Eaton Transmission TRTS2000 Service Manual

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

2015.10.20

| 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

2015.10.20

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

2015.10.20

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.

2015.10.20

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.

2015.10.20

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.

2015.10.20

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

+ 446 hidden pages