455

Typical DC/DC Converter Circuit. . . . . . . . . . . . . 457

iii

2015.10.19

TRTS1000 General Information | Warnings & Cautions

DANGER

HAZARDOUS VOLTAGE

You will be severely injured or killed if you do not follow the procedure. Components marked with DANGER High Voltage should be avoided. Service must be performed by qualified personnel only.

Warnings & 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 must be read, understood, and heeded before continuing the procedure or performing the step(s).

Danger: Danger indicates you will be severely injured or killed if do not follow the indicated procedure.

Warning: Warning indicates an immediate hazard, which could result in severe personal injury if you do not follow the indicated procedure.

Caution: Caution indicates vehicle or property damage could occur if you do not follow the indicated procedure.

Note: Note indicates additional detail that will aid in the

diagnosis or repair of a component/system.

Follow the specified procedures in the indicated order to avoid personal injury:

1. If the high-voltage cones are around the vehicle and the lockout is installed on the PEC, the only person that should be allowed to start the 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 place the 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. In vehicles with ePTO, the engine and/or Motor/Generator can start in ePTO mode. Never perform any maintenance or work on vehicle, while in this mode.

6. 12-Volt Battery positive (+) and negative (-) must be disconnected prior to any welding on any Hybrid equipped vehicle.

Caution: Follow the specified procedures in the indicated

order to avoid equipment malfunction or damage.

Caution: Do not release the parking brake or attempt to

select a gear until the air pressure is at the correct level.

Caution: T o 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.

2015.10.19

Warnings & Cautions | General Information TRTS1000

WARNING

To reduce risk of possible serious injury (Shock, Burn or Death): Components marked with High Voltage should be avoided. Service must be performed by qualified personnel only.

HAZARDOUS VOLTAGE

DANGER

HAZARDOUS VOLTAGE

You will be severely injured or killed if you do not follow the procedure. Components marked with DANGER High Voltage should be avoided. Service must be performed by qualified personnel only.

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.

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 instructions may result in severe personal injury or death.

The rubber-insulated gloves that must be worn while working on the high-voltage system are class 0 with leather protectors. The rubber gloves should be tested before EVERY use following the rubber insulation gloves testing procedure found in “Diagnostic Tools/Service Publications” on page 6. 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 Service Shutdown and Power-Up Procedure” on page 4 should be followed. Failure to follow these instructions may result in severe personal injury or death.

The Lockout and Tagout devices should only be removed by the technician that placed the Lockout and Tagout devices on the vehicle. Failure to follow these instructions may result in severe personal injury or death.

High-voltage rubber insulated gloves (class 0 with leather protectors) must be worn when working on any high-voltage cables. The “High-Voltage Service Shutdown and Power-Up Procedure” on page 4 must be followed prior to removing any high-voltage cables. Failure to follow these instructions may result in severe personal injury or death.

High-voltage cables and wiring are orange and contain a warning label at the connectors. High-voltage components are marked with a label. High-voltage rubber insulated gloves (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.

2015.10.19

TRTS1000 General Information | Insulated Rubber Glove T est and High-V oltage W ork Area

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 gloves should be tested before EVERY use following the rubber insulation gloves testing procedure found in “Diagnostic Tools/Service Publications” on page 6. Failure to follow these instructions may result in severe personal injury or death.

The insulated rubber gloves that must be worn while working on the high-voltage system are class 0 rated. They must be inspected before each use and must always be worn in conjunction with the leather outer glove. Any hole in the insulated rubber glove is a potential entry point for high-voltage.

• Roll the glove up from the open end until the lower portion of the glove begins to balloon from the 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 to protect them.

High-Voltage Work Area Requirements

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 any high voltage. Failure to follow these instructions may result in severe personal injury or death.

The buffer zone is required only when working on the high-voltage DC or AC systems and is called out both in the “High-Voltage Service Shutdown and Power-Up Procedure” on page 4 and the individual repair procedure.

• Position the vehicle in the service bay.

• Position 4 orange cones around the corners of the vehicle to mark off a 3' (1m) 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.

• The rubber insulating gloves must be class 0 and meet all of the American Safety Testing Materials standards.

2015.10.19

High-Voltage Service Shutdown and Power-Up Procedure | General Information TRTS1000

WARNING

To reduce risk of possible serious injury (Shock, Burn or Death): Components marked with High Voltage should be avoided. Service must be performed by qualified personnel only.

HAZARDOUS VOLTAGE

DANGER

HAZARDOUS VOLTAGE

You will be severely injured or killed if you do not follow the procedure. Components marked with DANGER High Voltage should be avoided. Service must be performed by qualified personnel only.

High-Voltage Service Shutdown and Power-Up Procedure

A buffer zone must be set up and ASTM Class 0 electrical insulating rubber gloves with leather protectors are required prior to working on high-voltage. Failure to follow these instructions may result in severe personal injury or death.

The rubber-insulated gloves that must be worn while working on the high-voltage system are class 0 with leather protectors. The rubber gloves should be tested before EVERY use following the rubber insulation gloves testing procedure found in the “Tool Specification” section. Failure to follow these instructions may result in severe personal injury or death.

Before inspecting or working on any high-voltage cables or components this “High-Voltage Service Shutdown Procedure” should be followed. Failure to follow these instructions may result in severe personal injury or death.

The lockout tagout devices should only be removed by the technician that placed the lockout tagout devices on the vehicle. Failure to follow these instructions may result in severe personal injury or death.

ASTM Class 0 electrical insulating rubber gloves with leather protectors must be worn when working on any high-voltage cables. This “High-Voltage Service Shutdown Procedure” must be followed prior to removing any high-voltage cables. Failure to follow these instructions may result in severe personal injury or death.

High-voltage cables and wiring are orange and contain a warning label at the connectors. High-voltage components are marked with a label. ASTM Class 0 electrical insulating rubber gloves 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.

2015.10.19

TRTS1000 General Information | High-Voltage Service Shutdown and Power-Up Procedure

High-Voltage Service Shutdown Procedures

1. Follow “High-Voltage Work Area” procedure.

2. Locate the red PEC Service Switch on the front of the PEC and push switch off.

3. Remove the Service Switch Cover and install the Lockout Bracket (J48506).

4. Fasten tag to the Lockout Bracket.

5. Ensure the PEC Service Switch can not move from the off position.

6. Allow the system to set for a minimum of 5 minutes to discharge high voltage.

7. Connect ServiceRanger and view the Data Monitor PID 116 called “High-Voltage Battery Potential.” Use SPN 520323 for J1939 connection “Battery Voltage RB” (Relay Box).

8. The voltage should be 30 volts or less. If the voltage is above 30 volts, do not work on the vehicle and contact Eaton® at 1-800-826-HELP (4357).

9. Turn ignition key off and proceed to repair or troubleshooting step.

Note: The voltage drops to zero when the key is off.

High-Voltage Service Power-Up Procedure

1. Install all high-voltage connectors into their locked positions.

2. If you are the person working on the vehicle, remove the Lockout Bracket and tag.

3. Reinstall the Lockout Bracket over the Service Switch.

4. Pull the Service Switch out and let vehicle set for 2 minutes.

5. Start vehicle when appropriate.

2015.10.19

Diagnostic Tools/Service Publications | General Information TRTS1000

Diagnostic Tools/Service Publications

Eaton Tools

• Visit Roadranger.com

Tool Description

ServiceRanger version 3 ServiceRanger PC based Diagnostic Tool

SPX/OTC Tools

• Contact SPX / OTC at (800) 328-6657

Tool Description

J49818 Eaton Hybrid Tool Safety Kit - Basic PPE (Items listed below can be ordered separately) J48603 ASTM Class 0 electrical insulating rubber gloves with leather protectors (1000 volt) J48605 Hybrid Safety Cones (set of 4) J48506 Lockout Switch Plate J48906 Lockout Tags (per 25)

Tool Description

J49819 Eaton Hybrid Tool Safety Kit - Basic Plus PPE (Items listed below can be ordered separately) J48603 ASTM Class 0 electrical insulating rubber gloves with leather protectors (1000 volt) J48605 Hybrid Safety Cones (set of 4) J48506 Lockout Switch Plate J48906 Lockout Tags (per 25) J48907 Orange Magnetic Sign J48608 Hybrid Non-Conductive Safety Pole J48908 Glove Bag

2015.10.19

TRTS1000 General Information | Diagnostic Tools/Service Publications

Misc. Service Tools Items listed below are ordered separately

J48624 Nexiq USB-Link Communication Adapter J43318-A* Pin Adapter Kit - Interface Harness Diagnostics J48735* Alignment Pins - Hybrid Motor/Gen to Transmission Main Case AMB-45* Digital Megohmmeter - High-Voltage Leakage Detection J49111* Clutch Alignment Tool J46708* Fluke Digital Multimeter J48505 Input Shaft Turning Socket J48507 Lifting Fixture - Power Electronics Carrier J48502 Jack Adapter Plate - Hybrid Drive Unit 5019 Transmission Jack - Low Lift 5078 Transmission Jack - High Lift J48577 Engine/Transmission Stand Adapter Plate - Hybrid Drive Unit J29109-A Engine/Transmission Stand - 6000 lb. Rating

Tool Description

J48893 Hybrid PPE / Service Tool Kit (includes J49819 kit and items from Miscellaneous Service Tools

highlighted with *)

Service Publications

• Visit Roadranger.com

TRSM1000 Service Manual (covers external components on transmission and Hybrid components) TRSM0110 Service Manual (covers internal transmission repairs only) TRTS1000 Troubleshooting Guide TRDR1000 Drivers Instructions TRDR1110 First Responder Guide CLMT-0365 Eaton 365 mm Clutch Installation Procedure

2015.10.19

Hybrid Diagnostic Procedure | General Information TRTS1000

Key ON

Retrieve Active Faults

with ServiceRanger

Active Codes?

Yes

Go to "Fault Code Isolation Procedure

Index" (page 14)

Does Gear Display

Show an "N"?

Does Engine Crank?

Yes

If equipped, does

vehicle operate

normal in ePTO mode?

Go to "ePTO Test” (page 436)

Yes

If a mode other than neutral is selected does transmission engage a gear? NOTE: Service

Brake must be applied prior to selecting a gear

Yes

Is vehicle acceleration

performance acceptable?

Yes

Clear faults and

operate vehicle based

on customers

concern

Inactive Faults = Go

to "Product Diagnostic Mode (PDM)" (page 19)

Active Faults = Go to

"Fault Code Isolation

Procedure Index" (page 14)

No Fault = Test

Complete

Is Red "Stop Hybrid" or Amber “Check Hybrid” light blinking?

Yes

Go to “Hybrid Light and

Gear Display Descriptions”

(page 20)

Go to “Hybrid Light and Gear Display Descriptions” (page 20)

Go to “Gear Engagement

Test” (page 432)

Will vehicle move from a stop?

Yes

Note: If ServiceRanger fails

to communicate, go to

“ServiceRanger Test”

(page 427)

Go to “Engine Crank

Test” (page 420)

Go to "Hybrid

Performance Test"

(page 424)

Go to "Gear Engagement Test”

if solid “N” is displayed

(page 432)

Go to “Front Box Test” is

flashing gear number is

displayed (page 416)

Hybrid Diagnostic Procedure

2015.10.19

TRTS1000 General Information | Hybrid Component and Connector Locations

Hybrid Component and Connector Locations

Transmission Wiring Connections

Rail Position Sensor

Output Shaft Speed Sensor

Electronic Clutch Actuator

Top: 3-Way Connector Bottom: 8-Way Connector

Transmission Electronic Control Unit (TECU)

Left: 38-Way Vehicle Connector Right: 38-Way System Connector

Hybrid Control Module (HCM)

Left: 38-Way System Connector Right: 38-Way Vehicle Connector

2015.10.19

Hybrid Component and Connector Locations | General Information TRTS1000

Gear Position Sensor

High-Voltage 3-Way AC Connector

Motor/Generator Resolver Connector

Motor/Generator Temperature Connector

Input Shaft Speed Sensor

Transmission Diagnostic Port

2015.10.19

TRTS1000 General Information | Hybrid Component and Connector Locations

12V DC(-)

High Voltage DC Connector

Top: DC(-) Bottom: (DC(+)

OEM Connection

DC/DC Converter

HIgh Voltage 3-Way AC Connector

Low Voltage 56-Way Connector

High-Voltage DC Connector to PEC

Inverter

Coolant Ports

12V DC(+)

(-)

(+)

Coolant Port Inlet

Coolant Port Outlet

Component Wiring Connections

2015.10.19

Hybrid Component and Connector Locations | General Information TRTS1000

Red Service Switch with Cover

DC Connector to Inverter

DC Connector to DC/DC Converter (Optional)

DC Connector to APG (Optional)

Air Exhaust (not shown)

19-Pin Low-Voltage Connector

Air Intake

Power Electronics Carrier (PEC)

2015.10.19

TRTS1000 General Information | Fault Code Retrieval and Clearing

Fault Code Retrieval and Clearing

All Eaton® hybrid systems require ServiceRanger for all diagnostics. T o view fault codes or to clear them, follow the procedures below.

View Active and Inactive Faults

1. Connect ServiceRanger to the 9-Way 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 Step 4 and Step 5.

Clear Inactive Faults

1. Connect ServiceRanger to the 9-Way 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 Step 4 and Step 5.

2015.10.19

Fault Code Isolation Procedure Index | General Information TRTS1000

Fault Code Isolation Procedure Index

Fault Code FMI Description Page Number

1 0, 6 Motor/Ge nerat or Current Sensor 2 3 Motor/Generator Temperature Sensor 3 0 Motor/Generator Temperature 4 0, 2, 22–27 Motor/Generator Rotation Speed Sensor 5 22–29 Motor/Generator AC Cable 6 12 No ECU Operation (HCM) 7 13 Improper ECU Configuration (HCM) 8 4 Loss of Switched Ignition Power (HCM) 9 14 Weak Battery Voltage (HCM) 10 4 Low Battery Voltage (HCM) 11 12 No ECU Operation (TECU) 12 13 Improper ECU Configuration (TECU) 14 2, 3, 4 Invalid Shifter Range 16 2 High Integrity Link (HIL)

page 33 page 38 page 42 page 48 page 52 page 57 page 60 page 63 page 66 page 69 page 72 page 75 page 78 page 83

17 3, 4 Start Enable Relay 18 9, 2 ECA Communication 24 9 J1939 HCM Message (TECU) 26 10, 23 Clutch Slip 27 7, 13 Clutch Disengagement 32 2 Loss of Switched Ignition Power (TECU) 33 4 Low Battery Voltage (TECU) 34 14 Weak Battery Voltage (TECU) 35 2 J1939 Communication Link 36 14 J1939 Engine Message (TECU) 37 5 Power Supply (TE CU) 38 3, 4, 14 Battery Fan Relay 39 3, 4, 5 Heat Exchanger Relay

page 89 page 94 page 97 page 101 page 105 page 108 page 111 page 114 page 117 page 122 page 125 page 129 page 135

2015.10.19

TRTS1000 General Information | Fault Code Isolation Procedure Index

Fault Code FMI Description Page Number

40 3, 4, 5, 14 Cooling Pump Relay page 140 47 9, 2 J1939 ABS Message (HCM) page 146 48 9, 2 J1939 Transmission Message (HCM) page 149 49 9, 2 J1939 Engine Message (HCM) page 153 50 9, 2 J1939 Body Controller Message (HCM) page 156 51 2, 3, 4 Rail Position Sensor page 159 52 2, 3, 4 Gear Position Sensor page 164 53 12, 14 DC/DC Converter page 169 54 2, 4 DC/DC Converter Output Voltage page 172 56 2, 3, 4, 5, 10 Input Shaft Speed Sensor page 177 58 2, 3, 4, 5 Output Shaft Speed Sensor page 181 59 9, 2 J1939 Communication Link (HCM) page 185 60 9, 2 CAN Communication Link (HCM) page 190 61 5, 6 Rail Select Motor page 194 63 5, 6 Gear Select Motor page 197 64 12, 21–28 ECA page 201 65 2, 5 ECA Speed Sensor page 204 66 3, 4, 14 ECA Battery Voltage page 208 67 3, 4, 5 ECA Ignition Voltage page 211 70 0, 1, 2, 7 Engine Failed to Respond (HCM) page 215 71 7 Failed to Disengage Gear page 218 72 7 Failed to Select Rail page 222 73 7 Failed to Engage Gear page 225 74 7 Engine Failed to Respond (TECU) page 228 75 14 Power Down In Gear page 231 76 3, 4, 16, 18 High-Voltage Battery 1 Potential Voltage page 234 77 3, 4, 16, 18 High-Voltage Battery 2 Potential Voltage page 237 78 6 High-Voltage Battery 1 Current page 240 79 6 High-Voltage Battery 2 Current page 243 82 0, 16 High-Voltage Battery 1 Temperature page 246 83 12, 13 Invalid Shifter Range page 250

2015.10.19

Fault Code Isolation Procedure Index | General Information TRTS1000

Fault Code FMI Description Page Number

84 13 Shift Control Device Not Configured page 255 85 12 Shift Control Device Incompatible page 261 86 0, 16 High-Voltage Battery 2 Temperature page 265 87 9, 2 CAN ECA Message (HCM) page 269 88 9, 2 CAN Inverter Message (HCM) page 273 89 9, 2 CAN BCU 1 Message (HCM) page 277 90 9, 2 CAN BCU 2 Message (HCM) page 281 91 9 APG Unit 1 - CAN Fault page 285 95 3, 4 12-Volt Cranking Relay page 289 96 2 Accelerator Pedal Offset page 293 97 7, 14 PTO Engagement page 296 101 0, 22–31 High-Voltage Battery 1 page 303 102 22–31 High-Voltage Battery 2 page 307 103 22–26 High-Voltage Battery 1 Control Unit Communication page 311 104 22–26 High-Voltage Battery 2 Control Unit Communication page 315 105 22–30 High-Voltage Battery 1 Control Unit page 319 106 22–30 High-Voltage Battery 2 Control Unit page 323 107 1 High-Voltage Battery Leak Detection page 326 108 3, 4 High-Voltage Batter y 1 Control Unit Power Supply page 336 109 3, 4 High-Voltage Batter y 2 Control Unit Power Supply page 340 110 22–29 Inverter page 344 111 22–26 Inverter Communication page 347 112 3, 4 Inverter Voltage page 351 113 6 Inverter Current page 355 114 3, 4 Inverter Power Supp ly page 360 115 0 Inverter Temperature page 364 116 10, 14 High-Voltage Relays page 369 117 3, 14 BCU Relay Cut Request page 376 118 3, 4, 5 Auxiliary High-Voltage Relay Control Circuit page 381 120 3, 4 APG Unit 1 - AC Voltage page 387 122 6, 14, 15 APG Unit 1 - Output page 390

2015.10.19

TRTS1000 General Information | Fault Code Isolation Procedure Index

Fault Code FMI Description Page Number

123 3, 4, 14 APG Unit 1 - High Voltage Battery page 395 125 0 APG Unit 1 - Over Temperature page 398 126 22–27 APG Unit - Configuration page 401 127 0 APG Unit 1 - Ambient Air Over Temperature page 404 128 3 APG Unit 1 - Ambient Temperature Sensor page 407 129 9 APG Unit 1 - Communication page 410 131 13 APG Unit 1 - Configuration Error page 414

2015.10.19

Symptom-Driven Diagnostics Index | General Information TRTS1000

Symptom-Driven Diagnostics Index

Symptom Isolation Procedure Page Number

Power up no crank and gear display shows a dash “-”

Power up no crank and gear display shows a “N” Engine Crank Test page 422 Power up no crank and gear display shows a

double dash (-- ), double star, (**), or blank Power up vehicle cranks and gear display shows

(-- ), (**), or blank Vehicle acceleration performance is not acceptable Hybrid Performance Test page 426 ServiceRanger doesn’t communicate with vehicle ServiceRanger Test page 429 Transmission will not engage a gear from neutral

and warning tone sounds (solid “N” in gear display)

T ransmission will not move from a stop (solid gear number in gear display)

Transmission will not engage a gear from neutral (flashing gear number in gear display)

Red “Service” light on the Push Button Shift Control is on and blinking

Front Box T est page 418

Power Up Sequence T est page 22

Refer to OEM for gear display issue N/A

Gear Engagement Test page 434

Front Box T est page 418

Fault Code Retrieval and Clearing page 13

Amber “Check Hybrid” light is on Fault Code Retrieval and Clearing page 13 Red “Stop Hybrid” light is on Fault Code Retrieval and Clearing page 13 ePTO mode does not operate as expected ePTO Test page 438

2015.10.19

TRTS1000 General Information | Product Diagnostic Mode (PDM)

Product Diagnostic Mode (PDM)

Product Diagnostic Mode (PDM) is used to help diagnose Inactive codes that may have set during normal driving. This diagnostic mode increases the sensitivity of the fault sensing capabilities.

This procedure tests loose, degraded and intermittent connections. See “Fault Code Isolation Procedure Index” on page 14. Use the Index as a guide to the wiring and connectors associated with the Inactive fault codes. Flex the wiring harness and connectors in an 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). Turn the 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-Way Diagnostic Connector.

3. Select the “View Fault Codes” screen.

PDM only works with the following Inactive codes:

8, 9, 10, 13, 14, 16, 17, 18, 24, 33, 34, 35, 36, 38, 39, 40, 43, 44, 46, 47, 48, 49, 50, 51, 52, 56, 57, 58, 59, 60, 61, 63, 87, 88, 89, 90, 95

4. Perform 2 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 flashes a solid “PD” (Product Diagnostic Mode) and the mode is activated.

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 of Active.

8. If a fault is detected, exit PDM mode and perform the corresponding fault code troubleshooting procedure. See “Fault Code Isolation Procedure Index” on page 14.

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 off.

2015.10.19

Hybrid Light and Gear Display Descriptions | General Information TRTS1000

Hybrid Light and Gear Display Descriptions

All Eaton® hybrid systems use a combination of 3 lights to indicate failures of different operating systems and the ability of the vehicle to drive. These lights include the red “Service” light, amber “Check Hybrid” light, and the red “Stop Hybrid” light.

Red “Service” Light

• Light is located on the Push Button Shift Control

and reads “Service”.

• Light is turned on and off by the Transmission

Electronic Control Unit (TECU) for automated transmissions faults over the High Integrity Link

(HIL).

• Light also comes on momentarily at key on as part

of the TECU self-test.

Amber “Check Hybrid” Light

• Light is located near the middle of the dash. It is

amber and reads “Check Hybrid.”

• Light is turned on and off indirectly by the Hybrid

Control Module (HCM) and directly by the Body Controller over J1939.

• Light is turned on when a hybrid system fault

Active.

• When the amber light is on, the vehicle can still be

driven; however, the vehicle may operate without hybrid electric assist.

Blinking Amber “Check Hybrid” Light

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” light will blink.

• To reset, pull switch out and turn key off for 2 minutes. Continue to the diagnostic test for the fault that is currently Active.

• If the light remains on, go to “Hybrid Diagnostic Procedure” on page 8 and start with step 3 “Retrieve Active Faults with ServiceRanger.”

• There should be an Active Fault Code 76 FMI 4, or Fault Code 116, FMI 10.

“ST” in Gear Display

A “ST” in the gear display indicates a driver-triggered snapshot was recorded. Snapshot is a diagnostic tool that is used to capture specific data at the time a fault occurs. It is triggered through two different means listed below:

• Fault code triggered - Specific faults will trigger the HCM or TECU to capture a snapshot file for later retrieval. This method will not display an “ST” in the gear display.

• 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 and the Up button twice. To capture a HCM snapshot select, Drive or Low and the Up button and the Down button.

Red “Stop Hybrid” Light

• Light is located near the middle of the dash. The light is red and reads “Stop Hybrid”.

• Light is turned on and off indirectly by the HCM and directly by the Body Controller over J1939.

• Light is turned on when a hybrid system fault is

Active.

• When the light is on, vehicle should not be driven. Transport the vehicle to the OEM truck dealership.

“PD” in Gear Display

A “PD” in the gear display indicates the TECU and HCM are in a special diagnostic mode called Product Diagnostic Mode (PDM).For more details on the mode and its operation, see “Product Diagnostic Mode (PDM)” on page 19.

2015.10.19

TRTS1000 General Information | Hybrid Light and Gear Display Descriptions

“CA” in Gear Display

“CA” in gear display indicates HCM is detecting a clutch abuse situation.

• If the HCM detects a clutch abuse situation it will first tone the Push Button Shift Control and flash a “CA” in the gear display.

• If the clutch abuse situation continues, the hybrid system will allow only an electric launch in addition to continuing the tone and the “CA.”

• If the clutch abuse continues while driving, the hybrid system will open the clutch when vehicle speed is below 5 MPH and allow the clutch to cool.

“OS” in Gear Display

“OS” in the gear display indicates the HCM is detecting a motor overspeed situation. The vehicle will upshift in Drive and Low automatically; however , if the vehicle is in manual mode, close to motor overspeed and the driver fails to upshift, the vehicle will:

• Display an “OS” indicating the driver needs to depress the service brake pedal to slow the vehicle; or,

Blank Gear Display

A blank gear display indicates the display has lost power, or the TECU isn’t communicating with the gear display. See “Symptom-Driven Diagnostics Index” on page 18.

• The HCM will either upshift the vehicle or reduce torque to prevent the motor from going overspeed.

“F” in Gear Display

“F” in the gear display indicates the TECU has detected an Active fault. This fault can be accessed with ServiceRanger. See “Fault Code Isolation Procedure Index” on page 14.

Dash “-” in Gear Display

A dash “-” in the gear display indicates the transmission is stuck in gear. See “Symptom-Driven Diagnostics Index” on page 18.

Double Stars “**” in Gear Display

T wo stars “**” in the gear display indicates the gear display has power, but no communication on the data link. See “Symptom-Driven Diagnostics Index” on page 18.

Double Dashes “- -” in Gear Display

Two dashes “- -” in the gear display indicates the gear display has power, and there is no communication present on the data link, or the TECU isn’t communicating with the display. See “Symptom-Driven Diagnostics Index” on page 18.

2015.10.19

Power-Up Sequence Test | Electrical Pretest Procedures TRTS1000

Power-Up Sequence Test

Overview

This test must be performed only when experiencing a “vehicle won’t crank” with a double dash “- -”, double star“

”, or blank gear display. The Electrical Pretest must

be performed prior to this procedure (see “Electrical Pretest” on page 25.)

Detection

The power-up self-check is performed automatically at every key on. Turn key on and watch the “Service” light. If power up stops with the “Service” light constantly on, or it never comes on, self-check has failed.

Fallback

There is no fallback for this concern and the vehicle does not crank if the Transmission Electronic Control Unit (TECU) or Power Supply Harness has failed.

Possible Causes

This may be caused by any of the following:

• TECU Power Supply

• TECU

Additional Tools

• Basic hand tools

• Battery load tester

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

2015.10.19

TRTS1000 Electrical Pretest Procedures | Power -Up Sequence Test

Component Identification

see “Wiring Diagrams” on page 446.

2015.10.19

Power-Up Sequence Test | Electrical Pretest Procedures TRTS1000

Power-Up Sequence Test

Purpose: Perform the Electrical Pretest.

1. Perform the “Electrical Pretest” on page 25.

2. Is problem still present after the Electrical Pretest?

• Yes, replace the Transmission Electronic Control Unit (TECU), then return to the

“Hybrid Diagnostic Procedure” on page 8.

• No, test is complete. Return to the “Hybrid Diagnostic Procedure” on page 8.

2015.10.19

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