Eaton Transmission TRTS2000 Service Manual

Download

Troubleshooting Guide

MY09 PEC

MY09 Inverter

MY09 Motor Generator

with Connectors

1 2

6 5 4

Eaton Hybrid Drive Systems MY09 TRTS2000 EN-US

October 2015

MY09 PEC Models

EH-8E406A-U/P EH-8E406A-UP EH-8E406A-UPG EH-8E406A-CD EH-8E406A-CDG EH-8E406A-CDR EH-8E406A-T EH-6E706B - CD EH-6E706B- P EH-6E706B -UPG

TRTS2000 T able of Contents |

General Information

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

Warnings and 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 Procedure . . . . . . 5

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

Diagnostic Tools and 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. . . . . . . . . . . . . . 17

Product Diagnostic Mode (PDM). . . . . . . . . . . . . . . . 18

PDM will only work with the following Inactive

codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Hybrid Light and Gear Display Descriptions. . . . . . . . 19

Red “Service” Light . . . . . . . . . . . . . . . . . . . . . . . 19

Amber “Check Hybrid” Light . . . . . . . . . . . . . . . . 19

Red “Stop Hybrid” Light. . . . . . . . . . . . . . . . . . . . 19

Blinking Amber “Check Hybrid” Light. . . . . . . . . . 19

“ST” in Gear Display. . . . . . . . . . . . . . . . . . . . . . . 19

“PD” in Gear Display . . . . . . . . . . . . . . . . . . . . . . 19

“CA” in Gear Display. . . . . . . . . . . . . . . . . . . . . . . 20

“OS” in Gear Display . . . . . . . . . . . . . . . . . . . . . . 20

“F” in Gear Display . . . . . . . . . . . . . . . . . . . . . . . . 20

Dash “-” in Gear Display. . . . . . . . . . . . . . . . . . . . 20

Stars “**” in Gear Display . . . . . . . . . . . . . . . . . . 20

Two Dashes “- -” in Gear Display . . . . . . . . . . . . . 20

Blank Gear Display . . . . . . . . . . . . . . . . . . . . . . . . 20

Pretest Procedure

Power-Up Sequence Test. . . . . . . . . . . . . . . . . . . . . . 21

Electrical Pretest . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Hybrid Electrical Pretest. . . . . . . . . . . . . . . . . . . . . . . 28

Fault Isolation Procedure

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. . . . . . . . . . 54

Fault Code 6 - No HCM Operation . . . . . . . . . . . . . . . 60

Fault Code 7 - Improper HCM Configuration . . . . . . . 63

Fault Code 8 - Loss of Switched Ignition Power

Fault (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Fault Code 9 - Weak Battery Voltage . . . . . . . . . . . . . 70

Fault Code 10 - Low Battery Voltage (HCM). . . . . . . . 73

Fault Code 11 - No TECU Operation . . . . . . . . . . . . . . 76

Fault Code 12 - Improper ECU Configuration (TECU). 79

Fault Code 14 - Invalid Shifter Range. . . . . . . . . . . . . 82

Fault Code 16 - High Integrity Link (HIL) . . . . . . . . . . 87

Fault Code 17 - Start Enable Relay. . . . . . . . . . . . . . . 93

Fault Code 18 - ECA Communication Fault. . . . . . . . . 98

Fault Code 19 - CAN ECA Message Fault (HCM). . . . 101

Fault Code 22 - J1939 ABS Message Fault (HCM) . . 107 Fault Code 24 - J1939 HCM Message Fault (TECU) . 110

Fault Code 26 - Clutch Slip Fault . . . . . . . . . . . . . . . 114

Fault Code 27 - Clutch Disengagement Fault . . . . . . 117

Fault Code 32 - Loss of Switched Ignition

Power Fault (TECU) . . . . . . . . . . . . . . . . . . . . . . . . . 121

Fault Code 33 - Low Battery Voltage Fault (TECU) . . 124 Fault Code 34 - Weak Battery Voltage Fault (TECU) . 127 Fault Code 35 - J1939 Communication Link Fault

(TECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Fault Code 36 - J1939 Engine Message Faults. . . . . 135

Fault Code 37 - Power Supply Fault (TECU). . . . . . . 138

Fault Code 38 - Battery Fan Relay Fault . . . . . . . . . . 142

Fault Code 39 - Heat Exchanger Relay Fault. . . . . . . 148

Fault Code 40 - Cooling Pump Relay Fault. . . . . . . . 153

Fault Code 48 - J1939 Transmission Message

Fault (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Fault Code 49 - J1939 Engine Message Fault (HCM) 162 Fault Code 50 - J1939 Body Controller Message

Fault (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Fault Code 51 - Rail Position Sensor Fault. . . . . . . . 168

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| Table of Contents TRTS2000

Fault Code 52 - Gear Position Sensor Fault . . . . . . . 173

Fault Code 53 - DC/DC Converter Fault . . . . . . . . . . 178

Fault Code 54 - DC/DC Converter Output Voltage

Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Fault Code 56 - Input Shaft Speed Sensor Fault. . . . 186

Fault Code 58 - Output Shaft Speed Sensor Fault . . 190 Fault Code 59 - J1939 Communication Link Fault

(HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Fault Code 60 - CAN Communication Link Fault . . . 199

Fault Code 61: Rail Motor Circuit Fault . . . . . . . . . . 203

Fault Code 63: Gear Motor Circuit Fault. . . . . . . . . . 215

Fault Code 64 - ECA Fault . . . . . . . . . . . . . . . . . . . . 227

Fault Code 65 - ECA Speed Sensor Fault . . . . . . . . . 231

Fault Code 66 - ECA Battery Voltage Fault . . . . . . . . 235

Fault Code 67 - ECA Ignition Voltage Fault. . . . . . . . 238

Fault Code 68 - Grade Sensor Fault . . . . . . . . . . . . . 243

Fault Code 70 - Engine Failed to Respond Fault

(HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Fault Code 71 - Failed to Disengage a Gear . . . . . . . 250

Fault Code 72 - Failed to Select Rail Fault . . . . . . . . 254

Fault Code 73 - Failed to Engage a Gear Fault . . . . . 258

Fault Code 74 - Engine Failed to Respond Fault

(TECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Fault Code 75 - Power Down in Gear. . . . . . . . . . . . 265

Fault Code 76 - High Voltage Battery 1 Potential

Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Fault Code 78 - High Voltage Battery 1 Current Fault 271 Fault Code 82 - High Voltage Battery 1 Temperature

Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Fault Code 83 - Invalid Shift Range . . . . . . . . . . . . . 279

Fault Code 84 - Shift Control Device Not Configured

Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

Fault Code 85 - Shift Control Device Incompatible

Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

Fault Code 88 - Inverter CAN Message Fault (HCM) 294 Fault Code 89 - Battery Control Unit CAN Message

Fault (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Fault Code 94 - Transfer Case Message Fault . . . . . 308

Fault Code 95 - 12-Volt Cranking Relay Fault. . . . . . 311

Fault Code 97 - PTO Engagement Fault . . . . . . . . . . 316

Fault Code 101 - High Voltage Battery Fault. . . . . . . 322

Fault Code 103 - Battery Control Unit (BCU)

Communication Fault. . . . . . . . . . . . . . . . . . . . . . . . 325

Fault Code 105 - Battery Control Unit Fault . . . . . . . 329

Fault Code 107 - High Voltage Battery Leak

Detection Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Fault Code 108 - Battery Control Unit Power

Supply Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Fault Code 110 - Inverter Fault. . . . . . . . . . . . . . . . . 346

Fault Code 111 - Inverter CAN Message Fault

(HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

Fault Code 112 - Inverter Voltage Fault . . . . . . . . . . 355

Fault Code 113 - Inverter Current Fault . . . . . . . . . . 359

Fault Code 114 - Inverter Power Supply Fault . . . . . 364

Fault Code 115 - Inverter Temperature Fault . . . . . . 368

Fault Code 116 - High Voltage Relays Fault. . . . . . . 373

Fault Code 117 - Battery Control Unit Relay Cut

Request Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

Fault Code 118 - Auxiliary High Voltage Relay

Control Circuit Fault. . . . . . . . . . . . . . . . . . . . . . . . . 386

Fault Code 120 - APG Unit 1 - AC Voltage Fault. . . . 395

Fault Code 122 - APG Unit 1 Output . . . . . . . . . . . . 398

Fault Code 123 - APG Unit 1 High Voltage Battery. . 403 Fault Code 125 - APG Unit 1 - Over Temperature . . 406

Fault Code 126 - APG Unit 1 Configuration . . . . . . . 409

Fault Code 127 - APG Unit 1 Ambient Air Over

Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

Fault Code 128 - APG Unit 1 CAN Fault . . . . . . . . . . 415

Fault Code 165 - APG Unit 1 Configuration Error. . . 419

Symptom Isolation Procedure

Front Box Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423

Engine Crank Test . . . . . . . . . . . . . . . . . . . . . . . . . . 428

Hybrid Performance Test. . . . . . . . . . . . . . . . . . . . . 432

ServiceRanger Test . . . . . . . . . . . . . . . . . . . . . . . . . 436

Gear Engagement Test. . . . . . . . . . . . . . . . . . . . . . . 441

ePTO Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445

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TRTS2000 T able of Contents |

Appendix

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 453

Hybrid Tr ansmission ECU System Harness . . . . 453

Wiring Diagram with Push Button Shift

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454

Connector Pin Description . . . . . . . . . . . . . . . . . . . . 456

Hybrid and Transmission Connector Pins. . . . . . 456

TECU and HCM Connectors . . . . . . . . . . . . . . . . 457

Transmission Controller 38-Way (Vehicle Interface

Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

Hybrid Controller 38-Way (Vehicle Interface

Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

Hybrid Controller 38-Way (Hybrid System Interface

Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

Push Button Shift Control Connector . . . . . . . . . 461

Push Button 30-Way Connector. . . . . . . . . . . . . 461

Inverter Connectors . . . . . . . . . . . . . . . . . . . . . . 462

Power Electronics Carrier (PEC) Connectors . . . 464

PEC High-Voltage (DC) Connector to Inverter . . 465

Electric Clutch Actuator (ECA) Connectors. . . . . 466

Motor/Generator Connectors . . . . . . . . . . . . . . . 467

Typical DC/DC Converter Circuit. . . . . . . . . . . . . 469

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iii

Warnings & Cautions | General Information TRTS2000

Warnings & Cautions

Warnings and Cautions

Throughout this service manual there are paragraphs that are marked with a title of DANGER, WARNING, or CAUTION. These special paragraphs contain specific safety information and must be read, understood, and heeded before continuing the procedure or performing the step(s).

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.

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.

Caution: 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 (+) and (-) 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 tow-

ing place the Shift Lever in “N” and lift the drive wheels off the ground or disconnect the driveline.

2015.10.20

TRTS2000 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.

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

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 Power Electric Carrier (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 (see “Insulated Rubber Glove Test” on page 3). 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 Procedure” on page 5 should be followed. Failure to follow these instructions may result in severe personal injury or

death.

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

High-voltage rubber insulated gloves (class 0 with leather protectors) must be worn when working on any high-voltage cables. The “High-Voltage Service Shutdown Procedure” on page 5 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.

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Insulated Rubber Glove Test and High-Voltage Work Area | General Information TRTS2000

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 by following the procedure below. 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:

• 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. Any hole in the insulated rubber glove is a potential entry point for high-voltage.

• The gloves should not be used if they exhibit any signs of wear and tear.

• The leather gloves must always be worn over the rubber insulating gloves in order to protect them.

• The rubber insulating gloves must be ASTM Class

0 electrical insulating rubber gloves with

leather protectors.

High-Voltage Work Area Requirements

Warning: A buffer zone must be set up and ASTM Class 0

electrical insulating rubber gloves 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 Procedure” on page 5 and the individual repair procedures:

• Position the vehicle in the service bay.

• Position 4 orange cones around the corners of the

vehicle to mark off a 1m (3 ft.) perimeter

around the vehicle.

• Do not allow any unauthorized personnel into the

buffer zone during repairs involving high voltage. Only personnel trained for service on the

high-voltage system are permitted in the buffer

zone.

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High-Voltage Service Shutdown and Power-Up Procedure | General Information TRTS2000

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

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 use following the rubber insulation gloves testing procedure (see

“Insulated Rubber Glove Test” on page 3). 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 Procedure” on page 5 should be followed. Failure to follow these instructions may result in severe personal injury or

death.

The lockout and T ag-out devices should only be removed by the technician that placed the Lockout Tag-out 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 highvoltage cables. The

“High-Voltage Service Shutdown Procedure” on page 5 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

death.

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High-Voltage Service Shutdown and Power-Up Procedure | General Information TRTS2000

High-Voltage Service Shutdown Procedure

1. Follow “High-Voltage Work Area” procedure (see “High-Voltage Work Area Requirements” on page 3).

2. Locate the red Power Electric Carrier (PEC) service

switch on the front of the PEC and push

the Off position.

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 cannot 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 “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

the vehicle and contact Eaton® at

1-800-826-HELP

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

Note: The voltage drops to 0 when the key is

turned

off.

(4357).

High-Voltage Service Power-Up Procedure

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

2. Remove the Lockout Bracket and tag ONLY IF

YOU

ARE THE PERSON WHO IS WORKING ON

THE

VEHICLE.

3. Reinstall the protection bracket over the service

switch.

4. Pull the service switch out and let vehicle set for 2

minutes.

5. Start vehicle when appropriate.

2015.10.20

Diagnostic Tools and Service Publications | General Information TRTS2000

Diagnostic Tools and Ser vice Publications

Eaton Tools

• Visit Roadranger.com

Tool Description

ServiceRanger version 3 ServiceRanger PC-based Diagnostic Tool ServiceRanger version 4 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

2015.10.20

Diagnostic Tools and Service Publications | General Information TRTS2000

Tool Description

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

1. Visit Roadranger.com

TRSM2000 Service Manual (covers external components on transmission and hybrid components) TRSM0110 Service Manual (covers internal transmission repairs only) TRTS2000 Troubleshooting Guide TRTS2001 Troubleshooting Guide for Alternative PEC and Alternative APG TRDR1000 Drivers Instructions TRDR1110 First Responder Guide CLMT-0365 Eaton 365 mm Clutch Installation Procedure

2015.10.20

Hybrid Diagnostic Procedure | General Information TRTS2000

Key ON

Retrieve Active Faults

with ServiceRanger

Active Codes?

Yes

Go to "Fault Code Isolation Procedure

Index" (page 17)

Does Gear Display

Show an "N”?

Does Engine Crank?

Yes

If equipped, does

vehicle operate

normal in ePTO mode?

Go to "ePTO Test”

(page 187)

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 17)

No Fault = Test

Complete

Is Red "Stop Hybrid" or

Amber “Check Hybrid”

lamp 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 183)

Will vehicle move

from a stop?

Yes

Note: If ServiceRanger fails

to communicate, go to

“ServiceRanger Test”

(page 178)

Go to “Engine Crank

Test” (page 171)

Go to "Hybrid

Performance Test"

(page 175)

Go to "Gear Engagement Test”

if solid “N” is displayed

(page 183)

Go to “Front Box Test” if

flashing gear number is

displayed (page 167)

Hybrid Diagnostic Procedure

2015.10.20

Hybrid Component and Connector Locations | General Information TRTS2000

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

2015.10.20

TRTS2000 General Information | Hybrid Component and Connector Locations

XY Shifter

High-Voltage 3-Way AC Connector

Motor/Generator Resolver Connector

Motor/Generator Temperature Connector

Input Shaft Speed Sensor

Transmission Diagnostic Port

2015.10.20

Hybrid Component and Connector Locations | General Information TRTS2000

12V DC(-)

High Voltage DC Connector

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

OEM Connection

DC/DC Converter

Coolant Ports

12V DC(+)

(-)

(+)

HIgh Voltage 3-Way AC Connector

Low Voltage 40-Way Connector

High-Voltage DC Connector to PEC

Inverter

Coolant Port Inlet

Coolant Port Outlet

Component Wiring Connections

2015.10.20

TRTS2000 General Information | Hybrid Component and Connector Locations

Red Service Switch with Cover

DC Connector to DC/DC Converter

DC Connector to APG (Optional)

Air Exhaust (not shown)

19-Pin Low-Voltage Connector

Air Intake

Power Electronics Carrier (PEC)

DC Connector to Inverter

2015.10.20

Fault Code Retrieval and Clearing | General Information TRTS2000

Fault Code Retrieval and Clearing

All Eaton® Hybrid systems require the use of ServiceRanger for all diagnostics. To view fault codes or

clear them, follow the procedures below.

View Active and Inactive Faults

1. Connect ServiceRanger to the 9-Way Diagnostic

2. Go to the Tools menu and select the “Communication” tab.

3. Select the appropriate communication device for J1587 and J1939.

4. Select “Connect” on the main page.

5. Select the “View Fault Codes” tab.

Note: Initial use requires all steps; however,

subsequent uses require only steps 4 and 5.

Connector.

Clear Inactive Faults

1. Connect ServiceRanger to the 9-Way Diagnostic

2. Go to the Tools menu and select the “Communication” tab.

3. Select the appropriate communication device for

J1587 and J1939.

4. Select “Connect” on the main page.

5. Select the “View Fault Codes” tab.

6. Select the “Clear Faults” button.

Note: Initial use requires all steps, however

subsequent uses require only steps 4 and 5.

Connector.

2015.10.20

Fault Code Isolation Procedure Index | General Information TRTS2000

Fault Code Isolation Procedure Index

Fault Code SPN FMI Description Page Number

1 520225 0, 6, 15 Motor/Generator Current Sensor page 33 2 520226 3 Motor/Generator Temperature Sensor page 38 3 520227 0 Motor/Generator Temperature page 42 4 520228 0, 2, 21–27 Motor/Generator Rotation Speed Sensor page 48 5 520229 21–29 Motor/Generator AC Cable page 54 6 629 13 No ECU Operation (HCM) page 60 7 629 13 Improper ECU Configuration (HCM) page 63 8 158 4 Loss of Switched Ignition Power Fault (HCM) page 66 9 168 14 Weak Battery Voltage (HCM) page 70 10 168 4 Low Battery Voltage (HCM) page 73 11 629 12 No ECU Operation (TECU) page 76 12 629 13 Improper ECU Configuration (TECU) page 79 14 751 2, 3, 4 Invalid Shifter Range page 82 16 625 2 High Integrity Link (HIL) page 87 17 626 3, 4 Start Enable Relay page 93 18 520200 2, 9 ECA Communication page 98 19 520273 2, 9 CAN ECA Message page 101 22 563 2, 9, 14 J1939 ABS Message (HCM) page 107 24 525 9 J1939 HCM Message (TECU) page 110 26 522 10 Clutch Slip page 114 27 788 7, 14 Clutch Disengagement page 117 32 43 2 Loss of Switched Ignition Power (TECU) page 121 33 168 4 Low Battery Voltage (TECU) page 124 34 168 14 Weak Battery Voltage (TECU) page 127 35 639 2 J1939 Communication Link page 130 36 639 14 J1939 Engine Message (TECU) page 135 37 610 5 Power Supply (TECU) page 138 38 520243 3, 4, 5, 14 Battery Fan Relay page 142 39 520247 3, 4, 5 Heat Exchanger Relay page 148 40 520248 3, 4, 5, 14 Cooling Pump Relay page 153 48 523 2, 9 J1939 Transmission Message (HCM) page 159 49 190 2, 9 J1939 Engine Message (HCM) page 162 50 701 2, 9 J1939 Body Controller Message (HCM) page 165 51 60 2, 3, 4, 10 Rail Position Sensor page 168 52 59 2, 3, 4 Gear Position Sensor page 173 53 520244 12, 14 DC/DC Converter page 178 54 520245 2, 4 DC/DC Converter Ou tput Voltage page 181

2015.10.20

Fault Code Isolation Procedure Index | General Information TRTS2000

Fault Code SPN FMI Description Page Number

56 161 2, 3, 4, 5, 10Input Shaft Speed Sensor page 186

58 191 2, 3, 4, 5 Output Shaft Speed Sensor page 190 59 639 2, 9 J1939 Communication Link (HCM) page 194 60 625 2, 9 CAN Communication Link (HCM) page 199 61 772 5, 6 Rail Select Motor page 203 63 773 5, 6 Gear Select Motor page 215 64 788, 520198,

520199, 524035

0, 12, 13, 21–28

ECA page 227

65 520203 2, 5 ECA Speed Sensor page 231 66 520271 3, 4, 14 ECA Battery Voltage page 235 67 520274 3, 4, 5 ECA Ignition Voltage page 238 68 520231 12, 13, 14 Grade Sensor page 243 70 188, 518, 539, 544 0, 1, 2, 7 Engine Failed to Respond (HCM) page 247 71 520275 7 Failed to Disengage Gear page 250 72 520277 7 Failed to Select Rail page 254 73 520278 7 Failed to Engage Gear page 258 74 93, 190 7 Engine Failed to Respond (TECU) page 262 75* 520276 14 Power Down In Gear page 265 76 520250 3, 4, 16, 18 High-Voltage Battery 1 Potential Voltage page 268 78 520232 6 High-Voltage Battery 1 Current page 271 82 520233 0, 16 High-Voltage Battery 1 Temperature page 274 83 751 12, 13 Invalid Shifter Range page 279 84 751 13 Shift Control Device Not Configured page 284 85 639 12 Shift Control Device Incompatible page 290 88 520223 2, 9 Inverter CAN Message (HCM) page 294 89 520234 2, 9 PEC CAN Message (HCM) page 300 94 520237 9 Transfer Case Message page 308 95 520249 3, 4 12-volt Cranking Relay page 311 97 3460 3, 4, 5, 7, 14PTO Engagement page 316

101 520238 0, 22–31 High-Voltage Battery page 322 103 520265 22–26 Battery Control Unit Communication page 325 105 520240 22–30 Battery Control Unit page 329 107 520242 1 High-Voltage Battery Leak Detection page 332 108 520268 3, 4 Battery Cont rol Unit Power Supply page 342 110 520220 21–29 Inverter page 346 111 520260 12–28 Inverter Communication page 349 112 520221 3, 4 Inverter Voltage page 355

2015.10.20

TRTS2000 General Information | Fault Code Isolation Procedure Index

Fault Code SPN FMI Descriptio n Page Number

113 520222 6, 14 Inverter Current page 359 114 520261 3, 4 Inverter Power Supply page 364 115 520223 0 Inverter Temperature page 368 116 521210, 521211,

3, 4, 5 High-Voltage Relays page 373

521212 116 520224 10, 14, 20 High-Voltage Relays page 373 117 520251 3, 14, 29 PEC Relay Cut Request page 382 118 520252 3, 4, 5 Auxiliary High-Voltage Relay Control Circuit page 386 120 520275 3, 4 APG Unit 1 - AC Voltage page 395 122 520277 6, 14, 15 APG Unit 1 - Output page 398 123 520278 3, 4 APG Unit 1 - High Voltage Battery page 403 125 520280 0 APG Unit 1 - Over Temperature page 406 126 520281 25, 26, 27 APG Unit - Configuration page 409 127 520282 0 APG Unit 1 - Ambient Air Over Temperature page 412 128 520283 9 APG Unit 1 - CAN page 415 165 520320 2 APG Unit 1 -Configuration Error page 419

2015.10.20

Symptom-Driven Diagnostics Index | General Information TRTS2000

Symptom-Driven Diagnostics Index

Symptom Isolation Procedure Page Number

Power-up no crank and gear display shows a dash “-” Front Box Test page 423 Power-up no crank and gear display shows a “N” Engine Crank T est page 428 Power-up no crank and gear display shows double

dash “--”, double stars “**” or blank Power-up vehicle cranks and gear display shows “--”,

“**” or blank Vehicle acceleration performance is not acceptable Hybrid Performance Test page 432 Transmission will not engage a gear from neutral and

warning tone sounds (solid N in gear display) Transmission 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/blinking Amber “Check Hybrid” light on the dash is on Fault Code Retrieval and Clearing page 13 Red “Stop Hybrid” light on the dash is on Fault Code Retrieval and Clearing page 13 ePTO mode does not operate as expected ePTO Test page 445

Power Up Sequence T est page 21

Refer to OEM for gear display issue N/A

Gear Engagement Test page 441

Front Box T est page 423

Fault Code Retrieval and Clearing page 13

2015.10.20

Product Diagnostic Mode (PDM) | General Information TRTS2000

Product Diagnostic Mode (PDM)

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

This procedure tests loose, degraded and intermittent connections. page 14. Use the Index as a guide to the wiring and connectors that are associated with the Inactive fault codes. Flex the wiring harness and connectors and attempt to recreate the fault after activating PDM.

PDM is only to be used by a trained service technician in an authorized dealer.

To enter PDM mode: Note: The vehicle will not start in Product Diagnostic Mode

1. Vehicle must be stationary, engine must not be

2. Connect ServiceRanger to the 9-Way

3. Select the “View Fault Codes” screen.

See “Fault Code Isolation Procedure Index” on

(PDM). Turn vehicle key “OFF” and allow the system to power down to exit PDM.

running, vehicle parking brake must be set.

Diagnostic

Connector.

PDM will only work with the following Inactive codes

9, 10, 14, 16, 17, 18, 19, 22, 24, 32, 33, 34, 35, 36, 38, 39, 40, 48, 49, 50, 51, 52, 56, 58, 59, 60, 61, 63, 76, 87, 88, 89, 95, 118

4. Perform two key clicks of the ignition switch starting with the key on, and ending with the key

on.

Note: An "88" may show up in the dash at key on,

which is a normal power-up test of the display.

5. The gear display will flash a solid “PD” (Product Diagnostic Mode) and the mode will be 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. 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.

See “Fault Code Isolation Procedure

2015.10.20

Hybrid Light and Gear Display Descriptions | General Information TRTS2000

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 is

Active.

• When the amber light is on, the vehicle can still be driven; however, the vehicle may operate without hybrid electric assist.

Red “Stop Hybrid” Light

Blinking Amber “Check Hybrid” Light

The majority of vehicles have a red Stop Switch on the front of the Power Electric 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

“ST” in the gear display indicates a driver triggered Snapshot was recorded. Snapshot is a diagnostic tool used

to capture specific data from the HCM at the time of

fault. Snapshot is only available on models with an Eaton Push Button Shift Control. It is triggered through two different means:

• Fault code triggered - Specific faults will trigger the HCM 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/she needs to decide if he/she 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 down button in the following order: up, down, up, down.

• 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, page 18.

See “Product Diagnostic Mode (PDM)” on

2015.10.20

TRTS2000 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 5mph 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 press the service brake pedal to slow the vehicle; or,

Two 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. page 17.

See “Symptom-Driven Diagnostics Index” on

Blank Gear Display

A blank gear display indicates the display has lost power , or the TECU isn’t communicating with the gear display. “Symptom-Driven Diagnostics Index” on page 17.

See

• 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 “-” in the gear display indicates the transmission is stuck in gear. page 17.

See “Symptom-Driven Diagnostics Index” on

Stars “**” in Gear Display

T wo stars “**” in the gear display indicates the gear display has power, but no communication on the data link.

“Symptom-Driven Diagnostics Index” on page 17.

See

2015.10.20

TRTS2000 Electrical Pretest Procedures | Power-Up Sequence Test

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.

Detection

The power-up self-check is performed automatically at each 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 test and the vehicle will not crank if the Tr ansmission Electronic Co ntrol 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

2015.10.20

TRTS2000 Electrical Pretest Procedures | Power -Up Sequence Test

Component Identification

See “Wiring Diagrams” on page 453.

2015.10.20

Power-Up Sequence Test | Electrical Pretest Procedures TRTS2000

Power-Up Sequence Test

Purpose: Perform Electrical Pretest

1. Perform the “Electrical Pretest” on page 24.

2. Is problem still present after the Electrical Pretest?

• Yes, replace the Transmission Electronic Control Unit (TECU). Return to the “Hybrid

Diagnostic Procedure” on page 8.

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

2015.10.20

TRTS2000 Electrical Pretest Procedures | Electrical Pretest

Electrical Pretest

Overview

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

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

is required.

Detection

The power-up self-check is performed automatically each time the key is turned on. Turn the 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

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

2015.10.20

Electrical Pretest | Electrical Pretest Procedures TRTS2000

ECA - 3-Way Connector

Battery

Plus (+)

HCM

HCM Power (Vehicle)

ECA

ECA Power

ECA Ground

Neg (-)

Clutch Ignition (System)

Front View

(HCM - Vehicle Interface Connector)

ECA -Pack 8-Way Connector

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

HCM Ground (Vehicle)

TECU

TECU Ground

36 35

TECU Ignition

TECU Power

Front View

(TECU - Vehicle Interface Connector)

HCM Ignition (Vehicle)

Ignition Relay

Component Identification

2015.10.20

TRTS2000 Electrical Pretest Procedures | Electrical Pretest

Electrical Pretest

Purpose: Verify chassis battery voltage.

1. Key off.

2. Inspect starter, battery and in line fuse holder

connections on Electric 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 between 11–13 volts on a 12-volt

system, proceed with battery load test. Repair or replace batteries as required, go to Step B.

• 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 you must 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 C.

• 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

2015.10.20

Electrical Pretest | Electrical Pretest Procedures TRTS2000

Purpose: Verify HCM battery voltage and ignition

status.

1. Select the “Data Monitor” option and view the following parameters under the Hybrid Control Module 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, you must 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 D.

• 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, you must 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 directed you to 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

2015.10.20

TRTS2000 Electrical Pretest Procedures | Hybrid Electrical Pretest

Hybrid Electrical Pretest

Overview

This test must be performed prior to diagnosing certain specific Hybrid faults. This test verifies the power supply for the Inverter and the Power Electric Carrier (PEC).

Note: You must perform the Electrical Pretest before

performing the Hybrid Electrical Pretest.

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

is required.

Detection

Fallback

Loss of ignition power causes the hybrid system to be inoperable. In this situation, the vehicle will run under diesel power only.

Possible Causes

Low-voltage can be caused by power harness connections from Inverter or PEC.

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

2015.10.20

Hybrid Electrical Pretest | Electrical Pretest Procedures TRTS2000

Component Identification

Deutsch 19 - Way Mating Connector View (PEC - Low Voltage Connector)

123

10 20

Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)

Inverter

Chassis Ground 1

Chassis Ground 2

Inverter Enable

Relay Box Enable

Relay Box Enable 2

GND_BC

GND-BC2

7 1 14

24 15

PEC

HCM (Pin 2)

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

DC/DC Converter

DC/DC Converter 4-Way OEM Connector

Ground

2015.10.20

TRTS2000 Electrical Pretest Procedures | Hybrid Elec trical Pretest

Hybrid Electrical Pretest

Purpose: Verify Inverter ground continuity.

1. Perform the Electrical Pretest, then continue to

Step 2.

2. Key off.

3. Disconnect the Inverter 40-Way Connector. 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. Measure resistance from Pin 6 to battery negative and then from Pin 7 to battery negative:

• If resistance is 0–0.3 ohms from Pin 6 to battery negative and from Pin 7 to battery negative, go to Step B.

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

Connection Measurement

Purpose: Verify voltage at Inverter 40-Way

Connector.

1. Connect a volt/ohm meter to the Inverter 40-Way Connector Pin 1 and Pin 6.

2. Key on.

3. Observe Volt/Ohm Meter voltage reading:

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

• If voltage is outside of range, repair the

harness from the HCM. Repeat this step.

Connection Measurement

Pin 1 to Pin 6

Pin 6 to Battery Negative

Pin 7 to Battery Negative

2015.10.20

Hybrid Electrical Pretest | Electrical Pretest Procedures TRTS2000

Purpose: Verify continuity of Inverter to PEC

ground wire.

1. Key off.

2. Reconnect the Inverter 40-Way Connector.

3. Disconnect the Power Electric Carrier (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 D.

• If resistance is outside of range, repair the Inverter to PEC ground wire. Repeat this step.

Connection Measurement

Pin 7 to Battery Negative

Purpose: Verify voltage at PEC 19-Way Connector.

1. Connect a volt/ohm to the PEC 19-Way Connector

Pin 6 and Pin 7.

2. Key on.

3. Observe volt/ohm voltage reading.

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

• If voltage is 11–13 volts and vehicle does not

have ePTO feature, test is complete. Reconnect PEC 19-Way Connector. Go to “Fault Code Isolation Procedure Index” on page 14.

• If voltage is outside of range, repair the power supply harness from the Inverter. Repeat this step.

Connection Measurement

Pin 6 to Pin 7

2015.10.20

TRTS2000 Electrical Pretest Procedures | Hybrid Elec trical Pretest

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. Go to “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. Repeat this step.

Connection Measurement

Pin 4 to Battery Negative

2015.10.20

TRTS2000 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, 15 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, mounted in side the Inverter. This Inductive Sensor produces an output based on amperage present in the cables.

Detection

Fault is detected when the Inverter ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions may set the fault Active: 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. FMI 15 is set when the sensor offset is out of range at

initial check.

Fallback

When Fault Code 1 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.

Possible Causes

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

• FMI 0, 6

- Inverter

- Motor/Generator

-AC Cable

• FMI 15

- Inverter

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 1 - Motor/Generator Current Sensor

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 1

Note: Refer to “Hybrid Component and Connector Locations” on page 9 for connector locations.

Phase 3

Phase 2

Phase 1

2015.10.20

Fault Code 1 - Motor/Generator Current Sensor | Fault Isolation Procedures TRTS2000

Fault Code 1 - Motor/Generator Current Sensor

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. Verify Fault Code 1 is Active.

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; A-A, B-B, C-C:

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

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

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 C.

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

Connection Measurement

Pin A to ground

Pin B to ground

Pin C to ground

• If FMI 15 is Active, replace the Inverter . See the

MY09 Inverter Removal and Installation procedure in TRSM2000, go to Step V.

Connection Measurement

Pin A to Pin A

Pin B to Pin B

Pin C to Pin C

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 1 - Motor/Generator Current Sensor

Purpose: Verify continuity of high-voltage circuitry.

1. Key off.

2. Measure the resistance between the following

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

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

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

Connection Measurement

Pin A to Pin A

Pin B to Pin B

Pin C to Pin C

Purpose: Verify continuity of Motor/Generator

phases.

1. Measure resistance of each motor/generator phase at the following pins: A-A, B-B, C-C:

• If resistance of each phase is less than 10 ohms, replace the Inverter. See the MY09 Inverter Removal and Installation procedure in TRSM2000, go to Step V.

• If resistance is outside of range, replace the motor/generator. See the MY09 Motor/Generator Removal and Installation procedure in TRSM2000, go to Step V.

Connection Measurement

Pin A to Pin A

Pin B to Pin B

Pin C to Pin C

2015.10.20

Fault Code 1 - Motor/Generator Current Sensor | Fault Isolation Procedures TRTS2000

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes. See “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

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

• If a code other than 1 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 2 - Motor/Generator Temperature Sensor

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. The Temperature Sensor resistance varies based on the temperature of the motor/generator. The Inverter supplies a 5 volt reference voltage to the sensor and measures any 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 32 °F [0 °C]).

Detection

Fault is detected when the Inverter ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 3 is set when the sensor voltage is greater than

4.1 volts for 10 seconds, while the Inverter temperature is over 95 °F (35 °C) or if the sensor output voltage is less than 0.2 volts for 10 seconds.

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

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

2015.10.20

Fault Code 2 - Motor/Generator Temperature Sensor | Fault Isolation Procedures TRTS2000

Inverter

Motor/Generator Temperature Sensor

TM Ground

Temp Sensor

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

Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)

Terminal Side - Harness Connector

Temperature Sensor

(Deutsch 2-pin connector)

Component Identification

Note: Refer to “Hybrid Component and Connector Loca-

tions” on page 9 for connector locations.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 2 - Motor/Generator Temperature Sensor

Fault Code 2 - Motor/Generator Temperature Sensor

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. Verify Fault Code 2 is Active.

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. Disconnect the Temperature Sensor Connector at the motor/generator.

5. Measure resistance at the motor/generator 2-Way Temperature Sensor Connector from Pin 1 to Pin 2:

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

• If resistance is outside of range, replace the Motor/Generator. See the MY09 Motor/Generator Removal and Installation procedure in TRSM2000, go to Step V.

Purpose: Verify continuity of Inverter and

Motor/Generator Temperature Sensor circuit.

1. Key off.

2. Disconnect the Inverter 40-Way Connector.

3. Reconnect the motor/generator2-Way T emperature

Sensor Connector.

4. Measure resistance at the following; Inverter 40-Way Connector Pin 37 to Pin 36, Inverter 40-Way Connector Pin 37 to ground:

• If resistance is 0.8K–301.7K ohms between Pin 37 and Pin 36 and resistance between Pin 37 and ground is 10K ohms or greater, replace the Inverter. See the MY09 Inverter Removal and Installation procedure in TRSM2000, go to Step V.

• If resistance is outside of range, repair the open or short to ground in the harness between the Inverter 40-Way Connector and the motor/generator 2-Way Connector, then go to Step V.

Connection Measurement

Pin 1 to Pin 2

Pin 36 to Pin 37

Pin 37 to ground

2015.10.20

Fault Code 2 - Motor/Generator Temperature Sensor | Fault Isolation Procedures TRTS2000

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes. See “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

• If Fault Code 2 appears, find error in testing. Restart troubleshooting, then go to Step A.

• If a code other than 2 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature

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

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

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 0 is set when the temperature sensor value is greater

than 365 °F (185 °C) for 1 second.

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, the high-voltage relays remain powered.

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

• Transmission defaults start gear to 1st.

Possible Causes

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

•FMI 0

- Motor/generator

- Inverter

- Liquid cooling system (e.g. low coolant, no coolant flow, coolant pump, radiator, radiator fan, reservoir)

2015.10.20

Fault Code 3 - Motor/Generator Temperature | Fault Isolation Procedures TRTS2000

Inverter

Motor/Generator Temperature Sensor

TM Ground

Temp Sensor

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

Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)

Terminal Side - Harness Connector

Temperature Sensor

(Deutsch 2-pin connector)

Component Identification

Note: Refer to “Hybrid Component and Connector Loca-

tions” on page 9 for connector locations.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature

Fault Code 3 - Motor/Generator Temperature

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. Verify Fault Code 3 is Active.

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.

3. Key on.

4. Select the Data Monitor option and view PID 113

“Motor/Generator Temperature” in the Power Electronics list.

5. Observe PID 113 again after 20 minutes:

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

• If PID 113 Motor/Generator Temperature remained the same, go to Step H.

Purpose: Verify level of hybrid system coolant.

1. Key off.

2. Observe coolant level after system has cooled

down to ensure it is filled to proper level:

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

• If coolant is below 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 bled of air to ensure the coolant properly flows during normal operation.

Purpose: Verify integrity of hybrid cooling system

components.

Parameter Reading

Initial Temp.

20 Min. Temp.

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 D.

• If the radiator has debris, air flow is obstructed or coolants lines are bent sharply, repair the problem and go to Step V.

2015.10.20

Fault Code 3 - Motor/Generator Temperature | Fault Isolation Procedures TRTS2000

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 E.

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

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 problems.

• 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, system

needs to be purged of air to allow the coolant to flow. Bleed the air by using a coolant system pressurizing tool or a vacuum tool and go to Step V.

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

Pin A to Pin B

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature

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 problem.

• 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 40-Way Connector.

3. Measure resistance between Pin 36 and Pin 37, and

Pin 37 to ground of the Inverter 40-Way Connector:

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

Connection Measurement

Pin 36 to Pin 37

Pin 37 to Ground

Pin A to Pin B

2015.10.20

Fault Code 3 - Motor/Generator Temperature | Fault Isolation Procedures TRTS2000

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 1 to Pin 2:

• If resistance is 0.8K–301.7K ohms, repair the shorted HCM System Harness between the Inverter 40-Way Connector and Motor/Generator 2-Way Connector.

• If resistance is outside the range, replace the Motor/Generator. See the MY09 Motor/Generator Removal and Installation procedure in TRSM2000, go to Step V.

Connection Measurement

Pin 1 to Pin 2

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes. See “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

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

• If a code other than 3 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 4 - Motor/Generator Rotation Speed Sensor

Fault Code 4 - Motor/Generator Rotation Speed Sensor

J1939 SA 239 SPN 520228 FMI 0, 2, 3, 21–27 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

• 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 may set the fault Active: FMI 0: Set when the motor/generator speed exceeds the

normal allowable range. FMI 2: Set when the motor/generator speed is different than

T ransmission Input Shaft Speed by more than 100 RPM for at least 10 seconds.

FMI 3: Set when the resolver circuit is shorted to ground. FMI 21: Set when a resolver signal line short to 12-volt

battery or ground is detected. FMI 22, 24, 25: Set when the combination of the

analog-to-digital converter signals is a mismatch.

Fallback

When Fault Code 4 is set, the following conditions occur:

• The amber “Check Hybrid” light illuminates.

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

• Electric motor/generator assist and regenerate 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.

Possible Causes

This fault code can be caused by any of the following: FMI 0 or 26

• Long extended grades may require intermittent use of the service brakes to slow the vehicle

FMI 3, 21

• Inverter

• Resolver Harness between the motor/generator and Inverter

FMI 2, 22, 23, 24, 25, 27

• Inverter

• Motor/generator

• Resolver Harness between the motor/generator and Inverter

• Water in Inverter or Resolver wire connector.

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

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

FMI 27: Set when the Inverter detects an error in the initial check.

2015.10.20

Fault Code 4 - Motor/Generator Rotation Speed Sensor | Fault Isolation Procedures TRTS2000

Inverter

Motor/Generator Resolver

REZ_Minus

REZ_Plus

REZ_S2

REZ_S4

REZ_S1

REZ_S3

Resolver

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

Terminal Side - Harness Connector

Resolver

(Deutsch 6-pin connector)

10 20

Deutsch 40-Way Mating Connector View (Inverter - Low Voltage Connector)

Component Identification

Note: Refer to “Hybrid Component and Connector Loca-

tions” on page 9 for connector locations.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 4 - Motor/Generator Rotation Speed Sensor

Fault Code 4 - Motor/Generator Rotation Speed Sensor

Purpose: Check for Active or Inactive fault code status, perform Electrical Pretest and Hybrid

Electrical Pretest. Verify FMIs present.

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. Perform Electrical Pretest and Hybrid Electrical Pretest.

5. Check Inverter part number.

• If Inverter is part number 4306453, contact

Eaton Call Center at 1-800-826-HELP (4357)

6. Which FMIs are present?

• If FMI 22, 24, 25 or 27 are listed, replace the Inverter. See the MY09 Inverter Removal and Installation procedure in TRSM2000, go to Step V.

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

Purpose: Verify continuity of Resolver and Inverter

components.

1. Key off.

2. Disconnect the 40-Way Low-Voltage Connector at

the Inverter.

3. Inspect for water intrusion inside wire connector.

4. Determine if resistance for the Resolver at the

40-Way Harness Connector between the following pins is within the range listed:

- Pin 30 to Pin 40 is 8.6–10.5 ohms

- Pin 28 to Pin 38 is 28–34 ohms

- Pin 29 to Pin 39 is 23–27 ohms

Note: An auto-ranging digital volt/ohm meter must be used.

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

• If resistance is within range, go to Step C.

Connection Measurement

Pin 30 to Pin 40

Pin 28 to Pin 38

• If FMI 3 or 21 is listed, go to Step F.

• If FMI 0 is listed, go to Step G.

Pin 29 to Pin 39

2015.10.20

Fault Code 4 - Motor/Generator Rotation Speed Sensor | Fault Isolation Procedures TRTS2000

Purpose: Verify continuity of Resolver and Inverter

components.

1. Key off.

2. Disconnect the 40-Way Low-Voltage Connector at

the Inverter.

3. Measure Resolver resistance at the 40-Way Harness Connector between the following pins:

- Pin 38 to Pin 40

- Pin 38 to Pin 30

- Pin 28 to Pin 40

- Pin 28 to Pin 30

- Pin 28 to ground

- Pin 38 to ground

- Pin 30 to ground

- Pin 40 to ground

• If resistance is open or OL, replace Inverter.

• If resistance is anything other than OL, go to

Step D.

Purpose: Verify continuity of Resolver Harness

circuitry.

1. Disconnect the 6-Way motor/generator Resolver Connector (the connector going into the motor).

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

Note: An auto-ranging digital volt/ohm meter must

be used.

- Pin 1 to Pin 3

- Pin 1 to Pin 4

- Pin 2 to Pin 3

- Pin 2 to Pin 4

- Pin 1 to ground

- Pin 2 to ground

- Pin 3 to ground

- Pin 4 to ground

• If resistance is open or OL, repair wiring

between Resolver and Inverter.

Connection Measurement

Pin 38 to Pin 40

Pin 38 to Pin 30

Pin 28 to Pin 40

Pin 28 to Pin 30

Pin 28 to ground

Pin 38 to ground

Pin 30 to ground

Pin 40 to ground

• If resistance is anything other than OL, replace the motor/generator. See the MY09 Motor/Generator Removal and Installation procedure in TRSM2000, go to Step V.

Connection Measurement

Pin 1 to Pin 3

Pin 1 to Pin 4

Pin 2 to Pin 3

Pin 2 to Pin 4

Pin 1 to ground

Pin 2 to ground

Pin 3 to ground

Pin 4 to ground

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 4 - Motor/Generator Rotation Speed Sensor

Purpose: Measure resistance of Resolver circuit at

motor/generator.

1. Disconnect 6-Way Resolver wire connector at motor/generator.

2. Determine if resistance on the following pins falls within the listed range:

- Pin 1 to Pin 2 is between 28–34 ohms

- Pin 3 to Pin 4 is between 8.6–10.5 ohms

- Pin 5 to Pin 6 is between 23–27 ohms

• If resistance is outside of range, replace the

motor/generator (Resolver is not serviceable). After repairs are made go to Step V.

• If resistance is within range, repair wiring between Resolver and Inverter . After repairs are made go to Step V.

Connection Measurement

Pin 1 to Pin 2

Purpose: Verify the resistance at the Inverter.

1. Key off

2. Disconnect 40-Way Low Voltage Connector at the

Inverter.

3. Measure Resolver resistance at the 40-Way Harness connector between the following pins:

• Pin 28 to Pin 1

• Pin 28 to Pin 6

• Pin 29 to Pin 1

• Pin 29 to Pin 6

• Pin 38 to Pin 1

• Pin 38 to Pin 6

• Pin 39 to Pin 1

- Pin 39 to Pin 6 Note: An auto-ranging digital volt/ohm meter must

be used.

• If resistance is open or OL replace inverter. After repair is made go to Step V.

Pin 3 to Pin 4

Pin 5 to Pin 6

• If resistance is anything other than OL go to H.

Connection Measurement

Pin 28 to Pin 1

Pin 28 to Pin 6

Pin 29 to Pin 1

Pin 29 to Pin 6

Pin 38 to Pin 1

Pin 38 to Pin 6

Pin 39 to Pin 1

Pin 39 to Pin 6

2015.10.20

Fault Code 4 - Motor/Generator Rotation Speed Sensor | Fault Isolation Procedures TRTS2000

Purpose: Verify overspeed condition by test driving

the vehicle.

1. Test drive vehicle to verify an overspeed condition. This may require a downhill road condition, verify with customer the road condition when fault was set.

• If FMI 0 is set in a true overspeed condition, vehicle will need to be slowed down to prevent overspeed condition.

• If possible, update HCM software version number 672 or higher. If vehicle has HCM with primary hardware version 4306455, the most current software version available is 663. To update software version 672 or higher requires an HCM with hardware version 4306473. Hardware version number can be found in Service Ranger under Product Configurations, HCM, Primary Hardware Version.

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes. See “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

• If Fault Code 4 appears, find error in testing, go to Step A.

• If a code other than 4 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 5 - Motor/Generator AC Cable

Fault Code 5 - Motor/Generator AC Cable

J1939 SA 239 SPN 520229 FMI 21–29 Overview

The motor/generator AC Cables are connected from the motor/generator to the Inverter. These cables carry up to 500 volts 3-phase AC when the vehicle is in operation.

Detection

Fault is detected when:

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

• FMIs 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 may set the fault Active: FMI 21: Set when the AC interlock circuit is open.

FMI 22, 23, 24: Set when the 2-phase motor current is more than 360 amps for 0.9 MS.

FMI 25, 26, 27: 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.

Possible Causes

This fault code can be caused by any of the following: FMI 21

• AC Cable Interlock

FMI 22, 23, 24

• Inverter

• Motor/generator

•AC Cable

FMI 25, 26, 27, 28, 29

• Motor/generator

•AC Cable

FMI 28: Set when motor/generator current is less than 8 amps for 200 MS at a speed less than 500 RPM and current command greater than 20 amps.

FMI 29: Set during initialization, the Inverter checks 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 diesel-only mode.

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

2015.10.20

Fault Code 5 - Motor/Generator AC Cable | Fault Isolation Procedures TRTS2000

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 1

Note: Refer to “Hybrid Component and Connector Locations” on page 9 for connector locations.

Phase 3

Phase 2

Phase 1

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 5 - Motor/Generator AC Cable

Fault Code 5 - Motor/Generator AC Cable

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. 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. Which faults and FMIs are present?

• If Fault Code 5 FMI 21 is Active, go to Step E.

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

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

Purpose: Verify continuity of high-voltage cable.

1. Key off.

2. Remove AC High-Voltage Cable at the

Motor/Generator and Inverter.

3. Measure the resistance between the following AC Cable pins: Pin C and Pin B; Pin B and Pin A; Pin A and Pin C:

• If resistance between each phase is 5M ohms or greater, replace the Inverter. See the MY09 Inverter Removal and Installation procedure in TRSM2000, then go to Step V.

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

Connection Measurement

Pin C to Pin B

Pin B to Pin A

Pin A to Pin C

2015.10.20

Fault Code 5 - Motor/Generator AC Cable | Fault Isolation Procedures TRTS2000

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 and Pin A; Pin B and Pin B; Pin C and Pin C:

Note: An auto-ranging digital volt/ohm meter must

be used.

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

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

Connection Measurement

Pin A to Pin A

Purpose: Verify continuity of high-voltage cable.

1. 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 C and Pin B; Pin B and Pin A; Pin A and Pin C:

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 . See the MY09 Inverter Removal and Installation procedure in TRSM2000, go to Step V.

• If resistance is outside of range, replace the Motor/Generator. See the MY09 Motor/Generator Removal and Installation procedure in TRSM2000, go to Step V.

Connection Measurement

Pin B to Pin B

Pin C to Pin C

Pin C to Pin B

Pin B to Pin A

Pin A to Pin C

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 5 - Motor/Generator AC Cable

Purpose: Verify high-voltage cable connections.

1. Check the AC Cable Connectors at the

motor/generator and Inverter to ensure they are properly connected:

• If connections are loose or not properly connected, reconnect AC Cables to component and go to Step V.

• If connections are not loose and are properly connected, go to Step F.

Purpose: Verify continuity of interlock circuit.

1. Disconnect the AC cable from the motor/generator

and Inverter .

2. Measure the interlock circuit resistance from the Inverter Connector and the Motor/Generator Connector at the following pins: Pin D and Pin D; Pin E and Pin E

Note: An auto-ranging digital volt/ohm meter must

be used.

• If the resistance is 0–0.3 ohms, replace the Inverter. See the MY09 Inverter Removal and

Installation procedure in TRSM2000, go to Step V.

• If resistance is outside of range, replace the

AC cable between the Inverter and Motor/Generator, then go to Step V.

Connection Measurement

Pin D to Pin D

Pin E to Pin E

2015.10.20

Fault Code 5 - Motor/Generator AC Cable | Fault Isolation Procedures TRTS2000

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes. See “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for fault codes. See “Fault Code Retrieval and Clearing” on page 13.

• If no codes, test is complete.

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

• If a code other than 5 appears, go to Fault

Code Isolation Procedure Index on page 14.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 6 - No HCM Operation

Fault Code 6 - No HCM Operation

J1939 SA 239 SPN 629 FMI 14 Overview

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

Detection

Fault is detected when HCM ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 14 is set when HCM can not complete writing to the

Electrically Erasable Programmable Read-Only Memory (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.

Possible Causes

This fault code can be caused by the following:

•FMI 14

-HCM

2015.10.20

Fault Code 6 - No HCM Operation | Fault Isolation Procedures TRTS2000

Component Identification

Note: No schematic for this code.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 6: Troubleshooting

Fault Code 6: Troubleshooting

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 6 is Active, replace HCM (only when Fault Code 6 is Active). See the Hybrid

Control Module (HCM) Removal and Installation procedure in TRSM2000.

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

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 7 - Improper HCM Configuration

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 software to control both the hybrid power electronics as well as the transmission operation.

Detection

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

Conditions to Set Fault Code Active

The following conditions may set the fault 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.

Possible Causes

This fault code can be caused by any of the following: FMI 13: Improper Electronic Control Unit (ECU)

configuration software.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 7 - Improper HCM Configuration

Component Identification

1. Hybrid Control Module (HCM)

2. Nut (3)

3. 38-Way System Connector Plug-in

4. 38-Way Vehicle Connector Plug-in

5. Mounting Plate

2015.10.20

Fault Code 7 - Improper HCM Configuration | Fault Isolation Procedures TRTS2000

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 key off for 2 seconds.

3. Key on.

4. Is Fault Code 7 Active?

• If Fault Code 7 is Active, replace the HCM (only if the fault code is Active). See the Hybrid Control Module (HCM) Removal and Installation procedure in TRSM2000.

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

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 8 - Loss of Switched Ignition Power Fault (HCM)

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

J1939 SA 239 SPN 158 FMI 4 Overview

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 ignition power is a single 12-volt feed that is fused and runs through the HCM 38-Way Vehicle Connector.

Detection

Output Shaft speed must be greater than 0 RPM.

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 4 is set when the HCM loses ignition power during

operation for 2 seconds or longer. Note: When troubleshooting an Inactive code, see “Product

Diagnostic Mode (PDM)” on page 18.

Fallback

When Fault Code 8 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates 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 faults 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 operates in 1st and reverse from stop.

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

Possible Causes

This fault code is caused by any of the following:

•FMI 4

- Ignition power supply to HCM

-HCM

2015.10.20

Fault Code 8 - Loss of Switched Ignition Power Fault (HCM) | Fault Isolation Procedures TRTS2000

Component Identification

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 8 - Loss of Switched Ignition Power Fault (HCM)

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

2015.10.20

Fault Code 8 - Loss of Switched Ignition Power Fault (HCM) | Fault Isolation Procedures TRTS2000

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

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 Electrical Pretest.

• If Fault Code 8 is Active after performing the

Electrical Pretest, replace the HCM (only if fault code is Active). See the Hybrid Control Module (HCM) Removal and Installation procedure in TRSM2000, go to Step V.

• If Fault Code 8 is Inactive after performing the Electrical Pretest, 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 “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

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

• If a code other than 8 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 9 - Weak Battery Voltage

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

Detection

Fault is detected when:

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

• HCM System Battery Voltage Low Fault is not Active.

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 14 is set when the HCM battery voltage drops below

9 volts for 10 seconds. Note: When troubleshooting an Inactive code, see “Product

Diagnostic Mode (PDM)” on page 18.

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.

Fallback

When Fault Code 9 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates.

• Red “Hybrid Stop” lamp will display if there are 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.

2015.10.20

Fault Code 9 - Weak Battery Voltage | Fault Isolation Procedures TRTS20 00

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

Note: Refer to “Hybrid Component and Connector Locations” on page 9 for connector locations.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 9 - Weak Battery Voltage

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 Electrical Pretest:

• If Fault Code 9 is Active after performing the

Electrical Pretest, replace the HCM. See the

Hybrid Control Module (HCM) Removal and Installation procedure in TRSM2000 (only if Fault Code is Active), go to Step V.

• If Fault Code 9 is Inactive after performing

the Electrical Pretest, clear codes and 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 “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

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

• If a code other than 9 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

2015.10.20

TRTS2000 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

Detection

Fault is detected when HCM ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions may set the fault 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, see “Product

Diagnostic Mode (PDM)” on page 18.

Fallback

When Fault Code 10 is set the following conditions occur:

• Amber “Check Hybrid” light illuminates.

• Red “Hybrid Stop” lamp will display if there are 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.

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 power connection

- Charging system

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 10 - Low Battery Voltage (HCM)

HCM

Harness Front View

(HCM - Vehicle Interface Connector)

Typical Relay Switch

Ignition Relay

12V Truck Battery

12V Plus

VBATT

HCM Ground

Component Identification

Note: Refer to “Hybrid Component and Connector Locations” on page 9 for connector locations.

2015.10.20

Fault Code 10 - Low Battery Voltage (HCM) | Fault Isolation Procedures TRTS2000

Fault Code 10 - Low Battery Voltage (HCM)

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. Verify Fault Code 10 is Active.

3. Perform Electrical Pretest:

• If Fault Code 10 is still Active after performing

the Electrical Pretest, replace HCM (only if Fault Code is Active). See the Hybrid Control Module (HCM) Removal and Installation procedure in TRSM2000, go to Step V.

• If Fault Code 10 is Inactive after performing the Electrical Pretest, clear codes and 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 “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

• If Fault Code 10 appears, find error in testing, go to Step A.

• If a code other than 10 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 11 - No TECU Operation

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 operation; however, the Hybrid Control Module (HCM) controls the operation of the TECU during hybrid operation.

Detection

Fault is detected when HCM ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 12 is set if the TECU detects an intermittent failure in

the Electric 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.

Possible Causes

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

•FMI 12

- Electric Shifter

2015.10.20

Fault Code 11 - No TECU Operation | Fault Isolation Procedures TRTS2000

Component Identification

Note: No schematic for this code.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 11 - No ECU Operation

Fault Code 11 - No ECU Operation

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 Electric Shifter. See Electric Shifter Removal and Installation procedure in TRSM2000 (only if fault code is Active).

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

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 12 - Improper ECU Configuration (TECU)

Fault Code 12 - Improper ECU Configuration (TECU)

J1587 MID 130 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 software that controls the transmission operation; however, the HCM controls the operation of the TECU during hybrid mode.

Detection

Fault is detected when HCM ignition voltage is greater than 7 volts and less than 16 volts.

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 13 is set when the ECU 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 illuminate and an “F’ flashes in the gear display.

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

Possible Causes

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

•FMI 13

- Improper ECU configuration software.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 12 - Improper ECU Configuration (TECU)

TECU - Vehicle Interface Connector

Component Identification

2015.10.20

Fault Code 12 - Improper ECU Configuration (TECU) | Fault Isolation Procedures TRTS2000

Fault Code 12 - Improper ECU Configuration (TECU)

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)

(only if the fault code is Active).

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

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 14 - Invalid Shifter Range

Fault Code 14 - Invalid Shifter Range

J1587 SID 18, 19 PID 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 sends 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

Fault is detected when:

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

• TECU System Battery Voltage Low Fault is not Active.

• 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 may set the fault Active: FMI 2: Set when the shifter is not returning a valid position

(PRNDH1) FMI 3: Set when the Hall-Effect Sensor voltage is higher

than expected

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

- Hall-Effect Sensor input is shorted high or sensor ground in open.

•FMI 4

- Hall-Effect Sensor input is open circuit or shorted to ground.

FMI 4: Set when the Hall-Effect Sensor voltage is lower than expected

Note: When troubleshooting an Inactive code, see “Product

Diagnostic Mode (PDM)” on page 18.

Fallback

When Fault Code 14 is set the following conditions occur:

• An “F” appears in the gear display.

• Fault is stored in TECU memory.

• TECU changes to AutoShift control.

• Engine does not crank.

2015.10.20

Fault Code 14 - Invalid Shifter Range | Fault Isolation Procedures TRTS2000

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-Pin Park Pawl Actuator

Connector

Component Identification

Note: Refer to “Hybrid Component and Connector Locations” on page 9 for connector locations.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 14 - Invalid Shifter Range

Fault Code 14 - Invalid Shifter Range

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 to 4-Pin Connector at

Pin 1 and Pin 2.

• If voltage between Pin 1 and Pin 2 is between 8–14 volts of battery voltage, go to Step B.

• 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

position.

1. With the Actuator/Shift Lever in the Neutral position check voltage on Pin 3 to ground, Pin 4 to ground.

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

• If voltage is outside the range, replace the Sensor . See the Park Pawl Mechanism Sensor Removal and Installation procedure in TRSM2000, go to Step V.

Connection Measurement

Pin 3 to Ground

Pin 4 to Ground

2015.10.20

Fault Code 14 - Invalid Shifter Range | Fault Isolation Procedures TRTS2000

Purpose: Verify continuity of TECU Harness.

1. Disconnect the TECU 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 good, replace the Transmission Electronic Control Unit (TECU) and go to Step V.

• If an open is found, repair or replace the TECU Harness, then go to Step V.

Connection Measurement

38-Way Pin 15 to 4-Way Pin 4

38-Way Pin 16 to 4-Way Pin 3

Purpose: Verify continuity of TECU Harness.

1. Disconnect the TECU 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 good, replace the Transmission Electronic Control Unit (TECU) and go to Step V.

• If an open is found, repair or replace the TECU Harness, then go to Step V.

Connection Measurement

38-Way Pin 17 to 4-Way Pin 1

38-Way Pin 31 to 4-Way Pin 2

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 14 - Invalid Shifter Range

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes. See “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

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

• If a code other than 14 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL)

Fault Code 16 - High Integrity Link (HIL)

J1587 MID 130 SID 248 FMI 2 J1939 SA 3 SPN 625 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 transmits information such as driver mode selection and fault information to illuminate the “Service” light.

Detection

Fault is detected when:

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

• TECU System Battery Voltage Low Fault is not Active.

• TECU Driver Interface Configuration is set to High-Integrity Link (HIL).

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 2 is set when the TECU loses communication for

5 seconds or more with the PBSC. Note: When troubleshooting an Inactive code, See “Product

Diagnostic Mode (PDM)” on page 18.

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

Fallback

When Fault Code 16 is set the following conditions occur:

• “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 illuminate and then remain off if the data link fails at power up.

• Fault is stored in TECU memory.

• Operation mode changes to Auto Shift Fallback.

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

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

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL)

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

Note: Refer to “Hybrid Component and Connector Locations” on page 9 for connector locations.

2015.10.20

Fault Code 16 - High Integrity Link (HIL) | Fault Isolation Procedures TRTS2000

Fault Code 16 - High Integrity Link (HIL)

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. Verify Fault Code 16 is Active.

3. Key on and observe the red push button “Service” light.

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

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

Purpose: Verify voltages at Vehicle Harness.

Purpose: Verify voltage at Push Button Shift

Controller.

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 Push Button Shift Control (only if fault code is Active). See the Shift Control Removal and Installation procedure in TRSM2000, then go to Step V.

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

Connection Measurement

Pin F1 to Pin F2

1. Disconnect Shift Control 30-Way Connector.

2. Key on.

3. Measure voltage on 30-Way Connector Pin J3 and

Pin C1.

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

• If out of range, go to Step D.

Connection Measurement

Pin J3 to Pin C1

2015.10.20

TRTS2000 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL)

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 Peterbilt units, 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 E.

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

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, and between 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), then go to Step V.

• If any of the above conditions are not met,

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

Connection Measurement

Pin C1 to Pin 31

Pin C1 to Ground

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Fault Code 16 - High Integrity Link (HIL) | Fault Isolation Procedures TRTS2000

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 G.

• If any of the above conditions are not met,

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

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), then go to Step V.

• If any of the above conditions are not met,

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

Connection Measurement

Pin F2 to Pin 27

Pin F1 to Pin 28

Pin F1 to Ground

Pin F2 to Ground

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TRTS2000 Fault Isolation Procedures | Fault Code 16 - High Integrity Link (HIL)

Purpose: Verify repair.

1. Key off.

2. Reconnect all connectors and the negative

battery cable.

3. Key on.

4. Clear codes. See “Fault Code Retrieval and

Clearing” on page 13.

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

6. Check for codes. See “Fault Code Retrieval and

Clearing” on page 13.

• If no codes, test is complete.

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

• If a code other than 16 appears, go to “Fault

Code Isolation Procedure Index” on page 14.

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TRTS2000 Fault Isolation Procedures | Fault Code 17 - Start Enable Relay

Fault Code 17 - Start Enable Relay

J1587 MID 130 SID 237 FMI 3, 4 J1939 SA 3 SPN 626 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. This supplies battery power to the Start Enable Relay main feed, which then powers the Starter Solenoid.

Detection

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

Conditions to Set Fault Code Active

The following conditions may set the fault Active: FMI 3: TECU detects an open or short to VBATT in

the control circuit of the Start Enable Relay for 1 second or greater.

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

Note: When troubleshooting an Inactive code, see “Product Diagnostic Mode (PDM)” on page 18.

Possible Causes

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

• FMI 3, 4

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

- Start Enable Relay

-TECU

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.

2015.10.20

TRTS2000 Fault Isolation Procedures | Faul t Code 17 - Start Enable Relay

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

Note: Refer to “Hybrid Component and Connector Locations” on page 9 for connector locations.

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Fault Code 17 - Start Enable Relay | Fault Isolation Procedures TRTS2000

Fault Code 17 - Start Enable Relay

Purpose: Check for active or inactive fault code

status and FMIs present.

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

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

• If fault returns with new relay, go to St ep 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 D.

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

Connection Measurement

Pin 32 to Pin 4

1. Which FMIs were listed from Step A?

• If FMI 3 is listed, go to Step C.

• If FMI 4 is listed, go to Step E.

2015.10.20

Eaton Transmission TRTS2000 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual