Eaton Transmission TRTS1000 User Manual

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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

Electrical Pretest | Electrical Pretest Procedures TRTS1000

Electrical Pretest

Overview

This test must be performed prior to diagnosing certain specific faults. This test verifies the quality of the standard battery system and the main power and ground supplies to the Hybrid Control Module (HCM), Transmission Electronic Control Unit (TECU), and Electronic Clutch Actuator (ECA).

Note: This test is called out in the procedures where it is

required.

Detection

There is no detection process specifically for the basic electrical supply; however , failures of this type are generally detected by the transmission or driver as some other type of fault code or symptom.

Fallback

A weak power supply can cause many issues such as shift performance, power up or failure to crank.

Possible Causes

Low-voltage can be caused by the following:

• Low batteries

• Charging System

• Power harness connections or fuses to TECU, HCM or ECA

Additional Tools

• Basic hand tools

• Battery load tester

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

2015.10.19

Electrical Pretest | Electrical Pretest Procedures TRTS1000

Component Identification

(TECU - Vehicle Interface Connector)

Front View

ECA - 3-Way Connector

(HCM - Vehicle Interface Connector)

ECA -Pack 8-Way Connector

C F

Front View

D E

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

TECU

Battery

TECU Power

TECU Ground

TECU Ignition

HCM

HCM Ignition (Vehicle)

HCM Ground (Vehicle)

HCM Power (Vehicle)

Clutch Ignition (System)

38 36

Neg (-)

Plus (+)

Ignition Relay

ECA

C B

ECA Power

ECA Ground

2015.10.19

TRTS1000 Electrical Pretest Procedures | Electrical Pretest

Electrical Pretest

Purpose: Verify chassis battery voltage.

1. Key off.

2. Inspect starter/battery and Inline fuse holder

connections on Electronic Clutch Actuator (ECA), Hybrid Control Module (HCM) and Transmission Electronic Control Unit (TECU) for integrity.

Note: ECA, HCM and TECU use a 30-amp fuse.

Refer to OEM for locations.

3. Measure voltage across batteries.

• If voltage is 11–13 volts on a 12-volt system,

proceed with battery load test. Repair or replace batteries as required. Go to Step

• If voltage is outside of range, repair or replace batteries and charging system as required. Repeat this step.

Connection Measurement

Starter Battery to ECA Starter Battery to HCM Starter Battery to TECU

Purpose: Verify ECA battery voltage and ignition

status.

1. Key on.

2. Connect ServiceRanger to 9-Way Diagnostic

Connector in the cab.

3. Select the “Data Monitor” option and view the following parameters under the hybrid (clutch actuator) list:

- PID 132 “Clutch Actuator Battery Voltage.”

- PID 160 “Clutch Actuator Ignition Switch Status.” Note: If the clutch parameters can not be viewed on

ServiceRanger, check the power supply to the ECA with a voltmeter.

• If PID 132 is within 0.6 volts of battery voltage and PID 160 reads "1", go to Step

• If either voltage is out of range, repair main power or ignition supply to the ECA. Repeat this step.

Parameter Reading

PID 132 “Clutch Actuator Battery Voltage”

PID 160 “Clutch Actuator Ignition Switch Status”

2015.10.19

Electrical Pretest | Electrical Pretest Procedures TRTS1000

Purpose: Verify HCM battery voltage and ignition

status.

1. Select the “Data Monitor” option and view the following parameters under the HCM list:

- PID 165 “Battery Potential Voltage.”

- PID 166 “Ignition Switch Status.” Note: If the “Battery Potential Voltage” or “Ignition

Switch Status” can not be viewed on ServiceRanger, check the power supply to the HCM with a voltmeter.

• If PID 165 is within 0.6 volts of battery voltage and PID 166 reads "1", go to Step

• If either voltage is out of range, repair the main power or ignition supply to the HCM. Repeat this step.

Parameter Reading

PID 165 “Battery Potential Voltage”

PID 166 “Ignition Switch Status”

Purpose: Verify TECU battery and switched

voltage.

1. Select the “Data Monitor” option and view the following parameters under the hybrid (Transmission) list:

- PID 168 “Battery Potential Voltage.”

- PID 158 “Battery Potential Voltage Switched.” Note: If the “Battery Potential Voltage” or “Battery

Potential Voltage Switched” can not be viewed on ServiceRanger, check the power supply to the TECU with a voltmeter.

• If PID 168 is within 0.6 volts of battery voltage and PID 158 is within 0.6 volts of ignition voltage, test is complete. Return to the fault or symptom procedure that referenced this step.

• If either voltage is out of range, repair main power or ignition supply to the TECU. Repeat this step.

Parameter Reading

PID 168 “Battery Potential Voltage”

PID 158 “Battery Potential Voltage Switched”

2015.10.19

TRTS1000 Electrical Pretes t Procedures | Hybrid Electrical Pretest

Hybrid Electrical Pretest

Overview

This test must be performed prior to diagnosing select hybrid faults. This test verifies the power supply for the Inverter and Battery Control Unit (BCU).

Note: The Electrical Pretest must be performed before the

Hybrid Electrical Pretest.

Note: This test will be called out in the procedures where it

is required.

Detection

There is no detection process specifically for the basic electrical supply; however , failures of this type are generally detected by the hybrid system or driver as some other type of fault code or symptom.

Fallback

Loss of ignition power causes the hybrid system to be inoperable. The vehicle runs under diesel power only.

Possible Causes

Low-voltage can be caused by Power Harness connections from Inverter or BCU.

Additional Tools

• Basic hand tools

• ASTM Class 0 electrical insulating rubber gloves with leather protectors J48603

• Lockout bracket J48506

• Lockout tags

• Battery load tester

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

2015.10.19

Hybrid Electrical Pretest | Electrical Pretest Procedures TRTS1000

Component Identification

14 28

Delphi 56-Way Mating Connector View (Inverter - Low Voltage Connector)

Inverter

Chassis Ground 1

Chassis Ground 2

Inverter Enable

Relay Box Enable

Deutsch 19 - Way Mating Connector View

(PEC - Low Voltage Connector)

123

PEC

HCM (Pin 2)

Ground B

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

DC/DC Converter

Ground

DC/DC Converter 4-Way OEM Connector

2015.10.19

TRTS1000 Electrical Pretes t Procedures | Hybrid Electrical Pretest

Hybrid Electrical Pretest

Purpose: Verify Inverter ground continuity.

1. Perform the Electrical Pretest (see “Electrical

Pretest” on page 25.), then continue to step 2.

2. Key off. Warning: See “High-Voltage Service Shutdown and

Power-Up Procedure” on page 4. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.

3. Disconnect the Inverter 56-Way Connector.

4. Measure resistance from Pin 1 to battery negative

and then from Pin 2 to battery negative:

• If resistance is 0–0.3 ohms from Pin 1 to battery negative and from Pin 2 to battery negative, go to Step

• If resistance is outside of range, repair the Inverter Ground Harness, then repeat this step.

Connection Measurement

Pin 1 to battery negative

Purpose: Verify voltage at Inverter 56-Way

Connector.

1. Connect a multimeter to the Inverter 56-Way Connector Pin 15 and Pin 1.

2. Key on.

3. Observe multimeter voltage reading:

• If voltage is 11–13 volts, go to Step

• If voltage is outside of range, repair the

Harness from the HCM, then repeat this step.

Connection Measurement

Pin 15 to Pin 1

Purpose: Verify continuity of Inverter to PEC

Ground Wire.

1. Key off.

Pin 2 to battery negative

2. Reconnect the Inverter 56-Way Connector.

3. Disconnect the PEC 19-Way Connector.

4. Measure resistance from PEC Pin 7 to battery

negative:

• If resistance from Pin 7 to battery negative is 0–0.3 ohms, go to Step

• If resistance is outside of range, repair the Inverter to PEC Ground Wire, then repeat this step.

Connection Measurement

Pin 7 to battery negative

2015.10.19

Hybrid Electrical Pretest | Electrical Pretest Procedures TRTS1000

Purpose: Verify voltage at PEC 19-Way Connector.

1. Connect a multimeter to the PEC 19-Way

Connector Pin 6 and Pin 7.

2. Key on.

3. Observe multimeter voltage reading.

• If voltage is 11–13 volts, and vehicle has ePTO feature on Push Button, go to Step

• If vehicle does not have ePTO feature, test is

complete. Reconnect PEC 19-Way Connector. See “Fault Code Isolation Procedure Index” on page 14.

• If voltage is outside of range, repair the Power Supply Harness from the Inverter, then repeat this step.

Connection Measurement

6 to 7

Purpose: Verify continuity of DC/DC Ground Wire.

1. Key off.

2. Reconnect PEC 19-Way Connector.

3. Disconnect DC/DC Converter 4-Way Connector.

4. Measure resistance from DC/DC Converter 4-Way

Connector Pin 4 to battery negative:

• If resistance between Pin 4 and battery negative is 0–0.3 ohms, test is complete. Reconnect the 4-Way Connector. See “Fault Code Isolation Procedure Index” on page 14.

• If resistance is outside of range, repair the Ground Harness from the DC/DC Converter to battery negative, then repeat this step.

Connection Measurement

Pin 4 to battery negative

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 1 - Motor/Generator Current Sensor

Fault Code 1 - Motor/Generator Current Sensor

J1939: SA 239 SPN 520225 FMI 0, 6 Overview

The High-Voltage Motor/Generator Assembly is connected to the Inverter Assembly through an AC High-Voltage Cable that contains 3 separate cables. During operation, the Inverter monitors the amperage in the AC cables through a current sensor, which is mounted inside the Inverter. The inductive sensor produces an output based on amperage present in the cables.

Detection

The Inverter ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

Conditions to Set Fault:

• FMI 6 is set when Inverter detects current input from the Motor/Generator greater than 100 amps for 150 MS.

• FMI 0 is set when the Inverter detects current input from the Motor/Generator greater than 200 amps for 0.3 MS.

Fallback

When Fault Code 1 is set the following conditions occurs:

• Amber “Check Hybrid” light illuminates.

• Fault is stored in Hybrid Control Module (HCM) memory.

• Electric Motor/Generator Assist and Regeneration are disabled; however, the high-voltage relays remain powered.

• HCM continues to control the hybrid vehicle in a diesel-only mode.

• Transmission defaults start gear to 1st.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours and the HCM automatically clears the faults from history after the fault has stayed Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

• FMI 0, 6

- Inverter

- Motor/Generator

- AC cable

2015.10.19

Fault Code 1 - Motor/Generator Current Sensor | Fault Isolation Procedures TRTS1000

Component Identification

High-Voltage AC Harness Connector View (Amphenol Connector)

High-Voltage AC Motor/Gen Connector View (Amphenol Connector)

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Inverter Motor/

Generator

Phase 3

Phase 2

Phase 3

Phase 2

Phase 1

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 1 - Motor/Generator Current Sensor Test

Fault Code 1 - Motor/Generator Current Sensor Test

Purpose: Check for fault code status and continuity

of high-voltage circuitry.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

3. Key off. Danger: See “High-Voltage Service Shutdown and

Power-Up Procedure” on page 4. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.

4. Remove the AC Cable from the Motor/Generator and Inverter.

5. Measure resistance of each circuit in the AC High-Voltage Cable Pins A-A, B-B and C-C:

• If resistance for each circuit is less than 1 ohm, go to Step

• If resistance is outside of range, replace the AC High-Voltage Cable, then go to Step

Purpose: Verify continuity of high-voltage circuitry

to ground.

1. Measure resistance of each circuit to ground in the AC High-Voltage Cable:

• If resistance between each circuit and ground is 5M ohms or greater, go to Step

• If resistance is outside of range, replace the AC High-Voltage Cable, then go to Step

Connection Measurement

Pin A to ground

Pin B to ground

Pin C to ground

Connection Measurement

Pin A to Pin A

Pin B to Pin B

Pin C to Pin C

2015.10.19

Fault Code 1 - Motor/Generator Current Sensor Test | Fault Isolation Pro cedures TRTS1000

Purpose: Verify continuity of high-voltage circuitry.

1. Key off.

2. Measure the resistance between the following

AC High-Voltage Cable Pins A-B, B-C and C-A:

• If resistance of each phase is 5M or greater, go to Step

• If resistance is outside of range, replace the AC High-Voltage Cable, then go to Step

Connection Measurement

Pin A to Pin B

Pin B to Pin C

Pin C to Pin A

Purpose: Verify continuity of Motor/Generator

phases.

1. Measure resistance of each Motor/Generator phase at the following Pins: A-B, B-C and C-A:

• If resistance of each phase is less than 10 ohms, replace the Inverter go to Step

• If resistance is outside of range, replace the Motor/Generator

Connection Measurement

Pin A to Pin B

Pin B to Pin C

Pin C to Pin A

, then go to Step V.

, then

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 1 - Motor/Generator Current Sensor Test

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes, see “Clear Inactive Faults” on page 13.

5. Drive the vehicle and attempt to reset the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 1 appears, find error in testing, go to Step

• If a code other than 1 appears, see “Fault Code

Isolation Procedure Index” on page 14.

2015.10.19

Fault Code 2 - Motor/Generator Temperature Sensor | Fault Isolation Procedures TRTS1000

Fault Code 2 - Motor/Generator Temperature Sensor

J1939: SA 239 SPN 520226 FMI 3 Overview

The Motor/Generator Temperature Sensor is a thermistor located inside the Motor/Generator that changes in value based on the temperature. The Inverter supplies a 5-volt 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 low-voltage (0.2 volts equals 536 °F [280 °C]). When the Motor/Generator is cold the sensor resistance is high and the Inverter detects high voltage (4.1 volts equals or 32 °F [0 °C]).

Detection

The following preconditions must be met before the system detects the fault:

• Inverter ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• 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.

Fallback

When Fault Code 2 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates.

• Fault is stored in Hybrid Control Module (HCM) memory.

• High-Voltage Motor/Generator Assist is available, but at a reduced amount.

Conditions to Set Fault Code Inactive

Possible Causes

This fault code can be caused by any of the following:

•FMI 3

- Motor/Generator

- Short/open Temperature Sensor wires between the Motor/Generator and the Inverter

- Inverter

Additional Tools

• Basic hand tools

• ASTM Class 0 electrical insulating rubber gloves with leather protectors J48603

• Lockout bracket J48506

• Lockout tags

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 2 - Motor/Generator Temperature Sensor

Component Identification

Delphi 56-Way Mating Connector View

Temperature Sensor

14 28

(Harness View - Front Side)

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Inverter

TM Ground

Motor/Generator Temperature Sensor

Temp Sensor

2015.10.19

Fault Code 2 - Motor/Generator Temperature Sensor Test | Fault Isolation Procedures TRTS1000

Fault Code 2 - Motor/Generator Temperature Sensor Test

Purpose: Check for fault code status and continuity

of Motor/Generator Temperature Sensor circuit

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

3. Key off.

4. Disconnect the Temperature Sensor Connector at

the Motor/Generator. Warning: See “High-Voltage Service Shutdown and

Power-Up Procedure” on page 4. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.

5. Measure resistance at the Motor/Generator 2-Way T emperature Sensor Connector from Pin A to Pin B:

• If resistance is 0.8K ohms to 301.7K ohms, go to Step

• If resistance is outside of range, replace the Motor/Generator

, then go to Step V.

Purpose: Verify continuity of Inverter and

Motor/Generator Temperature Sensor circuit.

1. Key off.

2. Disconnect the Inverter 56-Way Connector.

3. Reconnect the Motor/Generator 2-Way

Temperature Sensor Connector.

4. Measure resistance at the following:

- Inverter 56-Way Connector Pin 50 to Pin 38

- Inverter 56-Way Connector Pin 50 to ground

Note: Gently flex the Inverter 56-Way Harness

near the Connector while monitoring the resistance values.

• If resistance is 0.8K–301.7K ohms between Pin 50 and Pin 38 and resistance between Pin 50 and ground is 10K ohms or greater, replace the Inverter

• If resistance is outside of range, repair the open or short to ground in the harness between the Inverter 56-Way Connector and the Motor/Generator 2-Way Connector, then go to Step

, then go to Step V.

Connection Measurement

Pin A to Pin B

Connection Measurement

Pin 50 to Pin 38

Pin 50 to ground

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 2 - Motor/Generator Te mperature Sensor Test

Purpose: Verify repair.

1. Key off.

2. Key on.

3. Reconnect all connectors and the negative

battery cable.

4. Clear codes, see “Fault Code Retrieval and Clearing” on page 13.

5. Drive vehicle and attempt to reset the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 2 appears, find error in testing, go to Step

• If a code other than 2 appears, see “Fault Code

Isolation Procedure Index” on page 14.

2015.10.19

Fault Code 3 - Motor/Generator Temperature | Fault Isolation Procedures TRTS1000

Fault Code 3 - Motor/Generator Temperature

J1939: SA 239 SPN 520227 FMI 0 Overview

The Motor/Generator temperature is measured through a thermistor sensor, which is located internal to the unit. The sensor changes value based on the temperature. The Inverter supplies a 5-volt 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 536 °F [280 °C]). When the Motor/Generator is cold, the sensor resistance is high and the Inverter detects a high voltage (4.1 volts equals 32 °F [0 °C]).

Detection

Inverter ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

When the Motor/Generator temperature is warm the sensor resistance is low and the Inverter detects a low-voltage (0.2 volts equals 536 °F [280 °C]). When the Motor/Generator is cold the sensor resistance is high and the Inverter detects a high-voltage (4.1 volts equals 32 °F [0 °C ]).

Fallback

When Fault Code 3 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates.

• Fault is stored in Hybrid Control Module (HCM) memory.

• Electric Motor/Generator Assist and Regeneration are disabled; however, high-voltage relays remain powered.

• HCM continues to control the hybrid vehicle in a diesel-only mode.

• Transmission defaults start gear to 1st.

Conditions to Set Fault Code Inactive

Possible Causes

This fault code can be caused by any of the following:

• FMI 0 (FMI 0 is set when the temperature sensor value is greater than 365 °F [185 °C] for 1 second):

- Motor/Generator

- Inverter

- Liquid cooling system (low coolant, no coolant

flow, Coolant Pump, Radiator, Radiator Fan, reservoir)

Additional Tools

• Basic hand tools

• ASTM Class 0 electrical insulating rubber gloves with leather protectors J48603

• Lockout bracket J48506

• Lockout tags

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature

Component Identification

Delphi 56-Way Mating Connector View

Temperature Sensor

14 28

(Harness View - Front Side)

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Inverter

TM Ground

Motor/Generator Temperature Sensor

Temp Sensor

2015.10.19

Fault Code 3 - Motor/Generator Temperature Test | Fault Isolation Procedures TRTS1000

Fault Code 3 - Motor/Generator Temperature Test

Purpose: Check for Active or Inactive fault code

status.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

Warning: See “High-Voltage Service Shutdown and Power-Up Procedure” on page 4. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.

3. Key on.

4. Find initial temperature by selecting the “Data

Monitor” option and view PID 113 “Motor/Generator Temperature” in the “Power Electronics” list.

5. View PID 113 again after 20 minutes:

• If PID 113 “Motor/Generator Temperature” dropped from the first reading, go to Step

• If PID 113 “Motor/Generator Temperature” remained the same, go to Step

Purpose: Verify level of hybrid system coolant.

1. Key off.

2. Observe the coolant level after the system has

cooled down to ensure if is filled to the proper level:

• If coolant is within the recommended limits, go to Step

• If coolant is below the recommended limits, refer to the OEM for coolant type and fill procedures. Check for source of coolant leak. When refilling the system it should be pressurized or vacuum bleed of air to ensure the coolant flows properly during normal operation.

Purpose: Verify integrity of hybrid cooling system

components.

Time Temperature

Initial check

20 minute

1. Key off.

2. Visually inspect the hybrid liquid cooling system

radiator for debris, obstruction to airflow, or sharp bends in the coolant lines:

• If the radiator is free of debris and the coolant lines are not bent sharply, go to Step

• If the radiator has debris, the air flow is obstructed, or the coolant lines are bent sharply, repair the concern, then go to Step

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature Test

Purpose: Verify operation of hybrid Coolant Pump.

1. Key on.

2. Connect ServiceRanger to the 9-Way Connector in

the cab.

3. Select the Advanced Product Functions option and select the “Cooling Pump” option.

4. Enable the “Cooling Pump” option:

• If the Coolant Pump turns on, go to Step

• If the Coolant Pump does not turn on, go to Step

Purpose: Verify operation of hybrid Heat

Exchanger Fan.

Purpose: Verify voltage at hybrid Coolant Pump.

1. Key on.

2. Disconnect the Coolant Pump 2-Way Connector.

3. Select the “Advanced Products Function” option

and select “Cooling Pump.”

4. Enable the Cooling Pump option.

5. Measure voltage at the 2-Way Connector from

Pin A to Pin B:

• If voltage between Pin A and Pin B is ±0.2 volts of battery voltage, refer to OEM for Coolant Pump concern.

• If voltage between Pin A and Pin B is outside of range, refer to OEM for repair procedures on Cooling Pump Power Harness or damaged fuse.

Connection Measurement

1. Select the Advanced Product Functions option and

select the “Heat Exchanger Fan” option.

2. Enable the Heat Exchanger Fan option:

• If the Heat Exchanger Fan turns on, the system

needs to be purged of air, allowing the coolant to flow. Bleed the air by using a coolant system pressurizing tool or a vacuum tool, then go to Step

• If the Heat Exchanger Fan does not turn on, go to Step

Pin A to Pin B

2015.10.19

Fault Code 3 - Motor/Generator Temperature Test | Fault Isolation Procedures TRTS1000

Purpose: Verify voltage at hybrid Heat Exchanger

Fan.

1. Key on.

2. Disconnect the Heat Exchanger Fan

2-way connector.

3. Select the “Advanced Products Function” option and select the “Heat Exchanger Fan.”

4. Enable the Heat Exchanger Fan option.

5. Measure voltage at the 2-Way Connector from

Pin A to Pin B:

• If voltage between Pin A and Pin B is ±0.2 volts of battery voltage, refer to OEM for Heat Exchanger Fan concern.

• If voltage between Pin A and Pin B is outside of range, refer to OEM for repair procedures on Heat Exchanger Fan Power Harness or damaged fuse.

Connection Measurement

Purpose: Verify continuity of Inverter circuitry.

1. Key off.

2. Disconnect the Inverter 56-Way Connector.

3. Measure resistance between Pin 38 and Pin 50, and

Pin 50 to ground of the Inverter 56-Way Connector.

• If resistance is 0.8K–301.7K ohms between Pin 50 and Pin 38 and resistance between Pin 50 and ground is 10K ohms or greater, replace the Inverter

• If resistance is outside the range, go to Step I.

Connection Measurement

Pin 50 to Pin 38

Pin 50 to ground

, then go to Step V.

Pin A to Pin B

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature Test

Purpose: Verify continuity of Temperature Sensor

circuit.

1. Key off.

2. Disconnect the Motor/Generator Temperature

Sensor 2-Way Connector located on the right side of the Motor/Generator.

3. Measure resistance between the 2-Way T emperature Sensor Connector from Pin A to Pin B:

• If resistance is 0.8K–301.7K ohms, repair the shorted HCM System Harness between the Inverter 56-Way Connector and Motor/Generator 2-Way Connector.

• If resistance is outside the range, replace the Motor/Generator

Connection Measurement

Pin A to Pin B

, then go to Step V.

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and negative

battery cable.

3. Key on.

4. Clear codes, see “Clear Inactive Faults” on page 13.

5. Drive the vehicle and attempt to reset the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 3 appears, find error in testing, go to Step

• If a code other than 3 appears, see “Fault Code

Isolation Procedure Index” on page 14.

2015.10.19

Fault Code 4 - Motor/Generator Rotation Speed Sensor | Fault Isolation Procedures TRTS1000

Fault Code 4 - Motor/Generator Rotation Speed Sensor

J1939: SA 239 SPN 520228 FMI 0, 2, 22–27 Overview

The Motor/Generator Rotation Speed Sensor is mounted to the back of the Motor/Generator around the Input Shaft. The sensor (two-piece design) is a rotor mounted to the Input Shaft and a Sensing Ring mounted to the motor housing. The Sensing Ring is supplied with low-voltage during operation. The rotor turns inducing a voltage fluctuation into the Sensing Ring, which is then converted into a digital signal for Motor/Generator RPM. Voltage output and frequency is low at idle and increases with RPM.

Detection

Fault is detected when:

• Inverter ignition voltage is greater than 7 volts and less than 16 volts.

• FMI 2 does not set if there is an Active Transmission Input Shaft Speed Sensor fault.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• 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 22, 24, 25 are set when the combination of analog-to-digital converter signals are a mismatch.

• FMI 27 is set when the Inverter detects an error during the initial check.

• FMI 23 is set when there is an analog-to-digital converter output error signal for 100 MS.

• FMI 26 is set when the rotation sensor speed is greater than 6000 min-1 for 10 MS.

Fallback

When Fault Code 4 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates.

• Fault is stored in Hybrid Control Module (HCM) memory.

• Electric Motor/Generator Assist and Regeneration are disabled; however, the high-voltage relays remain powered.

• HCM continues to control the hybrid vehicle in a diesel-only mode.

• Transmission defaults start gear to 1st.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours. The HCM automatically clears the faults from history after the fault has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

•FMI 0

- Long extended grades may require intermittent

use of the service brakes to slow the vehicle

• FMI 22, 24, 25, 27

- Inverter

• FMI 2, 23, 26

- Inverter

- Motor/generator

- Resolver Harness between the Motor/Generator

and Inverter

Additional Tools

• Basic hand tools

• ASTM Class 0 electrical insulating rubber gloves with leather protectors J48603

• Lockout bracket J48506

• Lockout tags

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 4 - Motor/Generator Rotation Speed Sensor

Inverter

Motor/Generator Resolver

14 28

Delphi 56-Way Mating Connector View

REZ S1

REZ S4

REZ Plus (+)

REZ Minus (-)

REZ S2

REZ S3

Resolver

Resolver Harness View (Front Side)

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Component Identification

2015.10.19

Fault Code 4 - Motor/Generator Rotation Speed Sensor Test | Fault Isolation Procedures TRTS1000

Fault Code 4 - Motor/Generator Rotation Speed Sensor Test

Purpose: Check for Active or Inactive fault code

status.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

3. Key off. Warning: See “High-Voltage Service Shutdown and

Power-Up Procedure” on page 4. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.

4. Which FMIs are present?

• If FMI 22, 24, 25, or 27 are listed, replace the Inverter

• If FMI 2, 23, or 26 are listed, go to Step B.

• If FMI 0 is listed, Using ServiceRanger select

the Advanced Product Functions and download the TECU and HCM snapshots then contact Eaton® at 1-800-826-HELP (4357).

, then go to Step V.

Purpose: Verify continuity of Resolver and Inverter

components.

1. Disconnect the 56-Way Low-Voltage Connector at the Inverter.

2. Measure Resolver resistance at the 56-Way Harness Connector between the following pins:

- Pin 55 to Pin 56

- Pin 53 to Pin 54

- Pin 51 to Pin 52

Note: Gently flex the Inverter 56-Way Connector

Harness near the Connector while monitoring the resistance values.

Resistance ranges for the pins are:

- Pins 55 to Pin 56: 10.5–8.6 ohms

- Pins 53 to Pin 54: 34–28 ohms

- Pins 51 to Pin 52: 27–23 ohms

• If the above resistances are found, and FMI 2 is Active, contact Eaton at 1-800-826-HELP (4357).

• If the above resistances are found, and FMI 26 or 23 are Active, replace the Inverter then go to Step

• If resistance is outside of range for any of the readings, go to Step

Connection Measurement

Pin 55 to Pin 56

Pin 53 to Pin 54

Pin 51 to Pin 52

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 4 - Motor/Generator Rotation Speed Sensor Test

Purpose: Verify continuity of Resolver Harness

circuitry.

1. Disconnect the 6-Way Motor/Generator Resolver Connector.

2. Measure the Resolver resistance at the 6-Way Harness Connector between the following pins:

- Pin 5 to Pin 6

- Pin 1 to Pin 3

- Pin 2 to Pin 4

Note: An auto-ranging digital Volt/Ohm Meter must

be used.

Resistance ranges for the pins are:

- Pins 5 to Pin 6: 10.5–8.6 ohms

- Pins 1 to Pin 3: 34–28 ohms

- Pins 2 to Pin 4: 27–23 ohms

• If the above resistances are found, repair the open harness between the Inverter 56-Way Connector and the Motor/Generator 6-Way Resolver Connector, then go to Step

• If resistance is outside of range, replace the Motor/Generator

, then go to Step V.

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes, see “Clear Inactive Faults” on page 13.

5. Drive the vehicle and attempt to recreate the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 4 appears, contact Eaton at

1-800-826-HELP (4357).

• If a code other than 4 appears, see “Fault Code Isolation Procedure Index” on page 14.

Connection Measurement

Pin 5 to Pin 6

Pin 1 to Pin 3

Pin 2 to Pin 4

2015.10.19

Fault Code 5 - Motor/Generator AC Cable | Fault Isolation Procedures TRTS1000

Fault Code 5 - Motor/Generator AC Cable

J1939: SA 239 SPN 520229 FMI 22–29 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.

Detection

The following preconditions must be met before the system detects the fault:

• Inverters ignition voltage is greater than 7 volts and less than 16 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 Code Active

The following conditions must be met to set the fault code Active:

• 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 200 MS at speeds greater than or equal to 500 RPM and current command from the Inverter is greater than 20 amps.

• FMI 28 is set when Motor/Generator current is less than 8 amps for 200 MS at speed less than 500 RPM and current command is greater than 20 amps.

• FMI 29 is set during initialization. The Inverter determines if the AC Cable is connected between the motor and Inverter by sending out 20 amps for 200 MS and checking the feedback.

Fallback

When Fault Code 5 is set the following conditions occur:

• Red “Stop Hybrid” light illuminates.

• 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.

• If FMI 28, or 29 is present at power up, the vehicle does not crank.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours. The HCM automatically clears the faults from history after the fault code has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

• FMI 22, 23, 24

- Inverter

- Motor/generator

- AC cable

• FMI 25, 26, 27, 28, 29

- Motor/generator

- AC cable

Additional Tools

• Basic hand tools

• ASTM Class 0 electrical insulating rubber gloves with leather protectors J48603

• Lockout bracket J48506

• Lockout tags

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 5 - Motor/Generator AC Cable

Component Identification

High-Voltage AC Harness Connector View (Amphenol Connector)

High-Voltage AC Motor/Gen Connector View (Amphenol Connector)

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Inverter Motor/

Generator

Phase 3

Phase 2

Phase 3

Phase 2

Phase 1

2015.10.19

Fault Code 5 - Motor/Generator AC Cable Test | Fault Isolation Procedures TRTS1000

Fault Code 5 - Motor/Generator AC Cable Test

Purpose: Check for Active or Inactive fault code

status.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

3. Key off. Warning: See “High-Voltage Service Shutdown and

Power-Up Procedure” on page 4. Follow the procedures to avoid shock, burn or death from improperly handled high-voltage.

4. Which faults are present?

• If Fault Code 5 FMI 22, 23, or 24 are Active, go to Step

• If Fault Code 5 FMI 25, 26, 27, 28, or 29 are Active, go to Step

Purpose: Verify continuity of high-voltage cable.

1. Key off.

2. Remove the AC high-voltage cable at the

Motor/Generator and Inverter.

3. Measure the resistance between the following AC cable pins:

- Pin A to Pin B

- Pin B to Pin C

- Pin C to Pin A

• If resistance between each phase is 5M ohms or greater, replace the Inverter Step

• If resistance is outside of range, replace the AC high-voltage cable, then go to Step

Connection Measurement

Pin A to Pin B

, then go to

Pin B to Pin C

Pin C to Pin A

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 5 - Motor/Generator AC Cable Test

Purpose: Verify continuity of high-voltage cable.

1. Disconnect the AC high-voltage cable from the

Inverter and Motor/Generator.

2. Measure the resistance of the AC High-Voltage Cable from the Inverter Connector to the Motor/Generator Connector on each of the following pins:

- Pin A to Pin A

- Pin B to Pin B

- Pin C to Pin C

Note: An auto-ranging digital Volt/Ohm Meter must

be used.

• If the resistance of each circuit is 1 ohm or less, go to Step

• If resistance is outside of range, replace the AC High-Voltage Cable, then go to Step

Connection Measurement

Purpose: Verify continuity of high-voltage cable.

1. Measure the resistance of each Motor/Generator

phase at the following pins:

- Pin A to Pin B

- Pin B to Pin C

- Pin C to Pin A

Note: An auto-ranging digital Volt/Ohm Meter must

be used.

• If the resistance of each phase is 10 ohms or less, replace the Inverter

• If resistance is outside of range, replace the Motor/Generator

Connection Measurement

Pin A to Pin B

Pin B to Pin C

, then go to Step V.

Pin A to Pin A

Pin B to Pin B

Pin C to Pin C

Pin C to Pin A

2015.10.19

Fault Code 5 - Motor/Generator AC Cable Test | Fault Isolation Procedures TRTS1000

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes, see “Clear Inactive Faults” on page 13.

5. Drive the vehicle and attempt to reset the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 5 appears, find error in testing, go to Step

• If a code other than 5 appears, see “Fault Code

Isolation Procedure Index” on page 14.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 6 - No HCM Operation

Fault Code 6 - No HCM Operation

J1939: SA239 SPN 629 FMI 12, 14 Overview

The Hybrid Control Module (HCM) is mounted to the transmission and it contains all of the software to control both the hybrid power electronics as well as the transmission operation.

Detection

The following preconditions must be met before the system detects the fault:

• HCM ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 12 is set at key on if the HCM detects an internal failure.

• FMI 14 is set when HCM can not complete write of EEPROM during shut down.

Fallback

When Fault Code 6 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates if the HCM sets the fault after power up.

• If the fault occurs at power up the vehicle may not crank.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours. The HCM automatically clears the faults from history after the fault has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

• FMI 12, 14: HCM

Additional Tools

• Basic hand tools

• ServiceRanger

2015.10.19

Fault Code 6 - No HCM Operation | Fault Isolation Procedures TRTS1000

Component Identification

Note: No Schematic for this code. Note: For component location refer to the OEM service literature.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 6 - No HCM Operation T est

Fault Code 6 - No HCM Operation Test

Purpose: Check for Active and Inactive fault code

status.

1. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector:

• If Fault Code 6 is Active, replace the Hybrid Control Module (HCM).

• If Fault Code 6 is Inactive, test is complete.

2015.10.19

Fault Code 7 - Improper HCM Configuration | Fault Isolation Procedures TRTS1000

Fault Code 7 - Improper HCM Configuration

J1939: SA 239 SPN 629 FMI 13 Overview

The Hybrid Control Module (HCM) is mounted to the transmission and contains all of the software to control both the hybrid power electronics as well as the transmission operation.

Detection

The following preconditions must be met before the system detects the fault:

• HCM ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 13 is set at key on if the HCM data is not read from memory within 1 second.

Fallback

When Fault Code 7 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates.

• Fault is stored in HCM memory.

• If this fault occurs at power up, the vehicle does not crank.

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears faults from history after 200 hours. The HCM automatically clears faults from history after the fault has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

• FMI 13: Improper ECU configuration software

Additional Tools

• Basic hand tools

• ServiceRanger

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 7 - Improper HCM Configuration

Component Identification

Note: No Schematic for this code. Note: For component location refer OEM service literature.

2015.10.19

Fault Code 7 - Improper HCM Configuration | Fault Isolation Procedures TRTS1000

Fault Code 7 - Improper HCM Configuration

Purpose: Check for Active or Inactive fault code

status.

1. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

2. Turn ignition off for 2 seconds.

3. Key on:

• If Fault Code 7 is Active, replace the Hybrid Control Module (HCM).

• If Fault Code 7 is Inactive, test is complete.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 8 - Loss of Switched Ignition Power (HCM)

Fault Code 8 - Loss of Switched Ignition Power (HCM)

J1939: SA 239 SPN 158 FMI 4 Overview

The Hybrid Control Module (HCM) is mounted to the transmission and contains all of the software to control both the hybrid power electronics as well as the transmission operation. The HCM ignition power is a fused, single 12-volt feed that runs through the HCM 38-Way Vehicle Connector.

Detection

The following preconditions must be met before the system detects the fault:

• Output Shaft speed must be greater than 0 RPM.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 4 is set when the HCM loses ignition power during operation for 2 seconds or greater.

Note: When troubleshooting an Inactive code refer to the

“Product Diagnostic Mode (PDM)” on page 19.

Fallback

When Fault Code 8 is set the following conditions occurs:

• Amber “Check Hybrid” light illuminates only if the vehicle is moving.

• Fault is stored in HCM memory.

• Red “Service” light illuminates and an “F” flashes in the gear display, if the fault occurs prior to power up.

- Fault is stored in Transmission Electronic

Control Unit (TECU) memory due to lack of communication with the HCM.

• If fault occurs while the vehicle is moving, the transmission remains in place and the clutch opens when the vehicle comes to an idle. The clutch closes and the vehicle will operate in 1st and reverse from stop.

• If this fault occurs at power up, the vehicle does not crank.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the TECU or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours. The HCM automatically clears a fault from history after that fault has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

•FMI 4

- Ignition Power Supply to HCM

-HCM

Additional Tools

• Basic hand tools

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

2015.10.19

Fault Code 8 - Loss of Switched Ignition Power (HCM) | Fault Isolation Procedures TRTS1000

HCM

35Ignition

Front Harness View

(HCM - Vehicle Interface Connector)

Typical Relay Switch

Ignition Relay

Ground

Vehicle Ignition

12V Truck Battery

12V Plus

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Component Identification

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 8 - Loss of Switched Ignition Power (HCM) Test

Fault Code 8 - Loss of Switched Ignition Power (HCM) Test

Purpose: Check for Active or Inactive fault code

status and perform electrical pretest.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

3. Perform the “Electrical Pretest” on page 25:

• If Fault Code 8 is Active after performing the Electrical Pretest, replace the Hybrid Control Module (HCM), then go to Step V.

• If Fault Code 8 is Inactive after performing the Electrical Pretest, go to Step

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes, see “Clear Inactive Faults” on page 13.

5. Drive the vehicle and attempt to reset the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 8 appears, find error in testing, go to Step

• If a code other than 8 appears, see “Fault Code

Isolation Procedure Index” on page 14.

2015.10.19

Fault Code 9 - Weak Battery Voltage | Fault Isolation Procedures TRTS1000

Fault Code 9 - Weak Battery Voltage

J1939: SA 239 SPN 168 FMI 14 Overview

The Hybrid Control Module (HCM) is mounted to the transmission and contains all of the software to control both the hybrid power electronics as well as the transmission operation. The HCM main battery power is fused 12-volt feed that runs through the HCM 38-Way Vehicle Connector with the main ground wire returning to the battery negative terminal.

Detection

The following preconditions must be met before the system detects the fault:

• HCM ignition voltage is greater than 7 volts and less than 16 volts.

• HCM System Battery Voltage Low Fault is Inactive.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 14 is set when the HCM battery voltage drops below 9 volts for 10 seconds.

Note: When troubleshooting an Inactive code refer to the

“Product Diagnostic Mode (PDM)” on page 19.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the faults from history after 200 hours. The HCM automatically clears a fault from history after that fault has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

• FMI 14

- Power Supply Harness to the HCM

- Low batteries or bad main power connection

- Charging system

Additional Tools

• Basic hand tools

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

Fallback

When Fault Code 9 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates.

•

Red “Hybrid additional fault codes caused by the low or weak voltage. This feature was added with HCM Software 1107 and higher.

• Fault is stored in HCM memory.

Stop” lamp will display if there are

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 9 - Weak Battery Voltage

HCM

Harness Front View

(HCM - Vehicle Interface Connector)

Typical Relay Switch

Ignition Relay

12V Truck Battery

12V Plus

VBATT

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

HCM Ground

Component Identification

2015.10.19

Fault Code 9 - Weak Battery Voltage | Fault Isolation Procedures TRTS1000

Fault Code 9 - Weak Battery Voltage

Purpose: Check for Active or Inactive fault code

status and perform Electrical Pretest.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

3. Perform the “Electrical Pretest” on page 25:

• If Fault Code 9 is Active after performing the Electrical Pretest, replace the Hybrid Control Module (HCM), then go to Step V.

• If Fault Code 9 is Inactive after performing the

Electrical Pretest, clear codes (see “Clear Inactive Faults” on page 13.) Go to Step

Purpose: Verify repair.

1. Key off.

2. Key on.

3. Clear codes, see “Clear Inactive Faults” on page 13.

4. Reconnect all connectors and the negative

battery cable.

5. Drive the vehicle and attempt to reset the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 9 appears, find error in testing, go to Step

• If a code other than 9 appears, see “Fault Code

Isolation Procedure Index” on page 14.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 10 - Low Battery Voltage (HCM)

Fault Code 10 - Low Battery Voltage (HCM)

J1939: SA 239 SPN 168 FMI 4 Overview

The Hybrid Control Module (HCM) is mounted to the transmission and contains the software that controls both the hybrid power electronics as well as the transmission operation. The HCM main battery power is a fused, 12-volt feed and runs through the HCM 38-Way Vehicle Connector with the main ground wire returning to the battery negative terminal.

Detection

The following preconditions must be met before the system detects the fault:

• HCM ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 4 is set when the HCM battery voltage drops below 7 volts for more than 1 second.

Note: When troubleshooting an Inactive code refer to the

“Product Diagnostic Mode (PDM)” on page 19

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears the fault from history after 200 hours. The HCM automatically clears a fault from history after it has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

•FMI 4

- Power Supply Harness to the HCM.

- Low batteries or bad main power connection.

- Charging system.

Additional Tools

• Basic hand tools

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

Fallback

When Fault Code 10 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates. Red “Hybrid

• additional fault codes caused by the low or weak voltage. This feature was added with HCM Software 1107 and higher.

• Fault is stored in HCM memory.

Stop” lamp will display if there are

2015.10.19

Fault Code 10 - Low Battery Voltage (HCM) | Fault Isolation Procedures TRTS1000

HCM

Harness Front View

(HCM - Vehicle Interface Connector)

Typical Relay Switch

Ignition Relay

12V Truck Battery

12V Plus

VBATT

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

HCM Ground

Component Identification

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 10 - Low Battery Voltage (HCM) T est

Fault Code 10 - Low Battery Voltage (HCM) Test

Purpose: Check for Active or Inactive fault code

status and perform Electrical Pretest.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active viceRanger using the 9-Way Diagnostic Connector.

3. Perform the “Electrical Pretest” on page 25:

• If Fault Code 10 is Active after performi Electrical Pretest, replace the H Module (HCM), then go to Step V.

• If Fault Code 10 is Inactive after performing

the Electrical Pretest, Faults” on page

fault codes and FMIs with Ser-

ng the

ybrid Control

see “Clear

13. Go to Step

Inactive

Purpose: Verify repair.

1. Key off.

2. Key on.

3. Clear codes, see “Clear Inactive Faults” on page 13.

4. Reconnect all connectors

y cable.

batter

5. Drive the vehicle and attempt to reset the code.

6. Check for codes, see “View Active and

Faults” on pag

• If no codes, test is complete.

• If Fault Code 10 appears, find error in testing,

• If a code other than 10 appears, see “Fault Code Isolat

to Step

e 13.

ion Procedure Index” on page 14.

and the negative

Inactive

2015.10.19

Fault Code 11 - No TECU Operation | Fault Isolation Procedures TRTS1000

Fault Code 11 - No TECU Operation

J1587:MID 130 SID 254 FMI 12 J1939: SA 3 SPN 629 FMI 12

Overview

The Transmission Electronic Control Unit (TECU) is mounted to the transmission and contains all of the software to control the transmission; however, the hybrid Control Module (HCM) controls the operation of the TECU during hybrid operation.

Detection

The following preconditions must be met before the system detects the fault:

• TECU ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 12 is set if the TECU detects an intermittent failure in the Electronic Shifter position.

Fallback

When Fault Code 11 is set the following conditions occur:

• Red “Service” light illuminates and an “F” flashes in the gear display (only if the fault occurs after power up).

• Fault is stored in TECU memory.

• If the fault code occurs after power up, the transmission remains in the current gear and the clutch opens.

Conditions to Set Fault Code Inactive

Possible Causes

This fault code can be caused by any of the following:

• FMI 12: Electric Shifter

Additional Tools

• Basic hand tools

• ServiceRanger

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 11 - No TECU Operation

Component Identification

Note: No Schematic for this code. Note: For component location refer to the OEM service literature.

2015.10.19

Fault Code 11 - No TECU Operation Test | Fault Isolation Procedures TRTS1000

Fault Code 11 - No TECU Operation Test

Purpose: Check for Active or Inactive fault code

status.

1. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector:

• If Fault Code 11 is Active, replace the Electric Shifter.

• If Fault Code 11 is Inactive, test is complete.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 12 - Improper TECU Configuration

Fault Code 12 - Improper TECU Configuration

J1587: MID130 SID 254 FMI 13 J1939: SA 3 SPN 629 FMI 13

Overview

The Transmission Electronic Control Unit (TECU) is mounted to the transmission and contains all of the software to control the transmission operation; however, the Hybrid Control Module (HCM) controls the operation of the TECU during hybrid operation.

Detection

The following preconditions must be met before the system detects the fault:

• TECU is powered and ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 13 is set when the TECU is not reading valid information from memory, including the transmission table and calibration values within 1 second of power up.

Fallback

When Fault Code 12 is set the following conditions occur:

• Red “Service” light illuminates and “F” flashes in the gear display.

• If the fault occurs at power up the vehicle does not crank.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the TECU or HCM history using ServiceRanger. The TECU automatically clears the fault from history after 200 hours. The HCM automatically clears the fault from history after it has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

• FMI 13: Improper TECU configuration software

Additional Tools

• Basic hand tools

• ServiceRanger

2015.10.19

Fault Code 12 - Improper TECU Configuration | Fault Isolation Procedures TRTS1000

Component Identification

Note: No Schematic for this code. Note: For component location refer to the OEM service literature.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 12 - Improper TECU Configuration Test

Fault Code 12 - Improper TECU Configuration Test

Purpose: Check for Active or Inactive fault code

status.

1. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector:

• If Fault Code 12 is Active, replace the

Transmission Electronic Control Unit (TECU)

• If Fault Code 12 is Inactive, test is complete.

2015.10.19

Fault Code 14 - Invalid Shifter Range | Fault Isolation Procedures TRTS1000

Fault Code 14 - Invalid Shifter Range

J1587: MID 130 SID 18, 19 FMI 2, 3, 4 J1939: SA 3 SPN 751 FMI 2, 3, 4

Overview

The Transmission Electronic Control Unit (TECU) is connected to the shift device, which transmits driver mode selection data. The only compatible shift devices are the Eaton® Push Button Shift Control (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.

Detection

The following preconditions must be met before the system detects the fault:

• TECU ignition voltage is greater than 7 volts and

less than 16 volts.

• TECU System Battery Voltage Low Fault is Inactive.

• TECU is being powered up for the first time and no

shift device has been configured.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 2 is set when the shifter is not returning a

valid position (PRNDH1)

• FMI 3 is set when the sensor voltage is higher

than expected

• FMI 4 is set when the sensor voltage is lower

than expected

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the TECU or HCM history using ServiceRanger. The TECU automatically clears faults from history after 200 hours. The HCM automatically clears a fault from history after it has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

• FMI 2: Shifter is in between detent positions or sensor is out of calibration.

• FMI 3: Sensor input is shorted high or sensor ground in open

• FMI 4: Sensor input is open circuit or shorted to ground

Additional Tools

• Basic hand tools

• Eaton Test Adapter Kit

• Digital Volt/Ohm Meter

• ServiceRanger

Fallback

When Fault Code 14 is set the following conditions occur:

• “F” appears in the gear display.

• Fault is stored in TECU memory.

• TECU changes to AutoShift control.

• Engine does not crank.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 14 - Invalid Shifter Range

Harness Front View

(TECU - Vehicle Interface Connector)

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Park Pawl

Actuator

Park Pawl Actuator

Shift Return (Minus)

Shift Control Input 1

Shift Control (Plus)

Shift Control Input 2

TECU

4-way Park Pawl Actuator

Connector

Component Identification

2015.10.19

Fault Code 14 - Invalid Shifter Range Test | Fault Isolation Procedures TRTS1000

Fault Code 14 - Invalid Shifter Range Test

Purpose: Verify supply voltage at Shift Lever.

1. Review and follow the “Warnings & Cautions” on

page 1.

2. Disconnect the 4-Way Connector to the Park Pawl Actuator.

3. Key on.

4. Check for 12-volt supply at 4-Way Connector at

Pin 1 and Pin 2:

• If voltage between Pin 1 and Pin 2 is ±0.2 volts of battery voltage, go to Step

• If voltage is outside the range, go to Step D.

Connection Measurement

Pin 1 to Pin 2

Purpose: Verify voltage of Shift Lever in neutral po-

sition.

1. With the Actuator/Shift Lever in neutral, check voltage on the following pins:

- Pin 3 to ground

- Pin 4 to ground

• If voltage is between 2.25–2.75, go to Step

• If voltage is outside the range, replace the Park Pawl Mechanism Sensor, then go to Step V.

Connection Measurement

Pin 3 to ground

Pin 4 to ground

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 14 - Invalid Shifter Range Test

Purpose: Verify continuity of TECU Harness.

1. Disconnect the TECU Vehicle Harness

38-way connector.

2. Check continuity between:

- 38-Way Connector Pin 15 and 4-Way Connector

Pin 4

- 38-Way Connector Pin 16 and 4-Way Connector Pin 3

• If continuity is complete, replace the

Transmission Electronic Control Unit (TECU) then go to Step

• If an open is found, repair the Vehicle Harness,

then go to Step

Connection Measurement

Pin 15 to Pin 4

Pin 16 to Pin 3

Purpose: Verify continuity of TECU Harness.

1. Disconnect the TECU Vehicle Harness

38-way connector.

2. Check continuity between:

- 38-Way Connector Pin 17 and 4-Way Connector

Pin 1

- 38-Way Connector Pin 31 and 4-Way Connector Pin 2

• If continuity is complete, replace the

Transmission Electronic Control Unit (TECU) then go to Step

• If an open is found, repair the Vehicle Harness,

then go to Step

Connection Measurement

Pin 17 to Pin 1

Pin 31 to Pin 2

2015.10.19

Fault Code 14 - Invalid Shifter Range Test | Fault Isolation Procedures TRTS1000

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors.

3. Key on.

4. Clear Codes, see “Clear Inactive Faults” on page 13.

5. Drive the vehicle and attempt to reset the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 14 appears, find error in testing, go to Step

• If a fault code other than 14 appears, see

“Fault Code Isolation Procedure Index” on page 14.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL) Test

Fault Code 16 - High Integrity Link (HIL) Test

J1939: SA 3 SPN 625 FMI 2 J1587: MID 130 SID 248 FMI 2

Overview

The High Integrity Link (HIL) is a high-speed twisted pair 500K proprietary data link that connects the Transmission Electronic Control Unit (TECU) to the Push Button Shift Control (PBSC). Each module contains an internal 120 ohm resistor. The HIL carries information such as driver mode selection and fault information to illuminate the “Service” light.

Detection

The following preconditions must be met before the system detects the fault:

• TECU ignition voltage is greater than 7 volts and less than 16 volts.

• TECU System Battery Voltage Low Fault is Inactive.

• TECU driver interface configuration is set to HIL.

Conditions to Set Fault Code Active

FMI 2 is set when the TECU loses communication for 5 seconds or more with the PBSC.

Note: When troubleshooting an Inactive code refer to the

“Product Diagnostic Mode (PDM)” on page 19.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the TECU or HCM history using ServiceRanger. The TECU automatically clears faults from history after 200 hours. The HCM automatically clears faults from history after that fault has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

•FMI 2

- HIL Data Link

-PBSC

-TECU

- Power Supply Harness from TECU to PBSC

Additional Tools

• Basic hand tools

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

Fallback

When Fault Code 16 sets the following conditions occur:

• An “F” appears in the gear display.

• Push Button Mode Light flashes next to the selected mode and the “Service” light remains off.

• Push Button lights come on and then remains off if the data link fails at power up.

• Fault is stored in TECU memory.

• Operation mode changes to AutoShift Fallback mode.

• If the code is Active during power up, transmission does not engage a gear.

• If the fault is Active while driving, transmission remains in the current gear. It then shifts into the default gear once the vehicle stops. Clutch opens at idle and closes if the throttle is pressed. The vehicle moves into the default start gear only.

2015.10.19

Fault Code 16 - High Integrity Link (HIL) Test | Fault Isolation Procedures TRTS1000

Harness Front View

TECU - Vehicle Interface Connector

Harness Front View

Push Button Shift Control Connector

ABCD

1 2 3

TECU

PBSC

HIL Low

HIL High

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Shift Power (-)

Shift Power (+)

HIL Low

HIL High

Shift Power (-)

Shift Power (+)

Component Identification

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL) Test

Fault Code 16 - High Integrity Link (HIL) Test

Purpose: Check for Active or Inactive fault code

status.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector.

3. Key on and observe the red Push Button “Service” light.

• If the red “Service” light turns on, go to Step

• If the red “Service” light does not turn on, go to Step

Purpose: Verify voltages at Vehicle Harness.

Purpose: Verify voltage at Push Button Shift Con-

troller.

1. Key off.

2. Disconnect the 30-Way Push Button Shift

Control Connector.

3. Key on.

4. Connect voltmeter leads to Pin F1 and Pin F2. Note: Make sure the Volt/Ohm Meter is on the

proper scale (around 10 volts AC).

• If the voltage is 0.10 volts AC or greater, replace the Shift Control is Active), then go to Step

• If the voltage is out of range, go to Step F.

Connection Measurement

Pin F1 to Pin F2

(only if fault code

1. Disconnect Shift Control 30-Way Connector.

2. Key on.

3. Measure voltage on 30-Way Connector between

Pin J3 and Pin C1.

• If voltage is within 0.6 volts of battery voltage, go to Step

• If out of range, go to Step D.

Connection Measurement

Pin J3 to Pin C1

2015.10.19

Fault Code 16 - High Integrity Link (HIL) Test | Fault Isolation Procedures TRTS1000

Purpose: Verify continuity from Vehicle Harness to

Push Button Shift Controller.

1. Key off.

2. Disconnect negative battery cable.

3. Disconnect Vehicle Harness 38-Way Connector. Note: On Peterbilts, disconnect gear display.

4. Measure resistance between:

- Shift Control 30-Way Connector Pin J3 and

Vehicle Harness 38-Way Connector Pin 25.

• If resistance between Pin J3 and Pin 25 is 0–0.3 ohms, go to Step

• If any of the above conditions are not met, repair the Vehicle Harness between the Shift Control and TECU, then go to Step

Connection Measurement

Pin J3 to Pin 25

Purpose: Verify continuity from Push Button Shift

Controller circuits to ground.

1. Key off.

2. Measure the resistance between:

- Shift Control 30-Way Connector Pin C1

and Vehicle Harness 38-Way Connector Pin 31.

- Shift Control 30-Way Connector Pin C1 and ground.

• If resistance between Pin C1 and Pin 31 is

0–0.3 ohms and resistance between Pin C1 and ground is 10K ohms or greater, replace

Transmission Electronic Control Unit (TECU)

(Only if Fault Code is Active).

• If any of the above conditions are not met,

repair the Vehicle Harness between the TECU and Shift Control, then go to Step

Connection Measurement

Pin C1 to Pin 31

Pin C1 to ground

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL) Test

Purpose: Verify continuity from Push Button Shift

Controller circuits to ground.

1. Key off.

2. Disconnect negative battery cable.

3. Disconnect Vehicle Harness 38-Way Connector.

4. Measure resistance between:

- Shift Control 30-Way Connector Pin F1

and Vehicle Harness 38-Way Connector Pin 28.

- Shift Control 30-Way Connector Pin F1 and ground.

• If resistance between Pin F1 and Pin 28 is

0–0.3 ohms and if resistance between Pin F1 and ground is 10K ohms or greater, go to Step

• If any of the above conditions are not met,

repair the Vehicle Harness between the Shift Control and TECU, then go to Step

Connection Measurement

Purpose: Verify continuity from Vehicle Harness to

Push Button Shift Controller.

1. Key off.

2. Measure resistance between:

- Shift Control 30-Way Connector Pin F2 and

Vehicle Harness 38-Way Connector Pin 27.

- Shift Control 30-Way Connector Pin F2 and ground.

• If resistance between Pin F2 and Pin 27 is

0–0.3 ohms and resistance between Pin F2 and ground is 10K ohms or greater, replace

Transmission Electronic Control Unit (TECU) (Only if Fault Code is Active). Go to Step

• If any of the above conditions are not met,

repair the Vehicle Harness between the Shift Control and TECU, then go to Step

Connection Measurement

Pin F2 to Pin 27

Pin F1 to Pin 28

Pin F1 to ground

Pin F2 to ground

2015.10.19

Fault Code 16 - High Integrity Link (HIL) Test | Fault Isolation Procedures TRTS1000

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and negative

battery cable.

3. Key on.

4. Clear codes, see “Clear Inactive Faults” on page 13.

5. Drive the vehicle and attempt to reset the code.

6. Check for codes see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 16 appears, find error in testing, go to Step

• If a code other than 16 appears, see “Fault

Code Isolation Procedure Index” on page 14.

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 17 - Start Enable Relay

Fault Code 17 - Start Enable Relay

J1939:SA 3 SPN 626 FMI 3, 4 J1587:MID 130 SID 237 FMI 3, 4

Overview

The Start Enable Relay is wired into the Transmission Electronic Control Unit (TECU) on the coil side of the relay. At key on, the HCM determines which starting method to use (high-voltage Motor/Generator or Engine Starter). If the HCM uses the standard engine Starter , the 12-volt Cranking Relay is energized supplying battery power to the Start Enable Relay main feed, which then powers the Starter Solenoid.

Detection

The following preconditions must be met before the system detects the fault:

• Transmission Electronic Control Unit (TECU) ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 3 is set when the TECU detects an open or short in the control circuit of the Start Enable Relay for 1 second or greater.

• FMI 4 is set if the TECU detects a short to ground in the control circuit of the Start Enable Relay for 1 second or greater .

Conditions to Set Fault Code Inactive

Possible Causes

This fault code can be caused by any of the following:

• FMI 3, 4

- Loose or corroded connections, bent or burnt pins, short to ground, open, or short to VBATT on the circuit.

- Start Enable Relay

-TECU

Additional Tools

• Basic hand tools

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

Note: When troubleshooting an Inactive code refer to the

“Product Diagnostic Mode (PDM)” on page 19.

Fallback

When Fault Code 17 is set the following conditions occur:

• Red “Service” light illuminates and an “F” flashes in the gear display.

• Fault is stored in TECU memory.

• If the fault sets at power up the engine still cranks, provided the high-voltage batteries have a sufficient State of Charge (SOC).

• If the fault sets while driving, the vehicle continues to operate.

2015.10.19

Fault Code 17 - Start Enable Relay | Fault Isolation Procedures TRTS1000

Front Harness View

(TECU - Vehicle Interface Connector)

TECU

Start Enable Relay

Start Enable Minus

Start Enable Plus

Typical Relay Switch

NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations

Component Identification

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 17 - Start Enable Relay Test

Fault Code 17 - Start Enable Relay Test

Purpose: Check for Active or Inactive fault code

status.

1. Review and follow the “Warnings & Cautions” on page 1.

2. Retrieve Active fault codes and FMIs with ServiceRanger using the 9-Way Diagnostic Connector. View FMIs present.

3. Exchange the current Start Enable Relay with another relay and see if fault returns:

• If fault does not return with new relay, replace the Start Enable Relay (only if fault code is Active), then go to Step

• If fault returns with new relay, go to Step B.

Purpose: Verify FMI set.

Purpose: Verify continuity of Transmission

Harness circuits.

1. Key off.

2. Disconnect negative battery cable.

3. Disconnect the Transmission Harness

38-way connector.

4. Measure resistance between Vehicle Harness 38-Way Connector Pin 32 and Pin 4:

• If resistance between Pin 32 and Pin 4 is 40–120 ohms, go to Step

• If resistance is outside of range, repair the Vehicle Harness for an open circuit, then go to Step

Connection Measurement

Pin 32 to Pin 4

1. Which FMIs were listed from Step A?

• If FMI 3 is listed, go to Step

• If FMI 4 is listed, go to Step E.

2015.10.19

Fault Code 17 - Start Enable Relay Test | Fault Isolation Procedu res TRTS1000

Purpose: Verify voltages at Transmission Harness.

1. Key on.

2. Measure voltage between Vehicle Harness 38-Way

Connector Pin 32 and ground: Note: The voltage reads 5 volts for only

1–2 seconds.

• If the voltage between Pin 32 and ground is 5 volts, replace the Transmission Electronic Control Unit (TECU) (only if fault code is Active), then go to Step

• If the voltage between Pin 32 and ground is 12 volts, repair the short to VBATT on the harness. Voltage should remain at 5 volts for 1–2 seconds after initial key on. Go to Step

Connection Measurement

Pin 32 to ground

Purpose: Verify continuity of Transmission

Harness circuits to ground.

1. Key off.

2. Disconnect battery cable.

3. Disconnect the Transmission Harness

38-Way Connector.

4. Measure the resistance between Vehicle Harness 38-Way Connector Pin 32 and ground:

• If the resistance between 32 and ground is 10K ohms or greater, replace the Transmission Electronic Control Unit (TECU) (only if fault code is Active), then go to Step

• If the resistance is outside of range, repair the Vehicle Harness for a short to ground, then go to Step

Connection Measurement

Pin 32 to ground

2015.10.19

TRTS1000 Fault Isolation Procedures | Fault Code 17 - Start Enable Relay Test

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and negative

battery cable.

3. Key on.

4. Clear codes, see “Clear Inactive Faults” on page 13.

5. Drive the vehicle and attempt to reset the code.

6. Check for codes, see “View Active and Inactive

Faults” on page 13.

• If no codes, test is complete.

• If Fault Code 17 appears, find error in testing, go to Step

• If a code other than 17 appears, see “Fault

Code Isolation Procedure Index” on page 14.

2015.10.19

Fault Code 18 - ECA Communication | Fault Isolation Procedures TRTS1000

Fault Code 18 - ECA Communication

J1939: SA 239 SPN 520200 FMI 2, 9 Overview

The Electric Clutch Actuator (ECA) controls the position of the clutch assembly. The ECA communicates with the Hybrid Control Module (HCM) over the proprietary Controller Area Network (CAN) data link to change position, show faults or transmit other operation information.

Detection

The following preconditions must be met before the system detects the fault:

• HCM ignition voltage is greater than 7 volts and less than 16 volts.

• ECA ignition voltage is greater than 8.5 volts.

• HCM CAN data link error is Inactive.

Conditions to Set Fault Code Active

The following conditions must be met to set the fault code Active:

• FMI 9 is set when the ECA loses communication on the CAN Data Link for 2 seconds.

Fallback

When Fault Code 18 is set the following conditions occur:

• Red “Stop Hybrid” light illuminates.

• Fault is stored in HCM memory.

• ECA maintains current clutch position or moves to the last position commanded by the HCM. Upon approaching idle, the clutch opens and remains in this state.

• If the fault occurs at power up, the vehicle does not crank.

Conditions to Set Fault Code Inactive

Only Inactive faults can be cleared from the Transmission Electronic Control Unit (TECU) or HCM history using ServiceRanger. The TECU automatically clears faults from history after 200 hours. The HCM automatically clears a fault from history after that fault has been Inactive for 200 hours.

Possible Causes

This fault code can be caused by any of the following:

•FMI 9

- CAN Data Link from the ECA to the link

-ECA

-HCM

Additional Tools

• Basic hand tools

• Eaton® Test Adapter Kit J43318

• Digital Volt/Ohm Meter J46708

• ServiceRanger

2015.10.19

Eaton Transmission TRTS1000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual