Eaton Hybrid Drive System Model TRTS2500

Service Manual
Eaton Hybrid Drive System

TRTS2500
August 2012
EH-11NA1206A-PBD
4-Battery PEC Model
4-Battery PEC
i
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 INDICATES YOU WILL BE SEVERLY 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.
!
WARNING
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. When parking the vehicle or leaving the cab you should place the shift lever in N and set the
parking brake.
6. 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.
7. 24-volt Battery (+) and (-) must be disconnected prior to any welding on any Hybrid equipped
vehicle.
ii
High-Voltage Warnings & Cautions Warnings & Cautions
!
CAUTION
Do not release the parking brake or attempt to select a gear until the air
pressure is at the correct level.
!
CAUTION
To avoid damage to the transmission during towing place the shift lever in
"N" and lift the drive wheels off the ground or disconnect the driveline.
High-Voltage Warnings & Cautions
Use CO2 or Dry Chemical Fire Extinguishers.
The high-voltage wiring is covered in orange insulation or convoluted tubing and marked with
warning labels at the connectors.
All Eaton Hybrid Diesel/Electric vehicles will be marked 'Hybrid' on the outside of the vehicle,
along with the shift label on the dash.
Refer to OEM for specific location of chassis mounted hybrid components.
Do NOT cut into the orange high-voltage cables.
Do NOT cut into or open the PEC.
Do NOT cut into or open the DC/DC converter.
Do NOT cut into or open the Inverter.
Warning: A buffer zone must be set up and high-voltage insulated rubber gloves (class 0 with
leather protectors) are required prior to working on high-voltage. Failure to follow these instructions
may result in severe personal injury or death.
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 must be tested before EVERY use
following the rubber insulation gloves testing procedure found in the Insulated Rubber Glove Test
section. Failure to follow these instructions may result in severe personal injury or death.
Warning: Before inspecting or working on any high-voltage cables or components the High-
Voltage Service Shutdown Procedure should be followed. Failure to follow these instructions may
result in severe personal injury or death.
Warning: 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.
iii
Table of Contents
Warnings & Cautions . . . . . . . . . . . . . . . . i
Insulated Rubber Glove Test
and High-Voltage Work Area . . . . . . . . . 1
High-Voltage Service Shutdown
and Power-Up Procedures . . . . . . . . . . . 3
Diagnostic Tools/ Service Publications. 9
Hybrid Diagnostic Procedure . . . . . . . . 11
Hybrid Component & Connector Locations13
Fault Code Retrieval/Clearing. . . . . . . . 17
Fault Code Isolation Procedure Index . 19
Symptom-Driven Diagnostics Index . . 23
Product Diagnostic Mode (PDM) . . . . . 25
Hybrid Lamp and
Gear Display Descriptions . . . . . . . . . . 27
Power-Up Sequence Test . . . . . . . . . . . 29
Electrical Pretest . . . . . . . . . . . . . . . . . . 31
Hybrid Electrical Pretest . . . . . . . . . . . . 35
Fault Code Isolation Procedures
Fault Code 1 . . . . . . . . . . . . . . . . . . . . . . 41
Fault Code 2 . . . . . . . . . . . . . . . . . . . . . . 47
Fault Code 3 . . . . . . . . . . . . . . . . . . . . . . 53
Fault Code 4 . . . . . . . . . . . . . . . . . . . . . . 61
Fault Code 5 . . . . . . . . . . . . . . . . . . . . . . 67
Fault Code 6 . . . . . . . . . . . . . . . . . . . . . . 75
Fault Code 7 . . . . . . . . . . . . . . . . . . . . . . 77
Fault Code 8 . . . . . . . . . . . . . . . . . . . . . . 79
Fault Code 9 . . . . . . . . . . . . . . . . . . . . . . 83
Fault Code 10 . . . . . . . . . . . . . . . . . . . . . 87
Fault Code 11 . . . . . . . . . . . . . . . . . . . . . 91
Fault Code 12 . . . . . . . . . . . . . . . . . . . . . 93
Fault Code 14 . . . . . . . . . . . . . . . . . . . . . 95
Fault Code 16 . . . . . . . . . . . . . . . . . . . . . 99
Fault Code 17 . . . . . . . . . . . . . . . . . . . . 105
Fault Code 18 . . . . . . . . . . . . . . . . . . . . 111
Fault Code 19 . . . . . . . . . . . . . . . . . . . . 115
Fault Code 22 . . . . . . . . . . . . . . . . . . . . 119
Fault Code 24 . . . . . . . . . . . . . . . . . . . . 123
Fault Code 26 . . . . . . . . . . . . . . . . . . . . 127
Fault Code 27 . . . . . . . . . . . . . . . . . . . . 131
Fault Code 32 . . . . . . . . . . . . . . . . . . . . 135
Fault Code 33 . . . . . . . . . . . . . . . . . . . . 139
Fault Code 34 . . . . . . . . . . . . . . . . . . . . 143
Fault Code 35 . . . . . . . . . . . . . . . . . . . . 147
Fault Code 36 . . . . . . . . . . . . . . . . . . . . 153
Fault Code 37 . . . . . . . . . . . . . . . . . . . . 155
Fault Code 38 . . . . . . . . . . . . . . . . . . . . 161
Fault Code 39 . . . . . . . . . . . . . . . . . . . . 167
Fault Code 40 . . . . . . . . . . . . . . . . . . . . 173
Fault Code 48 . . . . . . . . . . . . . . . . . . . . 179
Fault Code 49 . . . . . . . . . . . . . . . . . . . . 183
Fault Code 50 . . . . . . . . . . . . . . . . . . . . 185
Fault Code 51 . . . . . . . . . . . . . . . . . . . . 187
Fault Code 52 . . . . . . . . . . . . . . . . . . . . 191
Fault Code 56 . . . . . . . . . . . . . . . . . . . . 197
Fault Code 58 . . . . . . . . . . . . . . . . . . . . 201
iv
Table of Contents
Fault Code Isolation Procedures (Continued)
Fault Code 59 . . . . . . . . . . . . . . . . . . . . 205
Fault Code 60 . . . . . . . . . . . . . . . . . . . . 211
Fault Code 61 . . . . . . . . . . . . . . . . . . . . 215
Fault Code 63 . . . . . . . . . . . . . . . . . . . . 219
Fault Code 64 . . . . . . . . . . . . . . . . . . . . 223
Fault Code 65 . . . . . . . . . . . . . . . . . . . . 227
Fault Code 66 . . . . . . . . . . . . . . . . . . . . 233
Fault Code 67 . . . . . . . . . . . . . . . . . . . . 237
Fault Code 68 . . . . . . . . . . . . . . . . . . . . 243
Fault Code 70 . . . . . . . . . . . . . . . . . . . . 247
Fault Code 71 . . . . . . . . . . . . . . . . . . . . 249
Fault Code 72 . . . . . . . . . . . . . . . . . . . . 253
Fault Code 73 . . . . . . . . . . . . . . . . . . . . 257
Fault Code 74 . . . . . . . . . . . . . . . . . . . . 261
Fault Code 75 . . . . . . . . . . . . . . . . . . . . 263
Fault Code 76 . . . . . . . . . . . . . . . . . . . . 265
Fault Code 78 . . . . . . . . . . . . . . . . . . . . 269
Fault Code 82 . . . . . . . . . . . . . . . . . . . . 273
Fault Code 83 . . . . . . . . . . . . . . . . . . . . 279
Fault Code 84 . . . . . . . . . . . . . . . . . . . . 285
Fault Code 85 . . . . . . . . . . . . . . . . . . . . 293
Fault Code 88 . . . . . . . . . . . . . . . . . . . . 299
Fault Code 89 . . . . . . . . . . . . . . . . . . . . 303
Fault Code 95 . . . . . . . . . . . . . . . . . . . . 309
Fault Code 101 . . . . . . . . . . . . . . . . . . . 315
Fault Code 103 . . . . . . . . . . . . . . . . . . . 319
Fault Code 105 . . . . . . . . . . . . . . . . . . . 325
Fault Code 107 . . . . . . . . . . . . . . . . . . . 331
Fault Code 108 . . . . . . . . . . . . . . . . . . . 347
Fault Code 110 . . . . . . . . . . . . . . . . . . . 353
Fault Code 111 . . . . . . . . . . . . . . . . . . . 357
Fault Code 112 . . . . . . . . . . . . . . . . . . . 363
Fault Code 113 . . . . . . . . . . . . . . . . . . . 369
Fault Code 114 . . . . . . . . . . . . . . . . . . . 375
Fault Code 115 . . . . . . . . . . . . . . . . . . . 381
Fault Code 116 . . . . . . . . . . . . . . . . . . . 387
Fault Code 116 . . . . . . . . . . . . . . . . . . . 395
Fault Code 117 . . . . . . . . . . . . . . . . . . . 405
Fault Code 166 . . . . . . . . . . . . . . . . . . . 411
Front Box Test . . . . . . . . . . . . . . . . . . . 413
Engine Crank Test . . . . . . . . . . . . . . . . 419
Hybrid Performance Test. . . . . . . . . . . 423
Gear Engagement Test . . . . . . . . . . . . 427
Wiring Diagrams. . . . . . . . . . . . . . . . . . 431
Connector Pin Description . . . . . . . . . 435
1
Insulated Rubber Glove Test and High-Voltage Work Area
Insulated Rubber Glove Test
!
WARNING
The rubber-insulated gloves that must be worn while working on the high-
voltage system are class 0 with leather protectors. The rubber gloves
should be tested before EVERY use following the rubber insulation gloves
testing procedure found in the Diagnostic Tools section. Failure to follow
these instructions may result in severe personal injury or death.
The insulated rubber gloves that must be worn while working on the high-voltage system are
class 0 rated. They must be inspected before each use and must always be worn in
conjunction with the leather outer glove. Any hole in the insulated rubber glove is a potential
entry point for high-voltage.
Roll the glove up from the open end until the lower portion of the glove begins to balloon from
the resulting air pressure. If the glove leaks any air it must not be used.
The gloves should not be used if they exhibit any signs of wear and tear.
The leather gloves must always be worn over the rubber insulating gloves in order to protect
them.
The rubber insulating gloves must be class 0 and meet all of the American Safety Testing
Materials Standards.
High-Voltage Work Area Requirements
!
WARNING
A buffer zone must be set up and high-voltage insulated rubber gloves
(class 0 with leather protectors) are required prior to working on any high-
voltage. Failure to follow these instructions may result in severe personal
injury or death.
The buffer zone is required only when working on the high-voltage DC or AC systems and is called
out both in the High-Voltage Service Shutdown Procedure and the individual repair procedures.
Position the vehicle in the service bay.
Position four orange cones around the corners of the vehicle to mark off a 1m (3 ft.) perimeter
around the vehicle.
Do not allow any unauthorized personnel into the buffer zone during repairs involving high-
voltage. Only personnel trained for service on the high-voltage system are to be permitted in
the buffer zone.
2
Insulated Rubber Glove Test Insulated Rubber Glove Test and High-Volt-
3
High-Voltage Service Shutdown and Power-Up Procedures
Warning: A buffer zone must be set up and high-voltage insulated rubber gloves (class 0 with
leather protectors) are required prior to working on high-voltage. Failure to follow these instructions
may result in severe personal injury or death.
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 must be tested before EVERY use
following the rubber insulation gloves testing procedure found in the Insulated Rubber Glove Test
section. Failure to follow these instructions may result in severe personal injury or death.
Warning: Before inspecting or working on any high-voltage cables or components the High-
Voltage Service Shutdown Procedure must be followed. Failure to follow these instructions may
Warning: 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 must
be followed prior to removing any high-voltage cables. Failure to follow these instructions may
Warning: 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.
Air Filter Cover Wing Nuts
Exhaust Duct
PEC Service Switch
Access Panel Covers
Access Panel
Security Screws
Low-Voltage 19-Pin Connector
Top Cover
Air Filter Cover
High-Voltage DC
Connector to Inverter
Air Outlet
Access Panel
(On side not shown)
Cooling Pipes
8 Mounting Holes
(Mounting hardware supplied by OEM)
Cover Bolts
Lifting Eyes
Cover Security Screws
4
High-Voltage Service Shutdown and Power-
4-Battery High-Voltage Service Shutdown Procedure
1. Follow High-Voltage Work Area procedure.
2. Locate the red PEC Service Switch on the front of the PEC and push to the Off position.
3. Turn ignition key On.
4. Allow the system to set for a minimum of 5 minutes to discharge high-voltage.
5. Connect ServiceRanger.
6. Select Vehicle Data Monitor from the main menu.
7. Select J1939 HV Battery.
8. Monitor the J1939 HV Battery (Parameter 520323) voltage until it displays 30 volts or less.
Note: If after 5 minutes J1939 HV Battery does not display 30 volts or less, contact Roadranger
Call Center at 1-800-826-4357.
9. Turn ignition key Off.
10. Proceed to repair or troubleshooting step. Perform the 4-Battery PEC Isolation Procedure
before making any internal repairs to the 4-Battery PEC.
PEC Service Switch
2
5 6
7 8
5
4-Battery High-Voltage Isolation Procedure
1. After performing the High-Voltage Service Shut-Down Procedure, if removal is necessary,
refer to the 4-Battery Power Electronics Carrier (PEC) Removal and Installation procedure in
the service manual TRSM2000.
2. Using a 13 mm socket, remove the 14 nuts and lock washers used to secure both access
panels. Using a T-27 Plus bit, remove the two security screws and lock washers used to secure
the access panels. Remove the access panel and gaskets.
3. Put on high voltage 0 rated gloves and leather protectors.
4. Remove the 4-Battery PEC main fuses by lifting up on each handle and gently pulling each
fuse from the socket.
Note: There are two main fuses in the 4-Battery PEC.
Access
Panels
Access
Panel
Security
Screws
Main Fuses
6
5. Wearing the high voltage 0 rated gloves and leather protectors, pull the battery connections
following the sequence in the image below.
6. To complete the 4-Battery PEC High-Voltage Isolation Procedure, it is required to place the
access covers back on the 4-Battery PEC. Secure access covers with lock washers and nuts
to service the 4-Battery PEC.
7. Proceed to repair or troubleshooting step.
1 2 3 4
7
4-Battery PEC High-Voltage Service Power-Up Procedure
1. Remove both access covers.
2. Put on high voltage 0 rated gloves and leather protectors.
3. Reinstall battery connections following the sequence in the image below.
4. Wearing the high voltage 0 rated gloves and leather protectors, reinstall the two main fuses.
5. Replace both access panel gaskets and reinstall the access panels. Reinstall the 14 lock
washers and nuts. Torque to 44-53 in-lb (5-6 Nm).
1 2 3 4
Main Fuses
8
6. Install the two lock washers and security screws. Torque to 44-53 in-lb (5-6 Nm).
7. Install the 4-Battery PEC to the vehicle using proper equipment and safety procedures.
Note: The weight of the 4-Battery PEC is 513 lbs (230 kg).
8. Using a 17 mm socket, install the eight OEM supplied mounting bolts, lock washers, and flat
washers. Torque fasteners to 43-48 ft-lb (32.5-36.6 Nm).
9. Connect the OEM supplied Low-Voltage 19-Pin Connector onto the 4-Battery PEC.
10. Wearing the high voltage 0 rated gloves and leather protectors, install the High-Voltage DC
Connector to the Inverter and lock it into place.
11. Reassemble the cooling pipes.
12. Pull out the red PEC Service Switch to the On position.
13. Start vehicle when appropriate.
Access
Panels
Access
Panel
Security
Screws
9
Diagnostic Tools/ Service Publications
Eaton Tools
Visit www.Roadranger.com
SPX/OTC Tools
Contact SPX / OTC at (800) 328-6657
Tool Description
ServiceRanger version 3 ServiceRanger PC based Diagnostic Tool
Tool Description
J-49818 Eaton Hybrid Tool Safety Kit - Basic PPE (Items listed below can be ordered
separately)
J-48603 High-Voltage Gloves w/leather protectors (1000 volt)
J-48605 Hybrid Safety Cones (set of 4)
Tool Description
J-49819 Eaton Hybrid Tool Safety Kit - Basic Plus PPE (Items listed below can be
ordered separately)
J-48603 High-Voltage Gloves w/leather protectors (1000 volt)
J-48605 Hybrid Safety Cones (set of 4)
J-48907 Orange Magnetic Sign
J-48608 Hybrid Non-Conductive Safety Pole
J-48908 Glove Bag
10
Eaton Tools Diagnostic Tools/ Service Publications
J-48893 - Hybrid PPE / Service Tool Kit (includes J-49819 kit and items from Miscellaneous
Service Tools highlighted with *)
Service Publications
Visit www.Roadranger.com
Tool Description
Misc. Service Tools Items listed below are ordered separately
J-48624 Nexiq USB-Link Communication Adapter
J-43318-A* Pin Adapter Kit - Interface Harness Diagnostics
J-48735* Alignment Pins - Hybrid Motor/Gen to Transmission Main Case
J-49111* Clutch Alignment Tool
J-46708* Fluke Digital Multimeter
J-48505 Input Shaft Turning Socket
J-48507 Lifting Fixture - Power Electronics Carrier
J-48502 Jack Adapter Plate - Hybrid Drive Unit
5019 Transmission Jack - Low Lift
5078 Transmission Jack - High Lift
J-48577 Engine/Transmission Stand Adapter Plate - Hybrid Drive Unit
J-29109-A Engine/Transmission Stand - 6000 lb. Rating
TRSM2000 Service Manual (covers external components on transmission and
Hybrid components)
TRSM0110 Service Manual (covers internal transmission repairs only)
TRTS2500 Troubleshooting Guide
TRDR1000 Driver Instructions
TRDR1110 First Responder Guide
11
Hybrid Diagnostic Procedure
Key ON
Retrieve Active Faults
with ServiceRanger.
Active Codes Yes
Go to "Fault Code Isolation Procedure
Index"
No
Does Gear Display
Show an "N"
Does Engine Crank
No
Yes
No
Go to "Engine Crank
Test"
Yes
If equipped, does
vehicle operate
normal in ePTO
mode?
No
Go to "ePTO Test
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.
No
Go to "Gear Engagement Test
if solid N is displayed
Go to Front Box Test is
flashing gear number is displayed
Yes
Is vehicle acceleration
performance acceptable No
Go to "Hybrid
Performance Test"
Yes
Clear faults and
operate vehicle based
on customers
concern
Inactive Faults = Go
to "Product
Diagnostic Mode"
Active Faults = Go to
"Fault Isolation
Procedure Index"
No Fault = Test
Complete
Is Red "Stop Hybrid" or
Amber Check Hybrid
lamp blinking?
Yes
No
Go to Hybrid Lamp
Gear Display Description
Go to Hybrid Lamp and
Gear Display description
Go to Gear Engagement
Test
Will vehicle move
from a stop?
Yes
No
12
13
Hybrid Component & Connector Locations
Transmission Wiring Connections
Hybrid Control Module (HCM)
Left: 38-Way System Connector
Right: 38-Way Vehicle Connector
Transmission Electronic Control Unit (TECU)
Left: 38-Way Vehicle Connector
Right: 38-Way System Connector
Electronic Clutch Actuator
Top: 3-Way Connector
Bottom: 8-Way Connector
Output Shaft Speed Sensor
Rail Position Sensor
14
Transmission Wiring Connections Hybrid Component & Connector Locations

Gear Position Sensor
High-Voltage 3-Way AC Connector
Motor/Generator
Resolver Connector
Motor/Generator
Temperature Connector
Input Shaft Speed Sensor
Transmission Diagnostic Port
15
Hybrid Component & Connector Locations Component Wiring Connections
Component Wiring Connections
24V DC(-)
High Voltage DC Connector
Top: DC(-)
Bottom: (DC(+)
Test Port Connection
(Not used)
OEM Connection
DC/DC Converter
HIgh Voltage 3-Way AC Connector
Low Voltage 40-Way Connector
High-Voltage DC Connector to PEC
Inverter
Coolant Ports
24V DC(+)
(-) (+)
Coolant Port Inlet
Coolant Port Outlet
16
Component Wiring Connections Hybrid Component & Connector Locations
Air Filter Cover Wing Nuts
Exhaust Duct
PEC Service Switch
Access Panel Covers
Access Panel
Security Screws
Low-Voltage 19-Pin Connector
Top Cover
Air Filter Cover
High-Voltage DC
Connector to Inverter
Air Outlet
Access Panel
(On side not shown)
Cooling Pipes
8 Mounting Holes
(Mounting hardware supplied by OEM)
Cover Bolts
Lifting Eyes
Power Electronics Carrier (PEC)
Cover Security Screws
17
Fault Code Retrieval/Clearing
All Eaton Hybrid systems require the use of ServiceRanger for all diagnostics. To view fault
codes or clear them follow the procedures below.
View Active and Inactive Faults
1. Connect ServiceRanger to the 9-pin diagnostic connector.
2. Go to the Tools menu and select the Communication tab.
3. Select the appropriate communication device for J1587 and J1939.
4. Select Connect on the main page.
5. Select the View Fault Codes tab.
Note: Initial use requires all steps, however subsequent uses require only steps 4 and 5.
Clear Inactive Faults
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.
18
Fault Code Retrieval/Clearing
19
Fault Code Isolation Procedure Index
Index
Fault Code SPN FMI Description Page Number
1 520225 0,6,15 Motor/Generator Current Sensor page 41
2 520226 3 Motor/Generator Temperature
Sensor
page 47
3 520227 0 Motor/Generator Temperature page 53
4 520228 0,2, 21-27 Motor/Generator Rotation Speed
Sensor
page 61
5 520229 21-29 Motor/Generator AC Cable page 67
6 629 13 No ECU Operation (HCM) page 75
7 629 13 Improper ECU Configuration
(HCM)
page 77
8 158 4 Loss of Switched Ignition Power
Fault (HCM)
page 79
9 168 14 Weak Battery Voltage (HCM) page 83
10 168 4 Low Battery Voltage (HCM) page 87
11 629 12 No ECU Operation (TECU) page 91
12 629 13 Improper ECU Configuration
(TECU)
page 93
14 751 2, 3, 4 Invalid Shifter Range page 95
16 625 2 High Integrity Link (HIL) page 99
17 626 3, 4 Start Enable Relay page 105
18 520200 2, 9 ECA Communication page 111
19 520273 2, 9 CAN ECA Message page 115
22 563 2, 9, 14 J1939 ABS Message (HCM) page 119
24 525 9 J1939 HCM Message (TECU) page 123
26 522 10 Clutch Slip page 127
27 788 7, 14 Clutch Disengagement page 131
32 43 2 Loss of Switched Ignition Power
(TECU)
page 135
33 168 4 Low Battery Voltage (TECU) page 139
34 168 14 Weak Battery Voltage (TECU) page 143
35 639 2 J1939 Communication Link page 147
36 639 14 J1939 Engine Message (TECU) page 153
37 610 5 Power Supply (TECU) page 155
38 520243 3, 4, 5, 14 Battery Fan Relay page 161
39 520247 3, 4, 5 Heat Exchanger Relay page 167
40 520248 3, 4, 5, 14 Cooling Pump Relay page 173
48 523 2, 9 J1939 Transmission Message
(HCM)
page 179
49 190 2, 9 J1939 Engine Message (HCM) page 183
20
Index Fault Code Isolation Procedure Index
50 701 2, 9 J1939 Body Controller Message
(HCM)
page 185
51 60 2, 3, 4, 10 Rail Position Sensor page 187
52 59 2, 3, 4 Gear Position Sensor page 191
56 161 2,3,4, 5,10 Input Shaft Speed Sensor page 197
58 191 2, 3, 4, 5 Output Shaft Speed Sensor page 201
59 639 2, 9 J1939 Communication Link
(HCM)
page 205
60 625 2, 9 CAN Communication Link (HCM) page 211
61 772 5, 6 Rail Select Motor page 215
63 773 5, 6 Gear Select Motor page 219
64 788, 520198,
520199, 524035
0, 12, 13,
21-28
ECA page 223
65 520203 2, 5 ECA Speed Sensor page 227
66 520271 3, 4, 14 ECA Battery Voltage page 233
67 520274 3, 4, 5 ECA Ignition Voltage page 237
68 520231 12, 13, 14 Grade Sensor page 243
70 188, 518, 539, 544 0, 1, 2, 7 Engine Failed to Respond (HCM) page 247
71 520275 7 Failed to Disengage Gear page 249
72 520277 7 Failed to Select Rail page 253
73 520278 7 Failed to Engage Gear page 257
74 93, 190 7 Engine Failed to Respond
(TECU)
page 261
75* 520276 14 Power Down In Gear page 263
76 520250 3, 4, 16,18 High-Voltage Battery Potential
Voltage
page 265
78 520232 6 High-Voltage Battery Current page 269
82 520233 0,16 High-Voltage Battery
Temperature
page 273
83 751 12, 13 Invalid Shifter Range page 279
84 751 13 Shift Control Device Not
Configured
page 285
85 639 12 Shift Control Device Incompatible page 293
88 520223 2, 9 Inverter CAN Message (HCM) page 299
89 520234 2, 9 BCU CAN Message (HCM) page 303
95 520249 3, 4 24-volt Cranking Relay page 309
101 520238 0, 22-31 High-Voltage Battery page 315
103 520265 22-26 Battery Control Unit
Communication
page 319
105 520240 22-30 Battery Control Unit page 325
107 520242 1 High-Voltage Battery Leak
Detection
page 331
108 520268 3, 4 Battery Control Unit Power
Supply
page 347
21
Fault Code Isolation Procedure Index Index
110 520220 21-29 Inverter page 353
111 520260 12 - 28 Inverter Communication page 357
112 520221 3, 4 Inverter Voltage page 363
113 520222 6, 14 Inverter Current page 369
114 520261 3, 4 Inverter Power Supply page 375
115 520223 0 Inverter Temperature page 381
116 521210, 521211,
521212
3, 4, 5 High-Voltage Relays page 387
116 520224 10, 14, 20 High-Voltage Relays page 395
117 520251 3, 14, 29 BCU Relay Cut Request page 405
22
Index Fault Code Isolation Procedure Index
23
Symptom-Driven Diagnostics Index
Index
Symptom Isolation Procedure Page
Number
Power-up no crank and Gear Display shows a
-
Front Box Test page 413
Power-up no crank and Gear Display shows a
N
Engine Crank Test page 419
Power-up no crank and Gear Display shows -
-, **, or blank
Power Up Sequence Test page 29
Power-up vehicle cranks and Gear Display
shows --, **, or blank
Refer to OEM for gear display issue
Vehicle acceleration performance is not
acceptable
Hybrid Performance Test page 423
Transmission will not engage a gear from
neutral and warning tone sounds (solid N in
gear display)
Gear Engagement Test page 427
Transmission will not move from a stop (solid
gear number in gear display)
Gear Engagement Test page 427
Transmission will not engage a gear from
neutral (flashing gear number in gear display)
Front Box Test page 413
Red Service lamp on the push button shift
control is on/blinking
Fault Code Retrieval and Clearing page 17
Amber Check Hybrid lamp on the dash is on Fault Code Retrieval and Clearing page 17
Red Stop Hybrid lamp on the dash is on Fault Code Retrieval and Clearing page 17
24
Symptom-Driven Diagnostics Index
25
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. Use the active fault isolation
procedure to guide you 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 (PDM). You must turn vehicle key
OFF and allow the system to power down to exit PDM.
1. Vehicle must be stationary, engine must not be running, vehicle parking brake must be set.
3. Select the View Fault Codes screen.
4. Perform two key clicks of the ignition switch starting in the ON position and ending in the
ON position
Note: An 88 may show up in the dash at key on, which is a normal power-up test of the display.
5. The gear display will flash a solid PD (Product Diagnostic Mode) and the mode will 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 Isolation
Procedure page 11.
Note: Active codes set during PDM mode will not be stored as inactive.
9. To exit PDM mode, power the system down by turning the key to the OFF position.
PDM will only work with the following inactive codes
9, 10, 14, 16, 17, 18, 19, 22, 24, 32, 33, 34, 35, 36, 38, 39, 40, 48, 49, 50, 51, 52, 56, 58, 59, 60,
61, 63, 76, 87, 88, 89, 95
26
Product Diagnostic Mode (PDM) is used to help diagnose inactive codes that may have
27
Hybrid Lamp and Gear Display Descriptions
All Eaton Hybrid systems use a combination of three lamps to indicate failures of different
operating systems and the ability of the vehicle to drive. These lamps include the red Service
lamp, amber Check Hybrid lamp, and the red Stop Hybrid lamp. The details for each lamp are
included below.
Red Service Lamp
1. This lamp is located on the Push Button Shift Control and reads SERVICE.
2. This lamp is turned on and off by the Transmission Electronic Control Unit (TECU) for
Automated Transmissions faults over the High Integrity Link (HIL).
3. This lamp also comes on momentarily at key on then goes out as part of the TECU self-test.
Amber Check Hybrid Lamp
1. This lamp is located near the middle of the dash. The lamp is amber and contains wording
below stating Check Hybrid.
2. This lamp is turned on and off indirectly by the Hybrid Control Module (HCM) and directly by
the Body Controller over J1939.
3. This lamp is turned on when a Hybrid system fault is active.
4. When the amber lamp is on, the vehicle can still be driven, however, the vehicle may operate
without Hybrid electric assist.
Red Stop Hybrid Lamp
1. This lamp is located near the middle of the dash. The lamp is red and contains wording below
stating Stop Hybrid.
2. This lamp is turned on and off indirectly by the Hybrid Control Module (HCM) and directly by
the Body Controller over J1939.
3. This lamp is turned on when a Hybrid system fault is active.
4. When the red lamp is on, the vehicle should not be driven. Have the vehicle towed or trailered
to the OEM truck dealership.
Blinking amber Check Hybrid Lamp
1. The majority of vehicles have a red stop switch on the front of the Power Electronics Carrier
(PEC). If this switch is pushed in, the amber Check Hybrid lamp will blink. To reset, pull the
switch out and turn the key off for 2 minutes. If the lamp remains on, go to the Hybrid
Diagnostic Procedure on page 11 and start with step 3 Retrieve Active Faults with
ServiceRanger. You should have an active Fault Code 76 FMI 4, or Fault Code 116, FMI 10.
Continue to the diagnostic test for the fault that is currently active.
ST in Gear Display
1. A ST in the gear display indicates a driver trigger Snapshot was recorded. Snapshot is a
diagnostic tool that is used to capture specific data at the time of a fault. It is triggered through
two different means listed below.
a. Fault code triggered - Specific faults will trigger the HCM or TECU to capture a Snapshot
file for later retrieval. This method will not display and ST in the gear display.
b. Driver triggered - If the driver chooses to capture a Snapshot of an event he needs to
decide if he wants TECU or HCM data. To capture a TECU Snapshot select, Low and
the up button twice. To capture a HCM Snapshot select, Drive or Low and the up button
and the down button.
28
Hybrid Lamp and Gear Display Descriptions
PD in Gear Display
1. A PD in the gear display indicates the TECU and HCM are in a special diagnostic mode
called Product Diagnostic Mode (PDM). For more details on the mode and its operation see
the Product Diagnostic Mode on page 25.
CA in Gear Display
1. A CA in the gear display indicates the HCM is detecting a clutch abuse situation. If the
vehicle 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 only
allow an electric only launch in addition to continuing the tone and the CA. If the clutch abuse
continues, while driving the Hybrid system will open the clutch once vehicle speed is below
5mph and allow the clutch to cool.
OS in Gear Display
1. A OS in the gear display indicates the HCM is detecting a motor overspeed situation. The
vehicle will upshift in Drive and Low automatically, however, if the user is in Manual they
perform the upshift unless the vehicle is close to the motor overspeed. If the vehicle is
descending a long steep grade in top gear, the driver may see an OS indicating he needs to
depress the service brake pedal to slow the vehicle. The HCM will normally shift the vehicle or
reduce torque to prevent the motor from going overspeed.
F in Gear Display
1. A F in the gear display indicates the TECU has detected an active fault. This fault can be
accessed with ServiceRanger. See the Fault Code Isolation Procedure Index starting on
page 19.
- in Gear Display
1. A - in the gear display indicates the transmission is stuck in gear. See the Symptom Driven
Diagnostic Index on page 23.
** in Gear Display
1. A ** in the gear display indicates the gear display has power but no communication on the
data link. See the Symptom Driven Diagnostic Index on page 23.
- - in Gear Display
1. A - - in the gear display indicates the gear display has power, and there is no communication
present on the data link, or the TECU isnt communicating with the display. See the Symptom
Driven Diagnostic Index on page 23.
Blank Gear Display
1. A Blank gear display indicates the display has lost power, or the TECU isnt communicating
with the gear display. See the Symptom Driven Diagnostic Index on page 23.
29
Power-Up Sequence Test
Overview
This test must be performed only if you experience a vehicle wont crank with a - -, **, or blank
gear display. You must perform the Electrical Pretest prior to this procedure.
Possible Causes
TECU Power Supply
TECU
Fallback Mode
There is no fallback for this concern and the vehicle will not crank if the TECU or power supply
harness has failed.
Required Tools
Basic Hand Tools
Battery Load Tester
Eaton Test Adapter Kit J-43318
Digital Volt/Ohm Meter J-46708
STEP A
Procedure Condition Action
1. Perform the Electrical Pretest
2. Is concern still present after
the Electrical Pretest.
Yes Replace the TECU. Return to the
Diagnostic Procedure.
No Test Complete. Return to the
Diagnostic Procedure.
30
Overview Power-Up Sequence Test
31
Electrical Pretest
Overview
This test must be performed prior to diagnosing select 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), Transmission Electronic Control Unit (TECU), and Electronic Clutch Actuator
(ECA).
Note: This test will be called out in the procedures where it is required.
Possible Causes
Low-voltage can be caused by the following:
Low batteries
Charging system
Power harness connections or fuses to TECU, HCM, or ECA
Fallback Mode When Fault is Set
A weak power supply can cause many issues such as shift performance, power-up or failure to
crank.
Required Tools
Basic Hand Tools
Battery Load Tester
ServiceRanger
32
Electrical Pretest Wiring Schematic Electrical Pretest
Electrical Pretest Wiring Schematic
A B C
ECA - 3-Way Connector
H
Battery
38
Plus (+)
B
HCM
HCM Power (Vehicle)
36
ECA
ECA Power C
ECA Ground
Neg (-)
Clutch Ignition (System)
Front View
(HCM - Vehicle Interface Connector)
37 38
35 36
1
6
7
12
13
22
23
28
29
34
ECA -Pack 8-Way Connector
E
A B C D
H G F
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
HCM Ground (Vehicle)
TECU
TECU Ground 36
35
38
TECU Ignition
TECU Power
13
Front View
(TECU - Vehicle Interface Connector)
37 38
35 36
1
6
12
13
22
23 28
29 34
7
35 HCM Ignition (Vehicle)
Ignition Relay
87
33
Electrical Pretest Electrical Pretest Procedures
Electrical Pretest Procedures
Electrical Pretest Procedures Continued
STEP A
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 23 to 25 volts on a
24-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.
STEP B
1. Key on.
2. Connect ServiceRanger to
9-pin diagnostic connector
in the cab.
3. Select the Data Monitor
option and view the
following parameters under
the Hybrid (clutch actuator)
list.
If PID 132 is within 0.6 volts of
battery voltage and PID 160
reads 1
Go to STEP C
a. PID 132 Clutch Actuator
Battery Voltage.
b. PID 160 Clutch Actuator
Ignition Switch Status.
If either voltage is out of range Repair main power or ignition
supply to the ECA. Repeat this
step.
Note: If the clutch parameters
can not be viewed on
ServiceRanger you
must check the power
supply to the ECA with
a voltmeter
34
Electrical Pretest Procedures Electrical Pretest
STEP C
option and view the
the Hybrid (Hybrid Control
Module) list.
a. PID 165 Battery
Potential Voltage
b. PID 166 Ignition
Switch Status.
battery voltage and PID 166
reads 1
Go to STEP D
Note: If the Battery Potential
Voltage or Ignition
Switch Status can not
be viewed on
ServiceRanger you
supply to the HCM with
a voltmeter.
If either voltage is out of range Repair the main power or
ignition supply to the HCM.
Repeat this step.
STEP D
option and view the
the Hybrid (Transmission)
list.
a. PID 168 Battery
Potential Voltage.
b. PID 158 Battery
Potential Voltage
Switched.
battery voltage and PID 158 is
within 0.6 volts of ignition
voltage
Test complete. Return to the
Fault or Symptom procedure
that directed you to this step.
Note: If the Battery Potential
Voltage or Battery
Potential Voltage
Switched can not be
viewed on
ServiceRanger you
supply to the TECU
with a voltmeter.
If either voltage is out of range Repair main power or ignition
supply to the TECU. Repeat this
step.
35
Hybrid Electrical Pretest
Overview
This test must be performed prior to diagnosing select Hybrid faults. This test verifies the power
supply for the Inverter and Battery Control Unit (BCU).
Note: You must perform the Electrical Pretest before the Hybrid Electrical Pretest.
Note: This test will be called out in the procedures where it is required.
Possible Causes
Low-voltage can be caused by the following:
Power harness connections from Inverter or BCU.
Loss of ignition power will cause the Hybrid system to be inoperable. The vehicle will run under
diesel power only.
Required Tools
Basic Hand Tools
High-Voltage Gloves J-48603
Battery Load Tester
ServiceRanger
36
Hybrid Electrical Pretest Wiring Schematic Hybrid Electrical Pretest
Hybrid Electrical Pretest Wiring Schematic
Inverter
Chassis Ground 1
Deutsch 19 - Way Mating Connector View
(PEC - Low Voltage Connector)
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
6
7
6
PEC

10
20
30
40
1
11
21
31
Deutsch 40-Way Mating Connector View
(Inverter - Low Voltage Connector)
7
9
14
25 GND-BC2
Relay Box Enable
Inverter Enable
Chassis Ground 2
HCM
(Pin 2)
DC/DC Converter
4-Way OEM Connector
4 3
1 2
DC/DC
Converter
4
Ground
Relay Box Enable 2
GND_BC
24
15
37
Hybrid Electrical Pretest Hybrid Electrical Pretest Procedures
Hybrid Electrical Pretest Procedures
STEP A
1. Perform the Electrical
Pretest then continue to
step two.
2. Key off.
!
WARNING
Follow Hybrid Shutdown
Procedure found at front of
book, to avoid shock, burn, or
death from improperly handled
high-voltage.
3. Disconnect the Inverter 40-
way connector.
4. Measure resistance from
pin 6 to battery negative
and then from pin 7 to
battery negative.
If resistance is 0 to 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.
STEP B
1. Connect a multi meter to
the Inverter 40-way
connector pin 9 and pin 6.
2. Key on.
3. Observe multi meter
voltage reading.
If voltage is 23 to 25 volts Go to STEP C
If voltage is outside of range Repair the harness from the
HCM. Repeat this step.
38
Hybrid Electrical Pretest Procedures Hybrid Electrical Pretest
STEP C
1. Key off.
2. Reconnect the Inverter 40-
way connector.
3. Disconnect the PEC 19-way
connector.
PEC pin 7 to battery
negative.
If resistance from pin 7 to
battery negative is 0 to 0.3
ohms
Go to STEP D
If resistance is outside of range Repair the Inverter to PEC
ground wire. Repeat this step.
STEP D
1. Connect a multi meter to
the PEC 19-way connector
pins 6 and pin 7.
2. Key on.
3. Observe multi meter
voltage reading.
If voltage is 23 to 25 volts If vehicle has ePTO feature on
Push Button go to STEP E.
If vehicle does not have ePTO
feature test complete.
Reconnect PEC 19-way
connector. Go to Fault Code
Isolation Procedure Index
page 19.
4. If voltage is outside of range Repair the power supply
harness from the Inverter.
Repeat this step.
39
Hybrid Electrical Pretest Hybrid Electrical Pretest Procedures
STEP E
1. Key off.
2. Reconnect PEC 19-way
connector.
3. Disconnect DC/DC
Converter 4-way connector.
DC/DC Converter 4-way
connector pin 4 to battery
negative.
If resistance between pin 4 and
battery negative is 0 to 0.3
ohms
Test Complete. Reconnect the
4-way connector. Return to
Fault Code Isolation Procedure
Index page 19.
If resistance is outside of range Repair the ground harness from
the DC/DC Converter to battery
negative. Repeat this step.
40
Hybrid Electrical Pretest Procedures Hybrid Electrical Pretest
41
Fault Code 1 Isolation Procedures
Motor/Generator Current Sensor Fault
SA 239
SPN 520225
FMI 0, 6, 15
Overview
The high-voltage Motor/Generator assembly is connected to the Inverter assembly through an AC
high-voltage cable that contains three separate cables. During operation the Inverter monitors the
amperage in the AC cables through a current sensor, which is mounted inside the Inverter. The
inductive sensor produces an output based on amperage present in the cables.
Conditions to Run Fault
The Inverter ignition voltage is greater than 7 volts and less than 32 volts.
Conditions to Set Fault
FMI 6 is set when Inverter detects current input from the Motor/Generator greater than 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.
Possible Causes
FMI 0,6
Inverter
Motor/Generator
AC Cable
FMI 15
- Inverter
When Fault Code 1 is set the following conditions will occur:
The amber Check Hybrid lamp will display.
Fault is stored in Hybrid Control Module (HCM) memory.
Electric Motor/Generator assist and regen are disabled, however, the high-voltage relays will
remain powered.
HCM continues to control the Hybrid vehicle in a diesel only mode.
Transmission defaults start gear to 1st.
Conditions to Clear the Fault
Only inactive faults can be cleared from the TECU or HCM history using ServiceRanger. The
TECU will automatically clear the faults from history after 200 hours and the HCM will
automatically clear the faults from history after 200 hours of the fault staying inactive.
42
Warnings and Cautions Fault Code 1 Isolation Procedures
Required Tools
A buffer zone must be set up and high-voltage insulated rubber gloves are required prior to
working on any high-voltage. Failure to follow these instructions may result in severe
personal injury or death.
The rubber insulating gloves that are to be worn while working on the high-voltage are
listed in this manual along with the glove protectors. The rubber gloves should be tested
before EVERY use following the rubber insulation gloves testing found in this manual.
Before inspecting or working on any high-voltage cables or components the 'High-Voltage
Shutdown Procedure' should be followed. Failure to follow these instructions may result in
severe personal injury or death.
The Lock-out and Tag-out devices should only be removed by the technician that placed the
Lock-out and Tag-out devices on the vehicle. Failure to follow these instructions may result
in severe personal injury or death.
High-voltage rubber insulated gloves must be worn when working on any high-voltage
cables. The 'High-Voltage Shutdown Procedure' must be followed prior to removing any
high-voltage cables. Failure to follow these instructions may result in severe personal
injury or death.
High-voltage cables and wiring are orange in color and contain a warning label at the
connectors, while high-voltage components are marked with a label. High-voltage rubber
insulated gloves must be used when working on any of these components. Failure to follow
Basic Hand Tools
ServiceRanger
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
43
Fault Code 1 Isolation Procedures Connector Views
Connector Views
High-Voltage AC Harness Connector View
(Amphenol Connector)
W U
V
E D
F
W
V
U
W
V
U
Inverter Motor/
Generator
Phase 1
Phase 2
Phase 3
High-Voltage AC Motor/Gen Connector View
U
V
W
F
E D
Phase 1
Phase 2
Phase 3
44
Fault Procedures Fault Code 1 Isolation Procedures
Fault Procedures
STEP A
1. Retrieve active fault codes
and FMIs with
ServiceRanger using the
9-pin diagnostic connector.
2. Key off.
3. Follow Hybrid Shutdown
Procedure page 3, to
avoid shock, burn, or death
from improperly handled
high-voltage.
4. Remove the AC cable from
the Motor/Generator and
Inverter
5. Measure resistance of each
circuit in the AC high-voltage
cable:
U-U
V-V
W-W
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. Go to STEP V
If FMI 15 is active Replace the Inverter. Go to
STEP V
STEP B
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
cable. Go to STEP V
45
Fault Code 1 Isolation Procedures Fault Procedures
STEP C
1. Key off.
2. Measure the resistance
between the following AC
high-voltage cable pins:
If resistance of each phase is 5M
or greater
Go to STEP D
U-U
V-V
W-W
cable. Go to STEP V
STEP D
Motor/Generator phase at
the following pins:
If resistance of each phase is less
than 10 ohms
Replace the Inverter. Go to
STEP V
U-U
V-V
W-W
If resistance is outside of range Replace the Motor/Generator. Go
to STEP V
STEP V
1. Key off.
2. Reconnect all connectors
and the negative battery
cable.
3. Key on.
4. Clear codes. Go to Fault
Code Retrieval/Clearing on
page 17
5. Drive the vehicle and attempt
to recreate the code
6. Check for codes. Go to Fault
page 17
If no codes Test complete.
If code 1 appears Return to STEP A to find
error in testing.
If code other than 1 appears Go to Fault Code Isolation
Procedure Index on page 19
46
Fault Procedures Fault Code 1 Isolation Procedures
47
Motor/Generator Temperature Sensor Fault
SA 239
SPN 520226
FMI 3
Overview
The Motor/Generator temperature sensor is a thermistor located inside the Motor/Generator that
changes in value based on the temperature. The Inverter supplies a 5 volt reference voltage to the
sensor and measures the volt drop in the circuit. When the Motor/Generator temperature is warm
the sensor resistance is low and the Inverter detects a low-voltage (0.2 volts equals 280C or
536F). When the Motor/Generator is cold the sensor resistance is high and the Inverter detects a
high-voltage (4.1 volts equals 0C or 32F).
The inverter ignition voltage is greater than 7 volts and less than 32 volts.
FMI 3 is set when the sensor voltage is greater than 4.1 volts for 10 seconds, while the
Inverter temperature is over 35 C or 95F, or if the sensor output voltage is less than 0.2
volts for 10 seconds.
Possible Causes
FMI 3
- Motor/Generator
- Short/open temperature sensor wires between the Motor/Generator and the
Inverter
- Inverter
The amber Check Hybrid lamp will display
Fault is stored in Hybrid Control Module (HCM) memory
High-voltage Motor/Generator assist is available, but at a reduced amount
Conditions to Clear Fault
48
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
49
Connector Views
36
37
2
1
Inverter
Motor/Generator
Temperature Sensor
TM Ground
TM
Temp Sensor
Temp Sensor
OTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Location
10
20
30
40
1
11
21
31
Terminal Side - Harness Connector
Temperature Sensor
(Deutsch 2-pin connector)
50
Fault Code Procedures Fault Code 2 Isolation Procedures
Fault Code Procedures
STEP A
and FMIs with
2. Key off.
Procedure found at front
of book, 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 to
301.7K ohms
Go to STEP B
If resistance is outside of range Replace the Motor/Generator.
Go to STEP V
WARNING
51
Fault Code 2 Isolation Procedures Fault Code Procedures
STEP B
1. Key Off.
2. Disconnect the Inverter
40-way connector.
3. Reconnect the Motor/
Generator 2-way temperature
sensor connector.
following:
a. Inverter 40-way
connector pin 37 to pin
36.
b. 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
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. Go to STEP V.
STEP V
1. Key off.
2. Reconnect all connectors and
the negative battery cable.
3. Key on.
4. Clear codes. See Fault Code
Retrieval/Clearing on page 17
5. Drive the vehicle and attempt to
recreate the code
6. Check for codes. See Fault
page 17
If code 2 appears Return to STEP A to find the error
in testing.
Procedure Index page 19
52
Fault Code Procedures Fault Code 2 Isolation Procedures
53
Motor/Generator Temperature Fault
SA 239
SPN 520227
FMI 0
Overview
The Motor/Generator temperature is measured through a thermistor style 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 280C or 536F). When the Motor/Generator is cold the sensor resistance is high
and the Inverter detects a high-voltage (4.1 volts equals 0C or 32F).
FMI 0 is set when the temperature sensor value is greater than 185C or 365F for 1 second.
Possible Causes
FMI 0
- Motor/Generator
- Inverter
- Liquid cooling system (low coolant, no coolant flow, coolant pump, radiator,
radiator fan, reservoir)
remain powered
HCM continues to control the Hybrid vehicle in a diesel only mode
Transmission defaults start gear to 1st
54
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
55
Connector Views
36
37
2
1
Inverter
Motor/Generator
Temperature Sensor
TM Ground
TM
Temp Sensor
Temp Sensor
10
20
30
40
1
11
21
31
Temperature Sensor
56
Fault Isolation Procedures Fault Code 3 Isolation Procedures
Fault Isolation Procedures
STEP A
and FMIs with
ServiceRanger using the 9-
pin diagnostic connector.
death from improperly
handled high-voltage.
3. Key on
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
STEP B
1. Key off
2. Observe the coolant level
after the system has cooled
down to ensure if is filled to
the proper level
If coolant is within the
recommended limits
Go to STEP C
If coolant is below the
recommended limits
Refer to the OEM for coolant type
and fill procedures. Check for
source of coolant leak. When
refilling the system it should be
pressurized or vacuum bleed of
air to ensure the coolant will flow
properly during normal operation.
WARNING
57
Fault Code 3 Isolation Procedures Fault Isolation Procedures
STEP C
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, the air
flow is obstructed, or the coolants
lines are bent sharply
Repair the concern. Go to
STEP V
STEP D
1. Key on.
the 9-pin 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
STEP E
the Heat Exchanger Fan
option
2. Enable the Heat Exchanger
Fan option
If the heat exchanger fan turns on The system needs to be purged
of air to allow the coolant to flow.
Bleed the air by using a coolant
system pressurizing tool or a
vacuum tool. Go to STEP V
If the heat exchanger fan does
not turn on
Go to STEP G
58
STEP F
1. Key on
2. Disconnect the Coolant
Pump 2-way connector
3. Select the Advanced
Products Function option and
select Cooling Pump.
option.
5. Measure voltage at the 2-way
connector from pin A to B.
If voltage between pins A and B is
+/- 0.2 volts of battery voltage
Refer to OEM for Coolant Pump
concern.
outside of range
Refer to OEM for repair
procedures on Cooling Pump
power harness or damaged fuse.
STEP G
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.
Fan option.
5. Measure voltage at the 2-way
connector from pin A to B.
Refer to OEM for Heat Exchanger
Fan concern.
outside of range
procedures on Heat Exchanger
Fan power harness or damaged
fuse.
59
STEP H
1. Key off
40-way connector
3. Measure resistance between
pins 36 and 37, and pin 37 to
ground of the Inverter 40-way
connector
ohms between pin 37 and pin 36
and resistance between pin 37
and ground is 10K ohms or
greater
STEP V
If resistance is outside the range Go to STEP I
STEP I
1. Key off
2. Disconnect the Motor/
Generator Temperature
Sensor 2-way connector
located on the right side of
the Motor/Generator
the 2-way Temperature
sensor connector from pin 1
to pin 2
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.
Go to STEP V
60
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
Code Removal/Clearing on
page 17
error in testing.
Procedure page 19
61
Motor/Generator Rotation Speed Sensor Fault
SA 239
SPN 520228
FMI 0, 2, 21-27
Overview
The Motor/Generator Rotation Speed Sensor is mounted to the back of the Motor/Generator
around the input shaft. The sensor is a two piece design with the rotor being mounted to the input
shaft and the sensing ring being mounted to the motor housing. The sensing ring is supplied with
low-voltage during operation. When the rotor turns it induces 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.
The Inverters ignition voltage is greater than 7 volts and less than 32 volts.
FMI 2 will not run if there is an active Transmission Input Shaft Speed Sensor fault.
FMI 0 is set when the Motor/Generator speed exceeds the normal allowable range.
FMI 2 is set when the Motor/Generator speed is different than Transmission Input Shaft Speed
by more than 100 RPM for at least 10 seconds.
FMI 21 is set when a resolver signal line short to 24-volt or ground is detected.
FMI 22,24,25 are set when the combination of the analog-to-digital converter signals is a
mismatch
FMI 27 is set when the Inverter detects and error in the initial check
FMI 23 is set when there is an analog-to-digital converter output error signal for 100ms
FMI 26 is set when the rotation sensor speed is greater than 6000 min-1 for 10 ms
Possible Causes
FMI 0
- Long extended grades may require intermittent use of the service brakes to slow
the vehicle
FMI 21
- Inverter
- Resolver Harness between the Motor/Generator and Inverter
FMI 22,24,25,27
- Inverter
FMI 2,23,26
- Inverter
- Motor/Generator
- Resolver Harness between the Motor/Generator and Inverter
62
remain powered
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
63
Connector Views
40
30
3
4
Inverter
Motor/Generator
Resolver
REZ_Minus
REZ_Plus
38
28
1
2
39
29
5
6 REZ_S2
REZ_S4
REZ_S1
REZ_S3 Resolver
Resolver
Resolver
Resolver
Resolver
Resolver
Resolver
10
20
30
40
1
11
21
31
64
STEP A
and FMIs with
2. Key off.
4. What FMIs are present. If FMI 22,24,25, or 27 are listed Replace the Inverter. Go to
STEP V
If FMI 2,23, or 26 are listed Go to STEP B
If FMI 21 is listed Go to STEP D
STEP B
1. Disconnect the 40-way low-
voltage connector at the
Inverter.
2. Measure Resolver resistance
at the 40-pin harness
connector between the
following pins:
30 - 40
28 - 38
29 - 39
If resistance for the following pins
are:
Pin 30-40 is 10.5 to
8.6 ohms
Pin 28-38 is 34 to 28
ohms
Pin 29-39 is 27 to 23
ohms
If FMI 2 is active contact Eaton at
1-800-826-HELP (4357). If FMI
26 or 23 are active replace the
Inverter. Go to STEP V
If resistance is outside of range
for any of the readings
Go to STEP C
WARNING
65
STEP C
1. Disconnect the 6-way Motor/
Generator resolver
connector.
2. Measure the Resolver
resistance at the 6-pin
harness connector between
the following pins:
3-4
1-2
5-6
Note: An auto-ranging digital
volt/ ohm meter must be
used.
If resistance for the following pins
are:
Pin 3-4 is 10.5 to 8.6
ohms
Pin 1-2 is 34 to 28
ohms
Pin 5-6 is 27 to 23
ohms
Repair the open harness
between the Inverter 40-pin
connector and the Motor/
Generator 6-pin Resolver
connector. Go to STEP V
If resistance is outside of range Replace the Motor/Generator.
Go to STEP V
STEP D
1. Disconnect the 40-way
connector at the inverter
2. Use an ohm meter to
measure a short to both
ground and vehicle battery
24 volt on the following pins
28
29
38
39
Note: An auto-ranging digital
volt/ ohm meter must be
used.
If there is continuity at any of the
following pins:
Pin 28
Pin 29
Pin 38
Pin 39
Repair resolver vehicle harness
between the Inverter and Motor/
Generator. Go to STEP V
If meter reads Open or OL Replace the Inverter. Go to
STEP V
66
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
If code 4 appears Return to STEP A to find error in
testing.
Procedure page 19
67
Motor/Generator AC Cable Fault
SA 239
SPN 520229
FMI 21-29
Overview
The Motor/Generator AC cables are connected from the Motor/Generator to the Inverter. These
cables carry up to 500 volts AC 3 phase when the vehicle is in operation.
The Inverters ignition voltage is greater than 7 volts and less than 32 volts.
FMI 25-27 require the Motor/Generator RPM to be greater than 500 RPM.
FMI 28 requires the Motor/Generator RPM to be less than 500 RPM.
FMI 29 requires the Motor/Generator RPM to be less than 50 RPM.
FMI 21 is set when the AC interlock circuit is open.
FMI 22,23,24 are set when the 2 phase motor current is more than 360 amps for 0.9 ms.
FMI 25,26,27 are set when the Inverter detects a single open wire and motor current is less
than 8 amps for 200ms at speeds >= 500 RPM and current command from the Inverter is > 20
amps.
FMI 28 is set when Motor/Generator current is less than 8A for 200ms at Speed < |500RPM|
and current command > 20A(rms).
FMI 29 is set during initialization, the Inverter checks if the AC cable is connected between the
Motor and Inverter by sending out 20A for 200ms and checking the feedback.
Possible Causes
FMI 21
- AC Cable Interlock
FMI 22,23,24
- Inverter
- Motor/Generator
- AC Cable
FMI 25,26,27,28,29
- Motor/Generator
- AC Cable
The red Stop Hybrid lamp will display.
Fault is stored in Hybrid Control Module (HCM) memory.
Inverter shuts high-voltage system off.
68
If FMI 28, or 29 is present at power-up, the vehicle will not crank.
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
WARNING
HAZARDOUS VOLTAGE
DANGER
HAZARDOUS VOLTAGE
You will be severly 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.
69
Connector Views
W U
V
E D
F
W
V
U
W
V
U
Inverter Motor/
Generator
Phase 1
Phase 2
Phase 3
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Location
U
V
W
F
E D
Phase 1
Phase 2
Phase 3
70
STEP A
and FMIs with
2. Key off.
4. What faults 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
STEP B
1. Key off.
2. Remove the AC high-voltage
cable at the Motor/Generator
and Inverter.
Cable pins:
U - V
V - W
W - U
If resistance between each phase
is 5M ohms or greater
STEP V
cable. Go to STEP V
WARNING
71
STEP C
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:
U - U
V - V
W - W
Note: An Auto Ranging Digital
Volt/Ohm Meter must be
used.
If the resistance of each circuit is
1 ohm or less
Go to STEP D
cable. Go to STEP V
STEP D
following pins:
U - V
V - W
W - U
used.
If the resistance of each phase is
10 ohms or less
STEP V
If resistance is outside of range Replace the Motor/Generator. Go
to STEP V
72
STEP E
1. Check the AC cable
connectors at the Motor/Gen
and Inverter to ensure they
are properly connected
If connections are loose or not
properly connected
Reconnect AC Cables to
component. Go to STEP V
If connections are not loose and
are properly connected
Go to STEP F
STEP F
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:
D - D
E - E
used.
If the resistance is 0 - 0.3 ohms Replace the Inverter. Go to
STEP V
If resistance is outside of range Replace the AC cable between
the Inverter and Motor/Generator.
Go to STEP V
73
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
74
75
No ECU Operation Fault (HCM)
SA 239
SPN 629
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 ignition voltage is greater than 7 volts and less than 32 volts.
FMI 14 is set when HCM can not complete the write of EEPROM during shut down.
Possible Causes
FMI 14
- HCM
The amber Check Hybrid lamp will display if the HCM sets the fault after power-up.
If the fault occurs at power-up the vehicle may not crank.
Required Tools
Basic Hand Tools
ServiceRanger
76
Note: No Schematic for this Code.
Note: For component location you must refer to the truck OEM's service literature.
STEP A
and FMIs with
If code 6 is active Replace
Hybrid Control Module (HCM)
(Only when fault code is active).
If code 6 is inactive Test complete.
77
Improper ECU Configuration Fault (HCM)
SA 239
SPN 629
FMI 13
Overview
software to control both the Hybrid power electronics as well as the transmission operation.
FMI 13 is set at key on if the HCM data is not read from memory within 1 second.
Possible Causes
FMI 13
- Improper ECU configuration software
Fault is stored in HCM memory.
If this fault occurs at power-up, the vehicle will not crank.
Required Tools
Basic Hand Tools
ServiceRanger
78
STEP A
and FMIs with
2. Turn ignition off for 2
seconds.
3. Key on.
4. Is fault code 7 active If code 7 is active Replace the Hybrid Control
Module (HCM) (only if the fault
codes are active)
79
Loss of Switched Ignition Power Fault (HCM)
SA 239
SPN 158
FMI 4
Overview
software to control both the Hybrid power electronics as well as the transmission operation. The
HCM ignition power is a single 24-volt feed that is fused and runs through the HCM 38-way vehicle
connector.
Output shaft speed must be greater than 0 rpm
FMI 4 is set when the HCM loses ignition power during operation for 2 seconds or greater.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM)
page 25.
Possible Causes
FMI 4
- Ignition power supply to HCM
- HCM
The amber Check Hybrid lamp will display only if the vehicle is moving.
The red 'Service lamp will display and an F will flash 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 the faults occurs while the vehicle is moving, the transmission will remain in place and the
clutch will open when the vehicle comes to an idle. The clutch will close and the vehicle will
operate in 1st and reverse from stop.
If this fault occurs at power-up, the vehicle will not crank.
80
Loss of Switched Ignition Power Fault (HCM) Fault Code 8 Isolation Procedures
Required Tools
Basic Hand Tools
ServiceRanger
HCM
30
86
87
85
87
86
85
30
35 Ignition

Front Harness View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
Typical Relay Switch
Ignition
Relay
Ground
Vehicle
Ignition
24V Truck
Battery
2
4
V

P
l
u
s
81
STEP A
and FMIs with
2. Perform Electrical Pretest If code 8 is active after performing
the Electrical Pretest
Replace the HCM (only if fault
code is active). go to Step V.
If code 8 is inactive after
performing the Electrical Pretest
Go to STEP V
STEP V
1. Key off.
2. Key off.
3. Key on.
4. Clear codes
cable.
to reset the code
7. Check for codes If code 8 appears Return to STEP A to find error in
testing.
Procedure page 19
82
83
Weak Battery Voltage Fault (HCM)
SA 239
SPN 168
FMI 14
Overview
HCM main battery power is a 24-volt feed that is fused and runs through the HCM 38-way vehicle
connector with the main ground wire returning to the battery negative terminal.
The HCM System Battery Voltage Low Fault is not active.
FMI 14 is set when the HCM battery voltage drops below 9 volts for 10 seconds.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) on
page 25.
Possible Causes
FMI 14
- Power supply harness to the HCM
- Low batteries or bad main power connection
- Charging system
Required Tools
Basic Hand Tools
ServiceRanger
84
Connector Views Fault Code 9 Isolation Procedures
Connector Views
HCM
30
86
87
85
30

Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
Ignition
Relay
24V Truck
Battery
2
4
V

P
l
u
s
38 VBATT
36
HCM Ground
85
STEP A
and FMIs with
2. Perform Electrical Pretest. If code 9 is active after performing
the Electrical Pretest
Replace HCM (only if Fault Code
is active). Go to STEP V
Clear codes. Go to STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
86
87
Low Battery Voltage Fault (HCM)
SA 239
SPN 168
FMI 4
Overview
HCM main battery power is a 24-volt feed that is fused and runs through the HCM 38-way vehicle
connector with the main ground wire returning to the battery negative terminal.
FMI 4 is set when the HCM battery voltage drops below 7 volts for more than 1 second.
page 25.
Possible Causes
FMI 4
- Power supply harness to the HCM.
- Low batteries or bad main power connection.
- Charging system.
Required Tools
Basic Hand Tools
ServiceRanger
88
Connector Views
HCM
30
86
87
85
30

Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
Ignition
Relay
24V Truck
Battery
2
4
V

P
l
u
s
38 VBATT
36
HCM Ground
89
STEP A
and FMIs with
2. Perform Electrical Pretest. If code 10 is active after
Replace HCM (only if Fault Code
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
90
91
No ECU Operation Fault (TECU)
SA 3
SPN 629
MID 130
SID 254
FMI 12
Overview
The Transmission Electronic Control Unit (TECU) is mounted to the transmission and it 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.
The TECU ignition voltage is greater than 7 volts and less than 32 volts.
FMI 12 is set if the TECU detects an intermittent failure in the Electronic Shifter position.
Possible Causes
FMI 12
- Electric Shifter
The red 'Service lamp will display and an F will flash 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 will remain in the current gear and the
clutch will open.
Required Tools
Basic Hand Tools
ServiceRanger
92
STEP A
and FMIs with
If code 11 is active Replace Electric Shifter (only if
fault code is active).
93
Improper ECU Configuration Fault (TECU)
SA 3
SPN 629
MID 130
SID 254
FMI 13
Overview
of the software to control the transmission operation, however, the HCM controls the operation of
the TECU during Hybrid operation.
The TECU is powered and ignition voltage is greater than 7 volts and less than 32 volts.
FMI 13 is set when the Gen 3 ECU is not reading valid information from memory, including the
transmission table and calibration values within 1 second of power-up.
Possible Causes
FMI 13
- Improper ECU Configuration Software
The red 'Service lamp will display and an F will flash in the gear display
If the fault occurs at power-up the vehicle will not crank
Required Tools
Basic Hand Tools
ServiceRanger
94
STEP A
and FMIs with
If code 12 is active Replace the Transmission ECU
(only if the fault code is active).
95
Invalid Shifter Range
SA 3
SPN 751
SID/PID 18, 19
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.
The TECU System Battery Voltage Low Fault is not active.
The TECU is being powered up for the first time and no shift device has been configured.
FMI 2 is set when the shifter is not returning a valid position (PRNDH1)
FMI 3 is set when the sensor voltage is higher than expected
FMI 4 is set when the sensor voltage is lower than expected
page 25.
Possible Causes
FMI 2 - shifter is in between detent positions or sensor is out of calibration.
FMI 3 - sensor input is shorted high or sensor ground in open
FMI 4 - sensor input is open circuit or shorted to ground
A F will show in the gear display
Fault is stored in TECU memory
TECU changes to AutoShift control
The engine will not crank
96
Required Tools
Basic Hand Tools
Eaton Test Adapter Kit
Digital Volt/Ohm Meter
ServiceRanger
Connector Views
Harness Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
Park Pawl
Actuator
3
1
4
2
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
17
16
15
31
Shift Return (Minus)
Shift Control Input 1
Shift Control (Plus)
TECU
2
3
4
1
4-Pin Park Pawl Actuator
Connector
97
STEP A
connector to the park pawl
actuator
2. Key on
3. Check for 24V supply at 4-pin
connector at pins 1 and 2
If voltage between pins 1 and 2 is
Go to STEP B
If voltage is outside the range Go to STEP D
STEP B
1. With the actuator/shift lever
in the Neutral position check
voltage on pins:
3 to ground
4 to ground
If voltage is between 2.25V and
2.75 V
Go to STEP C
If voltage is outside the range Replace Sensor. Go to STEP V
STEP C
1. Disconnect the TECU
Vehicle Harness 38-way
connector
2. Check continuity between:
38-way connector
pin 15 and 4-pin
connector pin 4
38-way connector
pin 16 and 4-pin
connector pin 3
If continuity is okay Replace the TECU. Go to
STEP V
If an open is found Repair or replace the
Harness. Go to STEP V
98
STEP D
connector
38-way connector
pin 17 and 4-pin
connector pin 1
38-way connector
pin 31 and 4-pin
connector pin 2
STEP V
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
99
High Integrity Link (HIL) Fault
SA 3
SPN 625
MID 130
SID 248
FMI 2
Overview
The High Integrity Link (HIL) is a high-speed twisted pair 500K proprietary data link that connects
the Transmission Electronic Control Unit (TECU) to the Push Button Shift Control (PBSC). Each
module contains a 120 ohm resistor internally. The link carries information like driver mode
selection as well as fault information to light the service lamp.
The TECU Driver Interface Configuration is set to High-Integrity Link (HIL).
FMI 2 is set when the TECU looses communication for 5 seconds or more with the PBSC.
page 25.
Possible Causes
FMI 2
- HIL data link
- PBSC
- TECU
- Power supply harness from TECU to PBSC
An F will show on the gear display.
The Push Button Mode lamp flashes next to the selected mode and the Service lamp will
remain off.
The Push Button lamps will come on and then remain off if the data link fails at power-up.
The operation mode will be changed to AutoShift Fallback Mode.
If the code is active during power-up, the transmission will not engage a gear.
100
If the fault is active while driving the transmission it will remain in the current gear and then
shift into the default gear once the vehicle comes to a stop. The will open at idle and will close
if the throttle is depressed. The vehicle will move into the default start gear only.
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Harness Front View
TECU - Vehicle Interface Connector
37 38
35 36
1
6
12
13
22
23 28
29 34
7
Harness Front View
Push Button Shift Control Connector
A B C D E F G H J K
1
2
3
A1
A3
K1
K3
TECU
PBSC
27
28
F1
F2 HIL Low
HIL High
31
25
J3
C1
Shift Power (-)
Shift Power (+)
HIL Low
HIL High
Shift Power (-)
Shift Power (+)
101
STEP A
and FMIs with
2. Key on and observe the red
push button Service lamp.
If the red Service lamp turns on Go to STEP C
If the red Service lamp does not
turn on
Go to STEP B
STEP B
1. Disconnect Shift Control
30-way connector.
2. Key on.
3. Measure voltage on 30-way
connector pins J3 and C1
If voltage is within 0.6 volts of
battery voltage
Go to STEP C
If out of range Go to STEP D
STEP C
1. Key off.
2. Disconnect the 30-way Push
Button Shift Control
Connector.
3. Key on.
4. Connect Voltmeter leads to
pins F1 and F2.
If the voltage is 0.10 volts AC or
greater
Replace
Push Button Shift Control (Only if
Fault Code is Active). Go to
STEP V
Note: Make sure the volt/ohm
meter is on the proper
scale (around 10 volts
AC).
If the voltage is out of range Go to STEP F
102
STEP D
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 pins J3 and
25 is 0 to 0.3 ohms.
Go to STEP E
If any of the above conditions are
not met
Repair harness between the Shift
Control and Transmission ECU.
Go to STEP V
STEP E
1. Key off.
between:
Shift Control
30-way connector
pin C1 and Vehicle
Harness 38-way
connector pin 31.
Shift Control
30-way connector
pin C1 and ground.
If resistance between pins C1
and 31 is 0 to 0.3 ohms and
resistance between pin C1 and
ground is 10K ohms or greater
Replace Transmission ECU (Only
if Fault Code is Active). Go to
STEP V
not met
Repair harness between the
Transmission ECU and Shift
Control. Go to STEP V
103
STEP F
1. Key off.
cable.
3. Disconnect Vehicle Harness
38-way connector.
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 pins F1 and
28 is 0 to 0.3 ohms and if
resistance between pin F1 and
Go to STEP G
not met
Go to STEP V
STEP G
1. Key off.
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 pins F2 and
27 is 0 to 0.3 ohms and
STEP V
not met
Go to STEP V
104
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
105
Start Enable Relay Fault
SA 3
SPN 626
MID 130
SID 237
FMI 3, 4
Overview
The Start Enable Relay is wired into the Transmission Electronic Control Unit (TECU) on the coil
side of the relay. At key on, the HCM determines the starting method (High-Voltage Motor/
Generator, or Engine Starter) to use. If the HCM decides to use the standard engine starter, the
24-volt Cranking Relay is energized suppling battery power to the Start Enable Relay main feed,
which then powers the starter solenoid.
The Transmission Electronic Control Unit (TECU) ignition voltage is greater than 7 volts and
less than 32 volts.
FMI 3 is set when the TECU detects an open or short to the vbatt in the control circuit of the
Start Enable Relay for 1 second or greater.
FMI 4 is set if the TECU detects a short to ground in the control circuit of the Start Enable
Relay for 1 second or greater.
page 25.
Possible Causes
FMI 3,4
- Loose or corroded connections, bent or burnt pins, short to ground, open, or short
to vbatt on the circuit
- Start Enable Relay
- TECU
The red Service lamp will display and an F will flash in the gear display.
If the fault sets at power-up the engine will still crank, provided the high-voltage batteries have
a sufficient State of Charge (SOC).
If the fault sets while driving, the vehicle will continue to operate.
106
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Front Harness View


37 38
35 36
1
6
12
13
22
23
28
29 34
7
TECU
30
86
87
85
4
32
85
86
Start Enable
Relay
Start Enable Minus
Start Enable Plus

107
STEP A
and FMIs with
2. Swap Start Enable Relay
with another relay and see if
fault returns
If fault does not return with new
relay
Replace Start Enable Relay (Only
STEP V
If fault returns with new relay Go to STEP B
STEP B
1. What FMIs were listed from
Step A?
If FMI 3 is listed Go to STEP C
If FMI 4 is listed Go to STEP E
STEP C
1. Key off.
cable.
3. Disconnect the Transmission
Harness 38-way connector.
connector pins 32 and 4
If resistance between 32 and 4 is
40-120 ohms
Go to STEP D
If resistance is outside of range Repair the vehicle harness for an
open circuit. Go to STEP V
108
STEP D
1. Key on.
2. Measure voltage between
connector pin 32 and ground
If the voltage between pin 32 and
ground is 5 volts
Replace the Transmission ECU
(only if fault code is active). Go to
STEP V
Note: The voltage will only
read 5 volts for 1-2
seconds.
If the voltage between pin 32 and
ground is 24 volts
Repair the short to vbatt on the
harness. Voltage should remain
at 5 volts for 1-2 seconds after
initial key on. Go to STEP V
STEP E
1. Key off.
2. Disconnect battery cable.
between Vehicle Harness
38-way connector pins 32
and ground
If the resistance between 32 and
(only if fault code is active). Go to
STEP V
If the resistance is outside of
range
Repair the vehicle harness for a
short to ground. Go to STEP V
109
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
110
111
ECA Communication Fault
SA 239
SPN 520200
FMI 2, 9
Overview
The Electric Clutch Actuator (ECA) controls the position of the clutch assembly. The ECA
communicates with the Hybrid Control Module (HCM) over the proprietary Controller Area
Network (CAN) data link to change position, show faults or include other operation information.
The ECA ignition voltage is greater than 8.5 volts.
The HCM CAN data link error is not active.
FMI 9 is set when the ECA looses communication on the CAN data link for 2 seconds.
page 25.
Possible Causes
FMI 2, 9
- CAN data link from the ECA to the link
- ECA
The ECA will either maintain current clutch position or move to the last position commanded
by the HCM. Upon approaching idle the clutch will open and remain in this state.
If the fault occurs at power-up, the vehicle will not crank.
Required Tools
Basic Hand Tools
112
ServiceRanger
Connector Views
27
28
2B
2A
HCM
ECA
CAN - High (Vehicle)
CAN - Low (Vehicle)
CAN - High
CAN - Low
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
ECA 8-Way Harness Connector
E
A B C D
H G F
113
STEP A
and FMIs with
2. What FMIs are present If Fault Code 18 is active Go to Fault Code 19 procedure
on page 115.
If Fault Code 18 is not active Test complete. Go to STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
114
115
CAN ECA Message Fault (HCM)
SA 239
SPN 520273
FMI 2, 9
Overview
Controller Area Network (CAN) is a high-speed twisted pair 500K proprietary data link with one
120 ohm resistor at each end of the link. The Hybrid Control Module (HCM) is connected to the
CAN data link at the 38-way connector. This link is used to transmit information to the HCM as well
as communicate or receive data from the other modules on the network like the Electric Clutch
Actuator (ECA).
The HCM CAN Communication Link Fault is not active.
FMI 9 is set when the HCM fails to receive ECA data (like clutch position) for 30 consecutive
messages or greater, and it is still communicating with other modules on CAN.
FMI 2 is only active in PDM and is set when the HCM does not receive 3 consecutive
messages from the ECA.
page 25.
Possible Causes
FMI 9, 2
- CAN data link
- ECA
The operation mode will be changed to AutoShift Only mode.
If the fault sets at power-up the engine will not crank.
Electric motor/generator assist and regen are disabled, however, the high-voltage relays will
remain powered.
If the fault occurs while driving, the ECA will either maintain current clutch position or move to
the last position commanded by the HCM.
116
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
27
28
2B
2A
HCM
ECA
CAN - Low (Vehicle)
CAN - High
CAN - Low
ECA 8-Way Connector
E
A B C D
H G F
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
117
STEP A
and FMIs with
2. Perform Electrical Pretest If no issues found during the
Electrical Pretest
Go to STEP B
If issue was repaired during the
Electrical Pretest
Go to STEP V
STEP B
1. Key off.
cable.
3. Disconnect ECA 8-way
connector.
ECA 8-way connector pins A
and B.
If resistance between pin A and B
is between 50-70 ohms
Replace ECA. Go to STEP V
scale (around 200 ohm
scale).
If resistance is outside of range Repair CAN data link Harness.
Go to STEP V
118
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
119
J1939 ABS Message Fault (HCM)
SA 239
SPN 563
FMI 2, 9, 14
Overview
J1939 is a high-speed twisted pair 250K data link with one 120 ohm resistor at each end of the
link. The HCM is connected to the J1939 data link at the 38-way connector. This link is used to
transmit information to the HCM as well as communicate or receive data from the other modules
on the network like the ABS module.
The J1939 data link communication fault is not active.
FMI 9 is set when the HCM fails to receive ABS messages and there are no active J1939
faults. In PDM mode (FMI 2) this fault will be set if 3 consecutive messages (EBC1) are not
received.
FMI 14 is set when the HCM receives an active ABS signal (SPN563) out of range or the ABS
Fully Operational Signal (SPN1243) is not present for 1 second.
page 25.
Possible Causes
FMI 2, 9
- J1939 data link
- ABS Module
FMI 14
- ABS module configured to communicate on J1708 or analog instead of J1939.
- ABS module reporting an active fault.
If the fault occurs while moving, the operation mode will go into AutoShift Only Mode.
remain powered.
120
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
ABS
HCM
2
J1939 Low J1939 Low
Front Harness View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
3 J1939 High J1939 High
121
STEP A
1. Retrieve the active fault
codes and FMIs with
2. What FMIs are present? If code 22 FMI 9 is listed Concern is either:
1. ABS Module
2. J1939 data link from ABS
module to J1939 data link
backbone. Refer to OEM for
repair procedures.
If code 22 FMI 14 is listed Concern is either:
1. ABS Module is configured for
J1708 instead of J1939
communication
2. ABS module. Refer to OEM for
repair procedure.
122
123
J1939 HCM Message Fault (TECU)
SA 3
SPN 525
MID 130
SID 231
FMI 9
Overview
The Transmission Electronic Control Unit (TECU) communicates with the Hybrid Control Module
over the J1939 data link during vehicle operation to exchange requested gear and current gear
information.
No J1939 data link fault currently active in the TECU.
FMI 9 is set when the TECU fails to receive transmission data (like requested gear) for 2
seconds on greater from the HCM, and it is still communicating with other modules on J1939.
page 25.
Possible Causes
FMI 9
- J1939 data link
- HCM
The red Service lamp will display and an F and will flash in the gear display.
The operation mode will be changed to AutoShift Fallback mode.
If the fault sets while driving, the vehicle will remain in current gear. When the vehicle comes to
a stop the clutch will open and remain in this position.
The amber Check Hybrid lamp may display on the dash due to an active fault code 48.
124
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Harness Front View
37 38
35 36
1
6
12
13
22
23
28
29
34
7
TECU
HCM
2 2
J1939 Low J1939 Low
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
3 J1939 High
3
J1939 High
125
STEP A
and FMIs with
Electrical Pretest
Go to STEP B
Electrical Pretest
Go to STEP V
STEP B
1. Key off.
cable.
3. Disconnect HCM Vehicle
HCM Vehicle Harness
38-way connector pin 2 and
3.
If resistance between pin 2 and 3
Replace HCM. Go to STEP V
scale).
If resistance is outside of range Repair J1939 Data link Harness.
Go to STEP V
126
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
127
Clutch Slip Fault
SA 239
SPN 522
FMI 10
Overview
The mechanical clutch assembly is controlled through the Electric Clutch Actuator (ECA) that is
mounted on the clutch housing. The Hybrid Control Module (HCM) controls the ECA position and
monitors several variables to determine if their is a slip concern in the clutch when it is in the
closed position.
The ECA ignition voltage is greater than 7 volts and less than 32 volts.
There is no active fault code 18 or 19 present.
FMI 10 is set when the gear position is not neutral, the clutch is in the engaged position and
the difference between the transmission input shaft speed sensor and the engine speed is
greater than 150 RPM for 1 second or longer.
Note: A CA will appear if the clutch is allowed to slip and create heat beyond the a set point. Do
not use the throttle as a hill hold device as it will cause clutch damage and a CA.
Possible Causes
FMI 10
- Clutch assembly
Required Tools
Basic Hand Tools
ServiceRanger
128
STEP A
1. Is fault code 64 also active Yes Go to procedure for fault code 64
on page 223.
No Go to STEP B
STEP B
1. Is fault code 27 FMI 13 also
active
Yes Go to procedure for fault code 27
FMI 13 on page 131.
No Go to STEP C
STEP C
1. Key on.
2. Start engine.
3. Drive the vehicle under load
in highest gear possible. At a
steady speed, quickly and
fully press and hold the
throttle.
If code 26 is active Replace Clutch. See CLMT-0365
for installation procedures. Go to
STEP V
If code 26 is not active Test is complete. Go to STEP V
129
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
130
131
Clutch Disengagement Fault
SA 239
SPN 788
FMI 7, 14
Overview
The mechanical clutch assembly is controlled through the Electric Clutch Actuator (ECA) that is
mounted on the clutch housing. The Hybrid Control Module (HCM) controls the ECA position and
monitors several variables to determine if their is a slip concern in the clutch when it is in the
closed position.
The ECA ignition voltage is greater than 7 volts and less than 32 volts.
FMI 7 is set when the set when engine torque is greater than 400 Nm, engine torque
commanded is less than 0 for 0.3 seconds and the clutch position commanded is open for 1
second with the gear position confirmed in neutral. Or, if the clutch input speed is greater than
300 RPM, the clutch output speed is greater than 300 RPM, the clutch is commanded open for
1 second, and the selected gear is neutral with everything above being true for 10 seconds.
FMI 14 is set when the HCM has commanded the ECA to disengage the clutch and the input
shaft speed is greater than 315 RPM for more than 11 seconds with the transmission in
neutral and the engine running.
Possible Causes
FMI 7
- Clutch Assembly
- ECA
FMI 14
- Clutch Assembly
- Cross-shafts
The red Stop Hybrid lamp will display for FMI 7.
The amber Check Hybrid lamp will display for FMI 14.
If this fault occurs while driving, the vehicle will operate and the transmission will shift to
neutral once the vehicle comes to a stop.
132
Required Tools
Basic Hand Tools
ServiceRanger
STEP A
and FMIs with
2. If fault code 64 is listed If fault code 27 FMI 7 or 14 are
listed with an active fault code 64
Go to procedure for fault code 64
on page 223
If fault code 27 FMI 7 is listed with
no active fault code 64
Go to STEP B
If fault code 27 FMI 14 is listed
with no active fault code 64
Go to STEP C
STEP B
1. Key on.
2. Start engine.
3. Launch vehicle and drive
until 6th gear is obtained.
Then slow down to a stop.
4. Repeat the launch 5 times.
5. Is FMI 7 active If FMI 7 is active Replace the Clutch. See
CLMT0365 for installation
procedure. Go to STEP V
If FMI 7 is not active Test is complete. Go to STEP V
133
STEP C
1. Key off.
2. Remove Electric Clutch
Actuator from transmission
housing.
3. Attempt to rotate the cross-
shaft and yoke assembly by
hand.
If the cross-shaft assembly
rotates by hand from the release
bearing to the transmission case
Replace the Clutch. See
CLMT0365 for installation
procedure. Go to STEP V
If the cross-shaft assembly does
not rotate by hand
Replace the cross-shaft,
bushings, and grease. Repeat
STEP C
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
134
135
Loss of Switched Ignition Power Fault (TECU)
SA 3
SPN 43
MID 130
PID 43
FMI 2
Overview
controls the operation of the TECU during Hybrid operation. Ignition powers is fused and provided
from the key switch. Application of this input initiates the power-up sequence.
Output Shaft Speed must be greater than 0 RPM.
FMI 2 is set when the TECU looses ignition power during operation for 2 seconds or greater.
Note: When troubleshooting an inactive code refer to the Product Diagnostic Mode (PDM) See
page 25.
Possible Causes
FMI 2
- Ignition power supply to TECU
- TECU
The red 'Service lamp will display and an F will flash in the gear display.
If the fault sets while driving, the vehicle will remain in the current gear and the clutch will open
when the vehicle approaches an idle. The default start gear will be engaged and the clutch will
close if the throttle is depressed.
No lamps will be illuminated on the Push Button if the fault occurs prior to power-up or while in
neutral.
Only the current mode lamp will be illuminated if the fault occurs while driving.
The Push Button will start to tone when the vehicle approaches a stop and continue until
power is returned.
136
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
TECU
30
86
87
85
87
86
85
30
35 Ignition

Ignition
Relay
Ground
Vehicle
Ignition
24V Truck
Battery
2
4
V

P
l
u
s
Front View


37 38
35 36
1
6
12
13
22
23 28
29 34
7
137
STEP A
and FMIs with
2. Perform Electrical Pretest If code 32 is active after
performing Electrical Pretest
Replace TECU (only if fault code
Clear Codes. Go to STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
138
139
Low Battery Voltage Fault (TECU)
SA 3
SPN 168
MID 130
PID 168
FMI 4
Overview
controls the operation of the TECU during normal Hybrid Mode operation. The HCM main battery
power is a 24-volt feed that is fused and runs through the HCM 38-way vehicle connector with the
main ground wire returning to the battery negative terminal.
FMI 4 is set when the TECU battery voltage drops below 7 volts for more than 1 second.
page 25.
Possible Causes
FMI 4 has several areas that may cause this fault.
- Power Supply to TECU
- Charging system
- TECU
TECU switches to AutoShift Fallback mode.
No lamps are illuminated on the Push Button.
If this fault occurs prior to power-up, the vehicle will not crank.
If this fault occurs while driving, the vehicle will maintain the current gear and the clutch will
open when the vehicle comes to a stop.
140
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
TECU
24V Truck
Battery
24V Plus 38 TECU Power
36
TECU Ground
Front View


37 38
35 36
1
6
12
13
22
23
28
29 34
7
Ground
141
Fault Code 33 Isolation Procedures Isolation Procedures
Isolation Procedures
STEP A
and FMIs with
Replace TECU (only if Fault Code
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
142
Isolation Procedures Fault Code 33 Isolation Procedures
143
Weak Battery Voltage Fault (TECU)
SA 3
SPN 168
MID 130
PID 168
FMI 14
Overview
controls the operation of the TECU during normal Hybrid Mode operation. The HCM main
battery power is a 24-volt feed that is fused and runs through the HCM 38-way vehicle connector
with the main ground wire returning to the battery negative terminal.
FMI 14 is set when the TECU battery voltage drops below 9 volts for 10 seconds.
page 25.
Possible Causes
FMI 14 has several areas that may cause this fault.
- Power supply to TECU
- Charging system
- TECU
TECU switches to AutoShift Fallback mode.
If this fault occurs while moving, it causes a 1-speed fallback.
If the vehicle is stopped, the starting gear and reverse can be engaged.
144
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
TECU
24V Truck
Battery
24V Plus 38 TECU Power
36
TECU Ground
Front View


37 38
35 36
1
6
12
13
22
23
28
29 34
7
Ground
145
STEP A
and FMIs with
Replace TECU (only if Fault Code
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
146
147
J1939 Communication Link Fault (TECU)
SA 3
SPN 639
MID 130
SID 231
FMI 2
Overview
link. The Transmission Electronic Control Unit (TECU) is connected to the J1939 data link at the
38-way connector. This link is used to transmit information to the Hybrid Control Module (HCM) as
well as communicate or receive data from the other modules on the network like the engine Engine
Control Module (ECM).
The TECU Battery Voltage Low fault is not active.
FMI 2 is set when the TECU looses communication will all modules on the J1939 data link for
5 seconds or greater.
page 25.
Possible Causes
FMI 2
- J1939 data link
- TECU
The operation mode will change to AutoShift Fallback mode.
If the fault sets while driving, the vehicle will remain in current gear and the clutch will open
once vehicle speed approaches idle.
148
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Front Harness View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
TECU
D
9 Pin Diagnostic
Connector
3 J1939 High TECU C
2
J1939 Low TECU
J1939 High
J1939 Low
9 Pin Diagnostic Connector
149
STEP A
and FMIs with
2. Key on.
3. Select the Vehicle
Components screen and
view the various modules
that are reporting on the
J1939 link
If TECU is not reporting on
J1939, but the HCM is listed
Go to STEP B
If the HCM and TECU are not
reporting on J1939
Go to STEP C
STEP B
1. Key off.
cable.
3. Disconnect TECU Vehicle
4. Measure resistance
between TECU Vehicle
Harness 38-way connector
pin 2 and 3.
5. Make sure the volt/ohm
meter is on the proper scale
(around 200 ohm scale).
3 is between 50-70 ohms
Replace TECU. Go to STEP V
If resistance is outside of range Repair the J1939 Data link
150
STEP C
1. Key off.
between the diagnostic
connector 9-way pins C
and D.
If resistance between pin C and
D is between 50-70 ohms
Go to STEP D
If resistance is 70 ohms or
greater
One or more of the terminating
resistors on the J1939 data link
harness is missing or out of
range, or there is an open in the
link. Go to STEP V
If resistance is 50 ohms or less There is an additional
terminating resistor present.
Repair the OEM J1939 data link
harness. Go to STEP V
STEP D
1. Key off.
between the following
9-way diagnostic connector
pins:
C to ground
D to ground
If resistance between pin C to
ground and D to ground are
both 10K ohms or greater
Attempt to communicate with
another vehicle to ensure
ServiceRanger is working. If
ServiceRanger fails to
communicate with another
vehicle, call 1-800-826-HELP
(4357).
If resistance is outside of range Repair J1939 Data link Harness
for a short to ground. Go to
STEP V
151
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
152
153
J1939 Engine Message Faults
SA 3
SPN 639
MID 130
SID 231
FMI 14
Overview
link. The Transmission Electronic Control Unit (TECU) is connected to the J1939 data link at the
38-way connector. This link is used to transmit information to the Hybrid Control Module (HCM) as
well as communicate or receive data from the other modules on the network like the engine Engine
Control Module (ECM).
The TECU Battery Voltage Low fault is not active.
The TECU J1939 data link fault is not active.
FMI 14 is set when the TECU fails to receive engine ECM data like engine torque for 5
seconds or greater, and it is still communicating with other modules on J1939.
page 25.
Possible Causes
FMI 14
- J1939 data link
- ECM
If the fault occurs while moving, the TECU will go into AutoShift Fallback Mode.
Once the vehicle stops, start and reverse gears can be selected and the transmission will
operate in AutoSelect mode.
If the fault occurs at power-up, the vehicle will crank.
154
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
STEP A
and FMIs with
If code 36 is active Concern is either:
1. Engine ECM
2. data link from Engine ECM to
J1939 data link backbone. Refer
to OEM for repair procedure.
Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
TECU
Engine ECM
3
J1939 High TECU
2
J1939 Low TECU
(refer to OEM engine wiring
diagram for pin outs)
155
Power Supply Fault (TECU)
SA 3
SPN 610
MID 130
SID 251
FMI 5
Overview
controls the operation of the TECU during normal Hybrid Mode operation. The TECU main
battery power is a 24-volt feed that is fused and runs through the TECU 38-way vehicle connector
with the main ground wire returning to the battery negative terminal.
The TECU will only run this test if the electric shifter is being cycled from N to gear.
Note: Changing the start gear from N will allow this test to run.
FMI 5 is set when the TECU power supply resistance is measured before and during an
electric shifter test and the results show a measurement of 0.4 ohms or greater.
Possible Causes
FMI 5
- Power supply to TECU
- Broken or corroded battery interconnect straps may also be the cause of high
resistance readings
156
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Front View


37 38
35 36
1
6
12
13
22
23 28
29 34
7
TECU
24V Battery
Negative (-)
38
TECU Power
Positive (+)
36
TECU Ground
4-Pin Diagnostics Port
4-way
B - Service Bat. +
C - Service Bat. -
A - Service Ignition +

B A
D C
4-Pin Diagnostic Port
(Located at the left rear
corner of the transmission.)
Warning! - Do Not Load Test at Diagnostic Port
157
STEP A
and FMIs with
Go to STEP B
STEP B
1. Locate diagnostic port on
transmission harness
2. Key on.
pins C and the battery
negative post
If voltage between pin C and
battery negative post is 0.7 volts
or less
Go to STEP C
If voltage is outside of range Repair battery ground supply to
transmission ECU. Go to STEP V
STEP C
1. Locate diagnostic port on
Transmission Harness.
2. Key on.
pins B and pin C.
If voltage between pins B and C is
within 0.6 volts of battery voltage
Go to STEP D
If voltage is outside of range Repair battery power supply to
Transmission ECU. Fuse may be
blown. Repeat test.
158
STEP D
1. Key on.
2. Measure voltage between pin
A and pin C.
If voltage between pins A and C is
within 0.6 volts of battery voltage
Go to STEP E
If voltage is outside of range Repair Ignition power supply to
ECU. Fuse may be blown. Repeat
test.
STEP E
1. Key off.
cable.
3. Disconnect the Vehicle
Harness 38-way.
4. Inspect main power 38-way
connector terminals pin 36
and 38, in-line fuse holder,
and power supply
connections for integrity and
corrosion.
If no problem found Go to STEP V
If problem is found Repair power/ground path for the
main power supply. Go to STEP V
159
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
160
161
Battery Fan Relay Fault
SA 239
SPN 520243
FMI 3, 4, 5, 14
Overview
The Battery Fan Relay is a normally open relay that is connected to the Hybrid Control Module
(HCM) on the control side. When the HCM wants to turn on the relay it powers the control circuit,
which closes the relay contacts. The relay powers the Battery Fan located in the Power Electronics
Carrier (PEC), which provides the cooling for the high-voltage batteries.
FMI 3 is set when the HCM detects a short to battery in the in the coil circuit of the battery fan
relay.
FMI 4 is set when the HCM detects a short to ground in the coil circuit of the battery fan relay.
FMI 5 is set when the HCM detects an open in the coil circuit of the battery fan relay.
FMI 14 is set when the following conditions are true for 10 minutes; the high-voltage battery
temperature is greater than 55C, the difference between the minimum and maximum battery
temperatures is less than 1C, and there are no battery temperature faults from the Battery
Control Module.
page 25.
Possible Causes
FMI 3, 4, 5
- Vehicle harness from HCM to Battery Fan Relay
- Battery Fan Relay
- HCM
FMI 14
- Battery Fan Relay
- Battery Fan
- Plugged Air Filter
- Battery Fan Relay main power supply
162
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
HCM
30
86
87
85
26
86
87
85
30
Battery Fan

Battery Fan
Relay
24V Truck
Battery
2
4
V

P
l
u
s
4
Battery Fan Return
PEC
12
Ground 14
Battery Fan Supply
Cooling Fan Plus
Cooling Fan Minus
Front Harness View
(HCM - Hybrid System Interface Connector)

37 38
35 36
1
6
7
12
13
22
23
28
29
34
Harness Connector View
(PEC 19 - Way)
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
163
STEP A
and FMIs with
book to avoid shock, burn, or
3. Change battery fan relay with
another relay to see if fault
returns
relay
Replace the battery fan relay. Go
to STEP V
STEP B
1. What FMIs were listed in
Step A?
Note: The Battery Fan Relay
must be wired according
to Eaton requirements
(shown on previous
page) for this test to work
properly. If wired
differently, consult OEM
for correct wiring
schematic.
If FMI 14 is listed Go to STEP F
WARNING
164
STEP C
1. Key off.
cable
3. Disconnect the HCM harness
38-way connector
between the HCM System
pins 26 and 4.
If the resistance between pins
26 and 4 is 40-120 ohms
Replace HCM (Only if Fault Code
is Active). Go to STEP V
If the resistance is outside the
range
Repair the Vehicle Harness for an
open circuit. Go to STEP V
STEP D
1. Key on.
HCM System Harness
and ground at key on
If voltage between pin 26 and
ground is 0 volts
Replace the HCM (only is fault
code is active). Go to STEP V
ground is 24 volts
STEP E
1. Key off.
cable.
3. Disconnect the HCM harness
38-way connector.
between HCM System
pins 26 and ground
If resistance is outside of range Repair the Vehicle Harness for a
165
STEP F
1. Key off.
2. Remove and inspect the Air
filter on the PEC inlet and the
exhaust screen on the PEC
outlet.
If the air filter and screen are
clean and free from debris
Go to STEP G
If the air filter is dirty or the
exhaust screen is plugged
Replace the Air Filter and clean
the Exhaust Screen. Go to
STEP V
STEP G
1. Key off.
the 9-pin diagnostic
connector in the cab.
3. Key on.
4. Go to Product Tests and
select Battery Fan Relay.
If airflow can be felt from the PEC
air inlet and exhaust
If Fault Code is Active contact
Eaton at 1-800-826-4357.
If airflow can not be felt from the
PEC air inlet and exhaust
Go to STEP H
STEP H
1. Key on.
connector at the PEC.
3. Measure voltage at the 19-
way connector from pin 12 to
pin 14.
If voltage between pins 12 and 14
is +/- 0.2 volts of battery voltage
Replace the PEC Fan. Go to
STEP V
is outside of range
Repair wiring or relay problem.
Refer to OEM.
166
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
167
Heat Exchanger Relay Fault
SA 239
SPN 520247
FMI 3, 4, 5
Overview
The Heat Exchanger Fan Relay is normally an open relay that is connected to the Hybrid Control
Module (HCM) on the control side. When the HCM wants to turn on the relay it powers the control
circuit, which closes the relay contacts. The relay powers the Heat Exchanger Fan located on the
hybrid liquid cooling system radiator. The fan is used to provide additional airflow in certain
situations like slow driving or ePTO operation.
FMI 3 is set when the HCM detects a short to battery in the coil circuit of the Heat Exchanger
Fan Relay.
FMI 4 is set when the HCM detects a short to ground in the coil circuit of the Heat Exchanger
Fan Relay.
FMI 5 is set when the HCM detects an open in the coil circuit of the Heat Exchanger Fan
Relay.
page 25.
Possible Causes
FMI 3,4,5
- Vehicle harness from HCM to Heat Exchanger Relay
- Heat Exchanger Relay
- HCM
- Heat Exchanger Relay Fuse
Fault is stored in HCM memory
168
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
HCM
30
86
87
85
35
86
87
85
30
Heat Exchange Fan HSD

Heat Exchanger
Fan Relay
24V Truck
Battery
2
4
V

P
l
u
s
37 Heat Exchange Fan LSD
Heat Exchanger
Fan
A
Ground B
HEF Supply
HEF Plus
HEF Minus
Harness Front View

37 38
35 36
1
6
7
12
13
22
23
28
29
34
HEF Plus
Fuse
169
STEP A
and FMIs with
2. Change heat exchanger fan
relay with another relay and
see if the fault returns
relay
Replace the Heat Exchanger Fan
Relay. Go to STEP V
STEP B
1. Key on.
connector.
3. Select Configurations menu
and pick the Hybrid Control
Module option.
4. Is there an option for Heat
Exchanger Fan
The Heat Exchanger Fan option
is shown and the vehicle has the
Hybrid cooling system heat
exchanger fan installed
Go to STEP C
The Heat Exchanger Fan option
is shown and the vehicle does not
have the Hybrid cooling system
heat exchanger fan installed
Write down the model number on
the transmission tag and contact
Eaton at 1-800-826-HELP (4357).
170
STEP C
Step A?
Note: The heat exchanger fan
relay must be wired
according to Eaton
requirements (shown on
previous page) for this
test to work properly. If
wired differently consult
OEM for correct wiring
schematic.
STEP D
1. Key off.
cable
3. Disconnect the HCM System
between HCM System
pins 35 and 37
If resistance between pins 35 and
37 is 40 - 120 ohms
If resistance is outside of range Repair the Vehicle Harness for an
open circuit or blown fuse. Go to
STEP V
STEP E
1. Key on.
2. Measure the voltage
between HCM system
harness 38-way connector
pins 35 and ground
ground is 0 volts
ground is 24 volts
171
STEP F
1. Key off.
cable
between HCM System
pins 35 and ground
If resistance between pins 35 and
If resistance is outside of range Repair the Vehicle Harness for a
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
172
173
Cooling Pump Relay Fault
SA 239
SPN 520248
FMI 3, 4, 5, 14
Overview
The Cooling Pump Relay is normally an open relay that is connected to the Hybrid Control Module
(HCM) on the control side. When the HCM wants to turn on the relay it powers the control circuit,
which closes the relay contacts. The relay powers the Cooling Pump that circulates the coolant on
the hybrid liquid system.
FMI 3 is set when the HCM detects a short to battery in the coil circuit of the Cooling Pump
Relay.
FMI 4 is set when the HCM detects a short to ground in the coil circuit of the Cooling Pump
Relay.
FMI 5 is set when the HCM detects an open in the coil circuit of the Cooling Pump Relay.
FMI 14 is set when the following occur for 10 minutes or longer; the Inverter temperature is
greater than 50C, the difference between the maximum battery temperature and the
Inverter temperature is greater than 20C, and there are no battery temperature or motor
temperature faults.
page 25.
Possible Causes
FMI 3,4,5
- Vehicle harness from HCM to Cooling Pump Relay
- Cooling Pump Relay
- HCM
FMI 14
- Cooling Pump Relay
- Cooling Pump
- Cooling Pump Relay main power supply
- Low Coolant, Low Coolant Flow, Plugged Radiator, Fan Operation
When Fault Code is set the following conditions will occur:
174
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
HCM
30
86
87
85
32
86
87
85
30
Coolant Pump

Coolant Pump
Relay
24V Truck
Battery
2
4
V

P
l
u
s
4 Coolant Pump Return
Coolant Pump
A
Ground B
Coolant Pump Supply
Coolant Pump Plus
Coolant Pump Minus
Harness Front View

37 38
35 36
1
6
7
12
13
22
23
28
29
34
175
STEP A
and FMIs with
book to avoid shock, burn, or
3. Change cooling pump relay
with another relay and see if
fault returns
relay
Replace the cooling pump relay.
Go to STEP V
STEP B
Step A?
Note: The Cooling Pump Relay
must be wired according
to Eaton requirements
(shown on previous
page) for this test to work
properly. If wired
for correct wiring
schematic.
WARNING
176
STEP C
1. Key off.
cable.
pins 32 and 4
If resistance between 32 and 4 is
40-120 ohms
If resistance is outside of range Repair the Vehicle Harness for an
open circuit.
Go to STEP V
STEP D
1. Key on.
HCM system harness 38-way
connector pin 32 and ground
at key on
ground is 0 volts
code is active).
Go to STEP V
ground is 24 volts
harness.
Go to STEP V
STEP E
1. Key off.
cable.
3. Disconnect the HCM system
harness 38-way connector.
between the HCM system
pins 32 and ground
code is active).
Go to STEP V
If resistance is outside of range Repair the vehicle harness for a
short to ground.
Go to STEP V
177
STEP F
1. Key off.
2. Note the level of the coolant
in the Hybrid Liquid Cooling
System.
If the coolant is within the
recommended limits.
Go to STEP G
If the coolant is below the
recommended limits.
Refer to OEM for coolant type
and fill procedure. Go to STEP V
STEP G
1. Key off.
3. Key on.
select Coolant Pump Relay.
5. Listen for the Coolant Pump
to turn on and watch for
coolant flow in the reservoir.
If the coolant pump runs and
coolant is moving through the
reservoir.
If Fault Code is Active contact
Eaton at 1-800-826-4357.
If the coolant pump does not run Go to STEP H
If the coolant pump does run and
coolant does not flow
Check for kinks or sharp bends in
the coolant lines. If okay contact
OEM for concerns with coolant
pump.
STEP H
1. Key on.
connector at the Coolant
Pump.
3. Measure voltage at the
2-way connector from pin A
to B.
+/- 0.2 volts of battery voltage.
problem.
outside of range.
Repair wiring or relay problem.
Refer to OEM.
178
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
179
J1939 Transmission Message Fault (HCM)
SA 239
SPN 523
FMI 2, 9
Overview
link. The Hybrid Control Module (HCM) is connected to the J1939 data link at the 38-way
connector. This link is used to transmit information to the HCM as well as communicate or receive
data from the other modules on the network like the Transmission Electronic Control Unit (TECU).
FMI 9 is set when the HCM fails to receive TECU data (like current gear) for 30 consecutive
messages or greater, and it is still communicating with other modules on J1939.
page 25.
Possible Causes
FMI 2, 9
- J1939 data link
- TECU
The red Service lamp may display and a F may flash in the gear display due to an active
fault code 24.
The operation mode is changed to AutoShift Only mode.
remain powered.
If the fault sets while driving, the vehicle will shift, however, when the vehicle comes to a stop
the clutch will open and remain in the open position.
180
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Harness Front View
37 38
35 36
1
6
12
13
22
23
28
29 34
7
TECU
HCM
2 2
J1939 Low J1939 Low
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
3 J1939 High
3
J1939 High
181
STEP A
1. Key off.
cable.
3. Disconnect TECU Vehicle
between the TECU Vehicle
pin 2 and 3.
is between 50 to 70 ohms.
Replace TECU. Go to STEP V
scale).
If resistance is outside of range. Repair J1939 Data link Harness.
Go to STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
182
183
J1939 Engine Message Fault (HCM)
SA 239
SPN 190
FMI 2, 9
Overview
data from the other modules on the network like the Engine Control Module (ECM).
The J1939 data link communication fault is not active
FMI 9 is set when the HCM fails to receive Engine ECM data (like engine torque) for 30
consecutive messages or greater, and it is still communicating with other modules on J1939.
page 25.
Possible Causes
FMI 9
- J1939 data link from Engine ECM
- ECM
remain powered.
184
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
STEP A
and FMIs with
1. Engine ECM
2. Data link from Engine ECM to
J1939 data link backbone. Refer
to OEM for repair procedure.
ECM
HCM
2
J1939 Low J1939 Low
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
185
J1939 Body Controller Message Fault (HCM)
SA 239
SPN 701
FMI 2, 9
Overview
data from the other modules on the network like the Body Controller.
FMI 2 is set when the HCM is in PDM mode and fails to receive messages from the body
controller for 1 second.
FMI 9 is set when the HCM fails to receive messages from the body controller for seconds.
page 25.
Possible Causes
FMI 2, 9
- J1939 data link
- Body Controller
No hybrid lamps are lit when this code is active.
HCM disables ePTO operation, since parameters like hydraulic demand are unavailable
186
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
STEP A
and FMIs with
a. Body Controller
b. Data link from Body
Controller to J1939 data
link backbone.
procedure.
Body Controller
HCM
2
J1939 Low J1939 Low
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
187
Rail Position Sensor Fault
SA 3
SPN 60
MID 130
PID 60
FMI 2, 3, 4, 10
Overview
The Rail Position Sensor is a Hall Effect position sensor that provides feedback on the position of
the shift finger. The Transmission Electronic Control Unit (TECU) delivers a constant 5 volt
reference to one terminal of the Rail Position Sensor. The signal output from sensor provides a
regulated voltage signal from 0.5 volts to 4.5 volts. The last terminal provides a ground for the Rail
Position Sensor to the TECU.
FMIs 3 and 4 will not be set if the TECU System Battery Voltage Low Fault is active.
FMI 2 will not set if FMI 3,4 is active.
FMI 2 sets when the transmission controller detects the rail sensor voltage is above 4.5 volts
or below 0.5 volts for 1 second of longer.
FMI 3 sets when the transmission controller detects the rail sensor supply voltage is 5% above
the expected supply voltage for 1 second or longer.
FMI 4 set when the transmission controller detects the rail sensor supply voltage is 5% below
FMI 10 (refer to troubleshooting guide TRTS0930)
page 25.
Possible Causes
FMI 2, 10
- Transmission Harness
- Rail Position Sensor
- TECU
FMIs 3, 4
- TECU
188
If this fault occurs while moving, the transmission will remain in the current gear and the clutch
will open when the vehicle comes to a stop.
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Harness Front View
(TECU - System Interface Connector)
37 38
35 36
1
6
12
13
22
23
28
29 34
7
B
A
C
Rail Position Sensor Pins
TECU
20
18
19
Hall Effect B C
A
C
A
B
Rail Position Plus
Rail Position Signal
Rail Position Minus
E: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locat
189
STEP A
and FMIs with
2. Key off.
3. What FMIs are present If FMI 3 or 4 is listed Replace the TECU. Go to
STEP V
If FMI 2, 10 is listed Go to STEP B
STEP B
1. Key off.
cable.
the Transmission Harness
38-way connector pins:
18 to 19
18 to 20
used.
If pin 18 and 19 resistance is 100
to 200 ohms and if pin 18 and 20
resistance is 5K to 7K ohms
Go to STEP C
not met
Go to STEP D
STEP C
Transmission Harness
38-way connector pin 18 to
ground.
If resistance is 10K ohms or
greater
Replace TECU (Only if Fault
Code is Active). Go to STEP V
If resistance is less than 10K
ohms
Go to STEP D
190
STEP D
1. Disconnect Transmission
Harness from Rail Select
Sensor.
Rail Select Sensor pins:
A to C
A to B
used.
If pin A and C resistance is 5K to
7K and if pin A and B resistance
is 100 to 200 ohms
Replace the transmission
If any to the above conditions are
not met
Replace Electric Shifter. Go to
STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
191
Gear Position Sensor Fault
SA 3
SPN 59
MID 130
PID 59
FMI 2, 3, 4
Overview
The Rail Position Sensor is a Hall Effect position sensor that provides feedback on the position of
the shift finger. The Transmission Electronic Control Unit (TECU) delivers a constant 5 volt
reference to one terminal of the Rail Position Sensor. The signal output from sensor provides a
regulated voltage signal from 0.5 volts to 4.5 volts. The last terminal provides a ground for the Rail
Position Sensor to the TECU.
FMI 3, 4 will not be set if the TECU System Battery Voltage Low Fault is active.
FMI 2 will not set if FMI 3, 4 is active.
FMI 2 sets when the transmission controller detects the rail sensor voltage is above 4.5 volts
or below 0.5 volts for 1 second of longer.
FMI 3 sets when the transmission controller detects the rail sensor supply voltage is 5% above
FMI 4 set when the transmission controller detects the rail sensor supply voltage is 5% below
page 25.
Possible Causes
FMI 2
- Rail Position Sensor
- TECU
FMI 3,4
- TECU
192
Gear Position Sensor Fault Fault Code 52 Isolation Procedures
Required Tools
Basic Hand Tools
ServiceRanger
193
Connector Views
STEP A
and FMIs with
2. Key off.
3. What FMIs are present. If FMI 3 or 4 is listed. Replace the TECU. Go to
STEP V
If FMI 2 is listed. Go to STEP B
Harness Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
B
A
C
Gear Position Sensor Pins
TECU
12
10
11
Hall Effect B C
A
C
A
B
Gear Position Plus
Gear Position Signal
Gear Position Minus
194
STEP B
1. Key off.
cable.
38-way connector pins:
18 and 19
18 and 20
used.
If pin 18 and 19 resistance is 100
to 200 ohms and if pin 18 and 20
resistance is 5K to 7K ohms.
Go to STEP C
not met.
Go to STEP D
STEP C
Transmission Harness
38-way connector pin 18 to
ground.
greater.
Replace TECU (Only if Fault
ohms.
Go to STEP D
195
STEP D
1. Disconnect Transmission
Harness from Rail Select
Sensor.
Rail Select Sensor pins:
A and C
A and B
used.
If pin A and C resistance is 5K to
7K and if pin A and B resistance
is 100 to 200 ohms.
Replace the transmission
If any to the above conditions are
not met.
Replace Electric Shifter. Go to
STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
196
197
Input Shaft Speed Sensor Fault
SA 3
SPN 161
MID 130
PID 161
FMI 2, 3, 4, 5, 10
Overview
The Input Shaft Speed Sensor is located on the 6-bolt PTO cover, which is standard on the right
side of the transmission. The sensor is a magnetic pickup that produces an AC voltage as the
countershaft gear teeth moves past the end of the sensor. At idle the speed sensor output is low
and increases as the speed of the countershaft increases.
less than 32 volts.
FMI 10 requires the transmission to be in neutral and the vehicle speed must be within range.
FMI 2 will not set if there is already an active FMI 5 for the Input or Output Shaft Speed
Sensors.
FMI 2 is set when the TECU input shaft speed is compared to the output shaft speed and it
produces an inconsistent reading for 1 second or greater.
FMI 3 and 4 are set when the TECU detects a short to ground, short to battery, and the input
shaft speed is 0 for 1 second or greater.
FMI 5 is set when the TECU detects an open circuit and the Input Shaft Speed Sensor is 0 for
1 second or greater.
FMI 10 is set when the TECU detects a 200 RPM or greater speed difference between the
input shaft speed and the raw input shaft speed for 10 ms or greater.
Note: When troubleshooting an inactive code refer to Product Diagnostic Mode (PDM) on
page 25
Possible Causes
FMI 2,10
- Input Shaft Speed Sensor
- TECU
- Damaged Transmission Gearing
- Contamination on the input shaft speed sensor
FMI 3, 4, 5
- Input Shaft Speed Sensor
- TECU
198
If this fault occurs at power-up, the vehicle will crank but the transmission will not engage a
gear.
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Harness Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
TECU
Input Shaft
Speed Sensor
7
8
B
A
A B
(Connect View)
Input Shaft Speed
Sensor High
Input Shaft Speed
Sensor Low
199
STEP A
and FMIs with
2. Key off.
cable.
between the transmission
pins 7 and 8 and pin 7 and
ground.
If resistance is 2K to 4.5K ohms
and pin 7 to ground is 10K ohms
or greater
Go to STEP B
If resistance is outside of the
range
Go to STEP D
STEP B
1. Key on.
2. Measure the voltage from
between the transmission
pin 7 and ground
If voltage is 0 volts Go to STEP C
If voltage is 23-25 volts Repair the short to battery in the
OEM harness. Go to STEP V
STEP C
1. Inspect Input Shaft Speed
Sensor for contamination or
damage.
If no problem found Replace Transmission ECU (Only
STEP V
If problem if found or you were
sent here from Step D or E
Replace Input Shaft Speed
Sensor and inspect the
countershaft gear for damage. Go
to STEP V
200
STEP D
Harness from Input Shaft
Speed Sensor.
pins A and B.
If resistance is 2K to 4.5K ohms Go to STEP E
If resistance is outside of range Go to STEP C
STEP E
Input Shaft Speed Sensor pin
A and ground.
greater
Replace Transmission Harness.
Go to STEP V
ohms
Go to STEP C
STEP V
1. Key off.
cable.
3. Verify proper installation of
speed sensor.
4. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
201
Output Shaft Speed Sensor Fault
SA 3
SPN 191
MID 130
PID 191
FMI 2, 3, 4, 5
Overview
The Output Shaft Speed Sensor is located on the rear bearing cover at the 12 oclock position. The
sensor is a magnetic pickup that produces an AC voltage as the tone wheel teeth moves past the
end of the sensor. At idle the speed sensor output is low and it increases as the speed of the
output shaft increases.
less than 32 volts.
FMI 2 will not set if there is already an active FMI 5 for the Input or Output Shaft Speed
Sensors.
FMI 2 is set when the TECU output shaft speed is compared to the input shaft speed and it
produces an inconsistent reading for 1 second or greater.
FMI 3,4 are set when the TECU detects a short to ground, short to battery, or the output shaft
speed is 0 for 1 second or greater.
FMI 5 is set when the TECU detects an open and the Output Shaft Speed Sensor is 0 for 1
second or greater.
page 25.
Possible Causes
FMI 2
- Output Shaft Speed Sensor
- TECU
- Damaged Transmission Gearing
- Contamination on the output shaft speed sensor
FMI 3, 4, 5
- Output Shaft Speed Sensor
- TECU
202
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Harness Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
TECU
Output Shaft
Speed Sensor
23
24
B
A
A B
(Connect View)
Output Shaft Speed
Sensor High
Output Shaft Speed
Sensor Low
203
STEP A
and FMIs with
2. Key off.
cable.
and 24 and 23 and ground.
If resistance is 2K to 4.5K ohms
and pin 23 to ground is 10K ohms
or greater
Go to STEP B
If resistance is outside of the
range
Go to STEP D
STEP B
1. Key on.
ground
If voltage is 0 volts Go to STEP C
STEP C
1. Inspect Output Shaft Speed
Sensor for contamination or
damage.
If no problem found
If problem is found or you were
sent here from Step D or E
STEP V
Replace OUtput Shaft Speed
Sensor and inspect the tone
wheel for damage, looseness or
corrosion. Go to STEP V
204
STEP D
Harness from the Output
Shaft Speed Sensor.
pins A and B.
If resistance is 2K to 4.5K ohms Go to STEP E
STEP E
pin A and ground.
greater
Go to STEP V
ohms
Go to STEP C
STEP V
1. Key off.
cable.
3. Verify proper installation of
speed sensor.
4. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
205
J1939 Communication Link Fault (HCM)
SA 239
SPN 639
FMI 2, 9
Overview
connector. This link is used to transmit or receive operation information from other modules on the
network like the Transmission Electronic Control Unit (TECU) or Engine Control Module (ECM).
FMI 2 is set in PDM mode and the HCM loses communication with other modules on the
J1938 data link for 3 consecutive messages.
FMI 9 is set when the HCM looses communication with all modules on the J1939 data link for
30 consecutive messages or greater.
page 25.
Possible Causes
FMI 2, 9
- J1939 data link
- HCM
The amber Check Hybrid and red Stop Hybrid lamps will not display, since the lamps are
driven over the J1939 data link.
If the fault sets while driving, the vehicle will shift, however, when the vehicle comes to a stop
the clutch will open and remain open.
Electric motor/generator assist and regen are disabled; however, the high-voltage relays will
remain powered.
You may see a red Service lamp, and a F will flash in the gear display due to the active fault
code 24,35, or 36.
206
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
HCM
D
Front Harness View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
9 Pin Diagnostic
Connector
3 J1939 High C
2
J1939 Low
J1939 High
J1939 Low
207
STEP A
and FMIs with
2. Key on.
3. Select the Vehicle
Components screen and
view the various modules
that are reporting on the
J1939 link
If the HCM is not reporting on
J1939 but the TECU is listed
Go to STEP B
If the HCM and TECU are not
reporting on J1939
Go to STEP C
STEP B
1. Key off.
cable.
HCM Vehicle Harness
3.
scale).
If resistance is outside of range Repair J1939 Data link Harness.
Go to STEP V
208
STEP C
1. Key off.
between pins C and D on the
If resistance between pin C and D
is 50-70 ohms
Go to STEP D
If resistance is 70 ohms or
greater
resistors on the J1939 data link
harness is missing, out of range,
or there is an open in the link.
Repair the OEM J1939 data link
If resistance is 50 ohms or less There is an additional terminating
resistor present. Repair the OEM
J1939 data link harness. Go to
STEP V
STEP D
1. Key off.
pins C and ground on the
If resistance between pin C and
Attempt to communicate with
another vehicle and ensure
ServiceRanger is working. If
ServiceRanger fails to
communicate with another
vehicle, call 1-800-826-HELP
(4357).
If resistance is outside of range Repair J1939 Data link Harness
for a short to ground. Go to
STEP V
209
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
210
211
CAN Communication Link Fault (HCM)
SA 239
SPN 625
FMI 2, 9
Overview
The Controller Area Network (CAN) is a high-speed twisted pair 500K proprietary data link that
connects the HCM to the Electric Clutch Actuator (ECA), Battery Control Module and Inverter. The
link contains one 120 ohm resistor at each end. The link is used to transmit information specific to
clutch position or power electronics operations.
The HCM is powered and ignition voltage is greater than 7 volts and less than 32 volts.
FMI 9 is set when the HCM loses communication with all modules on the CAN data link for 30
consecutive messages or greater.
FMI 2 is set in PDM mode when the HCM loses communication on the Hybrid CAN for 3
consecutive messages.
page 25.
Possible Causes
FMI 2, 9
- CAN data link
- HCM
Electric Motor/Generator assist and regeneration are disabled, however, the high-voltage
relays will remain powered.
If the fault sets while driving the clutch will either close or open and remain in this position
permanently.
212
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
HCM
H
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
9 Pin Diagnostic
Connector
28
CAN High
J
27 CAN Low
CAN Low
CAN High
(Terminating
Resistor in HCM)
213
STEP A
and FMIs with
2. Key off.
between one of the following:
Diagnostic the
9-pin connector
pins H and J.
Pins A and B on the
3-way connector.
Pins 1 and 2 on the
2-way connector.
If resistance between pin H and J,
A and B, or 1 and 2 is between 50
to 70 ohms
Go to STEP B
Note: The 3-way and 2-way
data link connectors are
located next to the 9-pin
diagnostic connector
If resistance is more than 70
ohms
resistors on the CAN data link
harness is either missing or out of
range, or there is an open in the
link. Repair OEM CAN data link
Harness.
Go to STEP V
scale).
If resistance is less than 50 ohms There is an additional terminating
resistor present. Repair the OEM
CAN data link Harness.
Go to STEP V
STEP B
1. Key off.
cable.
HCM Vehicle Harness
28.
scale)
If resistance is outside of range Repair the CAN data link
214
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
215
Rail Select Motor Fault
SA 3
SPN 772
MID 130
SID 39
FMI 5, 6
Overview
The Electric Shifter contains two electric motors called the Rail and Gear motors. These motors
move a shift finger between the various rails which engage the shift rails. Power is supplied from
the Transmission Electronic Control Unit (TECU).
The TECU System Battery Voltage Low Fault is not active
The TECU System Battery Voltage Weak Fault is not active
The Electric Shifter is not energized and the shift finger is not moving
FMI 5 and 6 are set when the TECU detects 5 continuous open or short conditions on the
Electric Shifter while the motor drive circuit is idle in a 500 ms interval.
page 25.
Possible Causes
FMI 5, 6
- Electric Shifter
- TECU
The red 'Service lamp will display and an F will flash in the gear display.
216
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Harness Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
TECU
35
37
Rail Select Motor
Rail Motor Minus
Rail Motor Plus
Harness Front View
(Rail Select Motor)
B A
217
STEP A
and FMIs with
2. Key Off.
cable.
from the Transmission ECU.
and 37
If resistance is 0.3 to 150 ohms Go to STEP B
STEP B
and ground.
greater
STEP V
ohms
Go to STEP C
STEP C
1. Disconnect 2-way Rail Select
motor connector from the
Transmission Harness.
Rail Select Motor harness
2-way connector pins A and
B and A to ground.
If resistance between A & B is 0.3
to 150 ohms and pin A to ground
is 10K ohms or greater
Go to STEP V
If resistance is outside of range Replace Electric Shifter. Go to
STEP V
218
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
219
Gear Select Motor Fault
SA 3
SPN 773
MID 130
SID 40
FMI 5, 6
Overview
The Electric Shifter contains two electric motors called the Rail and Gear motors. These motors
move a shift finger between the various rails which engage the shift rails. Power is supplied from
the Transmission Electronic Control Unit (TECU).
The TECU System Battery Voltage Weak Fault is not active
The Electric Shifter is not energized and the shift finger is not moving
FMI 5 and 6 are set when the TECU detects 5 continuous open or short conditions on the
Electric Shifter while the motor drive circuit is idle in a 500ms interval.
page 25.
Possible Causes
FMI 5, 6
- Electric Shifter
- TECU
If this fault occurs while moving, the transmission will remain in the current gear position and
the clutch will open when the vehicle comes to a stop.
220
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
Harness Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
TECU
36
38
Gear Select Motor
Gear Motor Minus
Gear Motor Plus
Harness Front View
(Gear Select Motor)
B A
221
STEP A
and FMIs with
2. Key Off.
cable.
from the Transmission ECU.
If resistance is 0.3 to 150 ohms Go to STEP B
STEP B
ground.
greater
STEP V
ohms
Go to STEP C
STEP C
1. Disconnect 2-way Gear
Select Motor connector from
the Transmission Harness.
Gear Select Motor harness
2-way connector pins A and
B and A to ground.
If resistance between A and B is
0.3 to 150 ohms and pin A to
Go to STEP V
If resistance is outside of range Replace Electric Shifter. Go to
STEP V
222
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
223
ECA Fault
SA 239
SPN 788, 520198, 520199, 524035
FMI 0, 12, 13, 21 - 28
Overview
The Electric Clutch Actuator (ECA) controls the position of the clutch assembly. The ECA has a
main power 3-way connector that is directly connected to the 24-volt battery and an 8-way
connector that is connected to inputs like the HCM and the Engine Speed Sensor. The ECA
communicates with the Hybrid Control Module (HCM) over the proprietary Controller Area
Network (CAN) data link to change position, show faults, or include other operation information.
The ECA Battery Voltage is greater than 7.8 when ignition voltage is greater than 8.5 volts.
FMI 12 is set for various internal ECA failures.
FMI 22-28 can be set for excessive motor current or incorrect shaft position.
FMI 0 is set when the ECA inverter temperature exceeds 130C.
FMI 13 is set when the ECA can not find the clutch release bearing touch point after three
attempts.
Possible Causes
FMI 12
- ECA
FMI 21-28
- Excessive debris buildup on/around the ECA.
- Binding cross-shafts.
FMI 0
- MIssing exhaust shield or exhaust to close to ECA
The red Stop Hybrid lamp will display for FMI 12, 21, 22, 23, 24, 26, 27, or 28.
The amber Check Hybrid lamp will display for FMI 0, 13, or 25.
the last position commanded by the HCM.
If the fault occurs at power-up, the vehicle will not crank.
224
Required Tools
Basic Hand Tools
Service Ranger
STEP A
and FMIs with
2. What FMIs are present If FMI 0is listed Check for damaged or missing
exhaust shielding by the ECA.
Replace or reroute exhaust to
reduce internal ECA
temperatures. Go to STEP V
If FMI 12 is listed Replace the ECA. Go to STEP V
If FMI 21-28 are listed Go to STEP B
225
STEP B
1. Disconnect the 24 volt
battery cables
2. Remove the ECA from the
clutch housing.
3. Check the ECA and clutch
housing for debris build-up
4. Rotate the clutch release
shaft by hand to check for
binding
If no excessive debris is found
and clutch release shaft rotates
without binding.
Replace ECA. Go to STEP V
If excessive debris is found
around ECA or inside the clutch
housing or the clutch release
shaft binds when rotated by hand.
Remove debris build up around
ECA area. Replace / repair clutch
release shaft and upper bushing
as needed for proper shaft
rotation. Go to STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
226
227
ECA Speed Sensor Fault
SA 239
SPN 520203
FMI 2, 5
Overview
main power 3-way connector that is directly connected to the 24-volt battery and an 8-way
connector that is connected to inputs like the Hybrid Control Module (HCM) and the Engine Speed
Sensor. The ECA communicates with the HCM over the proprietary Controller Area Network
(CAN) data link to change position, show faults, or include other operation information.
Fault Code 18 or 87 are active
FMI 2 is set when the HCM detects engine speed at idle, but does not detect ECA engine
speed.
FMI 5 is set when the ECA detects an open on the ECA speed sensor signal circuit at key on.
Possible Causes
FMI 2, 5
- ECA Speed Sensor
- ECA Speed Sensor harness
- ECA
Required Tools
Basic Hand Tools
228
ECA Speed Sensor Fault Fault Code 65 Isolation Procedures
ServiceRanger
229
Connector Views
STEP A
and FMIs with
2. What FMIs are listed? If FMI 5 is listed Go to STEP B
ECA
2G
2F
Speed Sensor
Eng Speed Sensor (-)
Eng Speed Sensor (+)
B A
A B C
ECA 8-Way Connector
E
A B C D
H G F
ECA 3-Way Connector
A B
ECA Speed Sensor
(Connect View)
230
STEP B
1. Check resistance between
ECA 8-way connector pins F
and G
If resistance between ECA 8-way
connector pins F and G is 140 -
180 ohms
Go to STEP C
If resistance is out of range Repair the open in the sensor or
the harness from the ECA to the
sensor. Go to STEP V
STEP C
1. Key off.
2. Check resistance between
ECA 8-way connector pins F
and ground
If resistance is 10K or greater Go to STEP D
If resistance is out of range Repair the short to ground in the
sensor or the harness from the
ECA to the sensor. Go to STEP V
STEP D
1. Key on.
2. Measure voltage from the
ECA 8-way connector pin G
and ground
If voltage is 0 volts at key on and
FMI 5 is active
Replace the ECA (only if Fault
Code is active). Go to STEP V
If voltage is 0 volts at key on and
FMI 2 is active
Go to STEP E
If voltage is greater than 0 volts at
key on
Repair the short to power on the
ECA speed sensor harness. Go
to STEP V
231
STEP E
1. Key off.
2. Remove the ECA speed
sensor and examine the
sensor end for signs of
damage or debris buildup
If the sensor shows no cracks or
signs of metallic debris buildup on
the end
Go to STEP F
If the sensor is damaged or has
debris buildup
Replace or clean the ECA sensor.
Go to STEP V
STEP F
1. Inspect the engine flywheel
to ensure there are no
missing or damaged teeth
If flywheel teeth are all intact and
in good condition
Reinstall flywheel sensor until it
touches the flywheel then rotate
counterclockwise 1/2 to 1 full
turn. Tighten jam nut and drive
vehicle. If fault returns replace the
sensor. Go to STEP V
If flywheel teeth are damaged or
missing
Concern is with the flywheel.
Contact your OEM for repair
procedures.
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
232
233
ECA Battery Voltage Fault
SA 239
SPN 520271
FMI 3, 4, 14
Overview
main power 3-way connector that is directly connected to the 24-volt battery positive and negative
terminals.
FMI 3 is set when the ECA battery voltage is above 17 volts for 10 ms or greater.
FMI 4 is set when the ECA battery voltage is below 8.5 volts for 10 ms or greater.
FMI 14 is set when the ECA battery voltage is below 8.5 volts for 10 ms or greater, but the
HCM reports the battery voltage is within range.
Possible Causes
FMI 3
- Charging system
- ECA
FMI 4
- ECA power supply harness, connections, and fuse holder
- Charging system
- ECA
FMI 14
- ECA power supply harness, connections, and fuse holder
The red Stop Hybrid lamp will display
the last position commanded by the HCM, then the ECA holding device will engage
If the fault occurs at power-up, the vehicle will not crank
234
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
ECA
1C
Battery
1B
P
l
u
s

(
+
)
Ground
ECA Ground
ECA Power
A B C
ECA 3-Way Connector
235
STEP A
and FMIs with
2. Perform Electrical Pretest. If FMI 3 or 4 is active after

Replace the ECA. Go to STEP V
If FMI 14 is active after
Replace the ECA power harness.
Go to STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
236
237
ECA Ignition Voltage Fault
SA 239
SPN 520274
FMI 3, 4, 5
Overview
The Electric Clutch Actuator (ECA) controls the position of the clutch assembly. The ECA has a 8-
way connector that supplies ignition power to the ECA from the Hybrid Control Module (HCM).
The Hybrid Control Module (HCM) ignition voltage is greater than 7 volts and less than 32
volts.
FMI 3 is set when the ECA ignition voltage is shorted to the 24-volt system which is detected
through the HCM prior to powering the ignition supply for the ECA.
FMI 4 is set when the ECA ignition voltage is shorted to ground during key on operation which
is detected by the HCM.
FMI 5 is set when the ECA ignition voltage is open circuit after the key is on.
Possible Causes
FMI 3, 4, 5
- ECA ignition supply harness from HCM
- HCM
- ECA
The red Stop Hybrid lamp will display
the last position commanded by the HCM, then the ECA holding device will engage
If the fault occurs at power-up, the vehicle will not crank
238
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
HCM
ECA
ECA Ignition (System)
13 2H
1C
Battery
1A
1B
P
l
u
s

(
+
)
Ground
ECA Ignition
ECA Ground
ECA Power
ECA 8-Way Connector
E
A B C D
H G F
Front Harness View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
239
STEP A
and FMIs with
2. Key off.
3. What FMIs are present If FMI 3 is listed Go to STEP B
STEP B
1. Key off.
2. Disconnect the ECA 8-way
connector.
3. Measure voltage on the ECA
8-way connector from pin H
to ground.
If voltage is less than 0 volts Replace the HCM. Go to STEP V
STEP C
1. Key off.
2. Disconnect the ECA 8-way
connector.
3. Key on.
4. Measure voltage from the
ECA 8-way connector from
pin H to ground.
If voltage from H to ground is
23-25 volts
Replace the HCM. Go to STEP V
If voltage is outside of range Go to STEP D
240
STEP D
1. Key off.
2. Disconnect the HCM 38-way
System Harness connector.
pin 13 and ground
If resistance from pin 13 to
If resistance is outside of range Repair the OEM harness from the
ECA to the HCM. Go to STEP V
STEP E
1. Key off.
2. Disconnect the HCM 38-way
System Harness connector.
and the ECA 8-way
connector on the following
pins:
HVM pin 13 to ECA
pin H
If the resistance between pins 13
and H is 0-0.3 ohms
Replace the ECA (only if Fault
If resistance is outside of range Repair the open in the harness
between the ECA and HCM. Go
to STEP V
241
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
242
243
Grade Sensor Fault
SA 239
SPN 520321
FMI 12, 13, 14
Overview
The grade sensor, an internal component of the HCM, calculates needed vehicle grade position for
Hill Start Assist (HSA) feature to function properly. HSA will momentarily hold the service brakes at
launch to allow single foot pedal operation without vehicle roll-back on grades.
FMI 12 is set when the grade sensor is not active or present and Hill Start Assist is enabled in
the HCM configuration.
FMI 13 is set when Hill Start Assist is enabled in the HCM configuration but the grade sensor
has not been calibrated.
FMI 14 is set when the HCM is equipped with a grade sensor, HSA is enabled and the signal
from the sensor is out of range.
Possible Causes
FMI 12
- Incorrect HCM configuration
- HCM
FMI 13
- Grade sensor calibration
- Incorrect HCM configuration
FMI 14
- HCM
- Incorrect HCM mounting to transmission
The amber Check Hybrid lamp will display only if the vehicle is moving.
244
Required Tools
Basic Hand Tools
ServiceRanger
STEP A
1. Key on.
and FMIs with
If FMI 12 is active Go to STEP B
If FMI 13 is active Go to STEP C
If FMI 14 is active Go to STEP D
STEP B
1. Key on.
2. Using ServiceRanger view
the Hybrid HCM
configuration
HSA configuration is set at HSA
Enabled and Hill Start Assist
feature is not needed
Select No HSA from the drop
down box on the right side of the
screen, then save this
configuration change by selecting
download. Go to STEP V
HSA configuration is set at HSA
Enabled and Hill Start Assist
feature is needed
The HCM must be changed to
hardware version 3.7 or higher
containing an internal grade
sensor. Contact Eaton for correct
HCM part number information.
245
STEP C
1. Key on.
2. Using ServiceRanger
calibrate the grade sensor by
selecting the Advanced
Product functions from the
main menu
3. Select Hybrid Control Module
from the upper left menu
4. Select Grade Sensor
Calibration and follow the on
screen instructions
If FMI 13 is not active after
calibrating
Calibration complete. Go to
STEP V
If FMI 13 is active after calibrating Contact Eaton at 1-800-826-
HELP (4357).
STEP D
1. Key on.
2. Ensure the HCM is properly
mounted to the transmission
If HCM is not properly mounted or
cap screws are loose
Tighten HCM mounting cap
screws. Go to STEP V
If HCM is properly mounted to the
transmission
246
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
error in testing.
Procedure page 19
247
Engine Failed to Respond Fault (HCM)
SA 239
SPN 188, 518, 539, 544
FMI 0, 1, 2, 7
Overview
The HCM communicates with the Engine ECM over the J1939 data link during normal operation to
control the engine torque and speed for transmission shifting.
J1939 Communication Link Fault (HCM) not active.
J1939 Engine Message Fault (HCM) not active.
FMI 7 is set when the HCM commanded engine torque is less than 80% Max Engine Torque,
HCM commanded engine torque is greater than 100 ft. lbs., and the difference between
commanded engine torque and engine torque feedback is greater than 80 lb-ft for more than 1
second. Or, if the engine speed or torque maps are received with an error.
Possible Causes
FMI 7
- Engine
- Fuel System
- Exhaust Back Pressure
- Turbo charger
- Air Intake/Filter Restriction
- Un-reported engine loads
- Incorrect engine configuration settings for transmission assembly
If the fault is set while driving, the vehicle may experience shifting concerns.
248
Required Tools
Basic Hand Tools
ServiceRanger
STEP A
and FMIs with
2. Key on.
3. Retrieve codes. See Fault
page 17
If code 70 is active Contact the OEM because the
engine is failing to respond to the
HCMs command during a shift or
the maps were received in error.
If code 70 is not active Test complete.
249
Failed to Disengage a Gear
SA 3
SPN 520275
MID 130
SID 60
FMI 7
Overview
The Transmission Electronic Control Unit controls the Electric Shifter, which engages the different
rails and gear positions. The Electric Shifter is comprised of two electric motors; one changes the
rail position and the other changes the gear position.
The TECU System Battery Voltage Weak Fault is not active.
TECU J1939 Communication Link Fault is not active.
J1939 engine torque is zero 5% and J1939 engine speed is within 50 RPM of synchronous.
FMI 7 is set when the Electric Shifter fails three consecutive attempts to disengage a gear.
Possible Causes
FMI 7
- Dragging Clutch
- ECA
- Shift Bar Housing
- Electric Shifter
- Gear Select Sensor
- Yoke, Sliding Clutch, Mainshaft
- TECU
- Torque locked in gear
If the fault sets while driving, the vehicle will maintain the current gear and the clutch will open
when the vehicle comes to a stop.
250
Failed to Disengage a Gear Fault Code 71 Isolation Procedures
Required Tools
Basic Hand Tools
ServiceRanger
Note: The picture above shows the shift forks in the neutral position.
251
STEP A
and FMIs with
2. Key on.
3. Depress N on the Push
Button Shift Control.
4. Observe Gear Display. If Gear Display shows: N Go to STEP V
If Gear Display shows: 71 Go to STEP B
STEP B
Pretest.
If no issues found during the
Electrical Pretest
Go to STEP C
Electrical Pretest
Repeat STEP A
STEP C
1. Key off.
2. Remove Electric Shifter
from Shift Bar Housing to
see what gear position is
currently engaged.
3. Attempt to move the
engaged rail back to neutral
If rails move from the engaged
position to neutral
Go to STEP D
If rails do not move from the
engaged position
Attempt to take the torque off
the driveline. If concern is still
present, inspect the main case
for a damaged mainshaft,
sliding clutch, or fork. Go to
STEP V.
252
STEP D
1. Key off.
2. Inspect the following:
Shift blocks are
fastened to shift
rails securely
Electric shifter is
free from any
excessive lube
contamination
buildup
Two gears positions
can not be
engaged at the
same time
If no problem found Replace the electric shifter. Go
to STEP V
If problem is found Repair as required. Go to
STEP V
STEP V
1. Key off.
cable.
3. Key on.
4. Clear codes. See Fault
page 17
5. Drive the vehicle and
attempt to recreate the
code
page 17
testing.
Procedure page 19
253
Failed to Select Rail Fault
SA 3
SPN 520277
MID 130
SID 59
FMI 7
Overview
This fault may occur at power-up after 15 seconds.
FMI 7 is set when the Electric Shifter fails five consecutive attempts to engage a particular rail
position.
Possible Causes
FMI 7
- Shift Bar Housing
- Electric Shifter
- Rail Select Sensor
- TECU
If the fault sets while driving, the vehicle will continue to select the proper rail position.
254
Failed to Select Rail Fault Fault Code 72 Isolation Procedures
Required Tools
Basic Hand Tools
ServiceRanger
255
STEP A
and FMIs with
2. Key on.
3. Place Shift Device in
Neutral.
4. Depress Service Brake.
5. Observe gear display. If you have an active code 72 Go to STEP B
If Gear Display shows solid
gear
Go to STEP V
STEP B
Pretest.
Electrical Pretest
Go to STEP C
Electrical Pretest
Repeat STEP A
256
STEP C
1. Key off.
from Shift Bar Housing.
Shift blocks are
fastened to shift
rails securely
Shift rails move into
each gear position
Electric shifter is
free from any
excessive lube
contamination
buildup
Two gear positions
can not be
engaged at the
same time
If no problem found Replace the Electric Shifter. Go
to STEP V
STEP V
STEP V
1. Key off.
cable.
3. Key on.
page 17
code
page 17
testing.
Procedure page 19
257
Failed to Engage a Gear Fault
SA 3
SPN 520278
MID 130
SID 58
FMI 7
Overview
FMI 7 is set when the Electric Shifter fails five consecutive attempts to engage a particular
gear position.
Possible Causes
FMI 7
- Dragging Clutch
- ECA
- Shift Bar Housing
- Electric Shifter
- Gear Select Sensor
- Yoke, Sliding Clutch, Mainshaft
- TECU
If the fault sets while driving, the vehicle will maintain the current position.
258
Failed to Engage a Gear Fault Fault Code 73 Isolation Procedures
Required Tools
Basic Hand Tools
ServiceRanger
259
STEP A
and FMIs with
2. Key on.
3. Place Shift Device in
Neutral.
4. Depress Service Brake.
5. Select Drive.
6. Observe gear display. If you have an active code 73 Go to STEP B
If Gear Display shows solid
gear
Go to STEP V
STEP B
Pretest.
Electrical Pretest
Go to STEP C
Electrical Pretest
Repeat STEP A
260
STEP C
1. Key off.
from Shift Bar Housing.
Shift blocks are
fastened to shift
rails securely.
Electric Shifter is
free from an
excessive lube
contamination
build-up.
Two gear positions
can not be
engaged at the
same time.
If no problem is found Replace the Electric Shifter. Go
to STEP V
STEP V
STEP V
1. Key off.
cable.
3. Key on.
page 17
code
page 17
testing.
Procedure page 19
261
Engine Failed to Respond Fault (TECU)
SA 3
SPN 93, 190
MID 130
PID 93, 190
FMI 7
Overview
The Transmission Electronic Control Unit (TECU) communicates with the Engine ECM over the
J1939 data link during normal operation, however, engine control is accomplished by the engine
Engine Control Module (ECM) during Hybrid mode. The TECU changes the mode to AutoShift
Only or AutoShift Fallback mode. Then the TECU is directly requesting changes in engine speed
and torque instead of the Hybrid Control Module (HCM).
J1939 Communication Link Fault (TECU) not active.
J1939 Engine Message Fault (TECU) not active.
J1939 engine speed is greater than 300 RPM if the TECU is in speed control mode, or greater
than 1000 RPM if the TECU is in torque control mode.
Desired Engine Speed is less than J1939 engine configuration map speed.
FMI 7 is set when the difference between actual engine percent torque and desired engine
percent torque is greater than 50 for 2 continuous seconds, or when the difference between
desired engine speed and actual engine speed is greater than 400 RPM for four continuous
seconds.
Possible Causes
FMI 7
- Engine
- Fuel System
- Exhaust Back Pressure
- Turbo charger
- Air Intake/Filter Restriction
- Un-reported engine loads
- Incorrect engine configuration settings for transmission assembly
262
If the fault sets while driving, the vehicle will remain in the current gear position. Once the
vehicle is stopped, start and reverse gears can be engaged.
TECU changes to Autoshift Fallback mode.
Required Tools
Basic Hand Tools
ServiceRanger
Note: No schematic for this code.
STEP A
and FMIs with
2. Key on.
3. Retrieve codes. See Fault
page 17
If code 74 is active Contact the OEM because the
engine is failing to respond to
the transmissions command
during a shift.
If code 74 is not active Test complete.
263
Power Down in Gear Fault
SA 3
SPN 520276
MID 130
SID 60
FMI 14
Overview
The Push Button Shift Control (PBSC) is connected to the Transmission Electronic Control Unit
(TECU) over the High Integrity Link (HIL) to communicate driver mode selection and fault status.
At power-down the PBSC should be placed in N to perform the proper calibration sequence and
to prevent a torque locked transmission.
The PBSC ignition voltage is greater than 7 volts and less than 32 volts.
FMI 14 is set when the TECU goes into the power-down sequence and a drive mode selection
other than N is confirmed.
Possible Causes
FMI 14
- Driver powered down in Non-neutral mode
Fault is stored in TECU memory only as an Inactive fault, since it only sets during the power-
down sequence.
Required Tools
Basic Hand Tools
264
ServiceRanger
STEP A
and FMIs with
2. Key on.
page 17
If code 75 is inactive No action necessary, this code
indicates the driver powered
down the system prior to
selecting neutral.
Note: Explain to driver, N
must be selected on the
Push Button Shift
Control before
powering down to
prevent a stuck in gear
situation and/ or a
power-up no crank
situation.
265
High Voltage Battery Potential Voltage Fault
SA 239
SPN 520250
FMI 3, 4, 16, 18
Overview
The High-Voltage Batteries are 172 volts each connected in series to produce 340 volts DC. The
Battery Control Unit located in the Relay Box communicates with each battery to determine
temperature, SOC, and voltage. This information is then sent to the Inverter.
The Inverter enable voltage is greater than 7 volts and less than 16 volts.
The Battery Control Unit ignition voltage is greater than 7 volts and less than 16 volts.
FMI 3 is set when the BCU detects the high-voltage battery is greater than 417 volts for 240
ms.
FMI 16 is set when the BCU detects the high-voltage battery is greater than 408 volts for 240
ms.
FMI 4 is set when the BCU detects the high-voltage battery is less than 211 volts for 240 ms.
FMI 18 is set when the BCU detects the high-voltage battery is less than 240 volts for 240 ms.
page 25.
Possible Causes
FMI 3, 4
- PEC
- DC cable
- DC interlock loop
- Inverter
- Service switch
- Inertia Switch
The amber Check Hybrid lamp will blink for FMI 4 and display solid for FMI 3, 16, 18
Inverter shuts high-voltage system off
266
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
267
Check to see if the red Service Switch on the front of the PEC is pulled out. If the switch is
pushed in pull the switch out and turn the ignition key off. After 2 minutes turn the ignition key on.
STEP A
1. Key off
2. Key on
and FMIs with
4. Key off
5. Follow the Hybrid Shutdown
Procedure on page 3, to
high-voltage.
6. What FMIs are present If Fault Code 76 is listed with an
active Fault Code 101 FMI 27,
28
Go to procedure for Fault Code
101 FMI 27 or 28 page 315
If Fault Code 76 is listed with an
active Fault Code 101 FMI 29
101 FMI 29 page 315
If Fault Code 76 FMI 3 or 4 are
listed with no other active
Hybrid Fault Codes
Contact Eaton at 1-800-826-
HELP (4357).
listed with other active Hybrid
Fault Codes
Go to procedure for active
Hybrid Fault Code(s).
If Fault Code 76 FMI 16 or 18
are listed
Test complete. FMIs 16 and 18
require no action or
replacement.
IMPORTANT
WARNING
268
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
code
page 17
testing.
Procedure page 19
269
High Voltage Battery Current Fault
SA 239
SPN 520232
FMI 6
Overview
Battery Control Unit (BCU) located in the Relay Box communicates with each battery to determine
FMI 6 is set when the BCU detects high-voltage battery current is greater than 200 amps for 1
second.
Possible Causes
FMI 6
- PEC
Required Tools
Basic Hand Tools
ServiceRanger
270
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
271
STEP A
and FMIs with
pin diagnostic connector.
2. Key off.
high-voltage.
4. What Faults are present If Fault Code 78 is listed with an
active Fault Code 113
113, FMI 6 on page 369
If Fault Code 78 is listed with no
Fault Code 113
Replace the PEC. Go to
STEP V
STEP V
1. Key off.
cable.
3. Key on.
page 17
code
page 17
testing.
Procedure page 19
WARNING
272
273
High Voltage Battery Temperature Fault
SA 239
SPN 520233
FMI 0, 16
Overview
The Battery Control Unit ignition voltage is greater than 7 volts.
FMI 0 is set when the BCU detects high-voltage battery temperature is greater than 70C for
6.4 seconds.
FMI 16 is set when the BCU detects high-voltage battery temperature is greater than 60C for
6.4 seconds.
Possible Causes
FMI 0
- PEC
- Battery Fan
- Battery Fan Air Filter
- Battery Fan Relay power supply harness
- Battery Fan Relay
- Battery Fan Exhaust Screen
Note: The conditions above are only present for FMI 0.
274
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
275
Connector Views
HCM
30
86
87
85
26
86
87
85
30
Battery Fan

Battery Fan
Relay
24V Truck
Battery
2
4
V

P
l
u
s
4
Battery Fan Return
PEC
12
Ground 14
Battery Fan Supply
Cooling Fan Plus
Cooling Fan Minus
Harness Front View

37 38
35 36
1
6
7
12
13
22
23
28
29
34
19 - Way Mating Connector View
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
276
STEP A
and FMIs with
2. Key off.
book, to avoid shock, burn,
or death from improperly
4. What Faults are present. If Fault Code 82 FMI 0 is listed Go to STEP B
If Fault Code 82 FMI 16 is listed Test complete. FMI 16 requires
no action or replacement.
STEP B
1. Remove and inspect the Air
filter on the PEC inlet and
the exhaust screen on the
PEC outlet.
If the air filter and screen are
clean and free from debris
Go to STEP C
If the air filter is dirty or the
exhaust screen is plugged
Replace the Air Filter and clean
the Exhaust Screen. Go to
STEP V
WARNING
277
STEP C
1. Key off.
3. Key on.
select Battery Fan Relay.
5. Check for airflow from the
front and rear air ports in
the PEC.
If airflow can be felt from the
Go to STEP E
If airflow can not be felt from the
Go to STEP D
STEP D
1. Key on.
connector at the PEC.
3. Measure voltage at the
19-way connector from pin
12 to pin 14.
If voltage between pins 12 and
14 is +/- 0.2 volts of battery
voltage
STEP V
If voltage between pins 12 and
14 is outside of range
Repair Battery Fan Relay
circuit. Refer to OEM.
STEP E
1. Is fault code 105 FMI 29
listed active
Fault code 105 FMI 29 is active Replace the PEC. Go to STEP V
Fault code 105 FMI 29 is not
active
Using ServiceRanger go to
Advanced Product Functions
menu and select the HCM option.
Download the Snapshot file and
contact Eaton at 1-800-826-
HELP (4357).
278
STEP V
1. Key off.
cable.
3. Key on.
page 17
code
page 17
testing.
Procedure page 19
279
Invalid Shift Range
SA 3
SPN 751
SID 18
PID 18
FMI 12, 13
Overview
driver mode selection data. The only compatible shift devices are the Eaton Push Button Shift
Fault Code 83 is set when redundant sensor voltages do not agree.
Possible Causes
Faulty Sensors
Harness
TECU
A F will show in the gear display
TECU changes to AutoShift control
The engine will not crank
280
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
281
Connector Views
STEP A
connector to the park pawl
actuator.
2. Key on.
3. Check for 24V supply at 4-
pin connector at pins 1 and
2.
is +/- 0.2 volts of battery voltage
Go to STEP B
If voltage is outside the range Go to STEP D
Harness Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
Park Pawl
Actuator
3
1
4
2
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
17
16
15
31
TECU
2
3
4
1
Connector
282
STEP B
1. With the actuator/shift lever
in the Neutral position
check voltage on pins:
3 to ground
4 to ground
If voltage is between 2.25V and
2.75 V
Go to STEP C
If voltage is outside the range Replace Sensor. Go to STEP V
STEP C
connector.
38-way connector
pin 15 and 4-pin
connector pin 4
38-way connector
pin 16 and 4-pin
connector pin 3
STEP V
STEP D
connector.
38-way connector
pin 17 and 4-pin
connector pin 1
38-way connector
pin 31 and 4-pin
connector pin 2
STEP V
283
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
code
page 17
testing.
Procedure page 19
284
285
Shift Control Device Not Configured Fault
SA 3
SPN 751
MID 130
SID 18
FMI 13, 14
Overview
driver mode selection data. The only compatible shift device is the Eaton Push Button Shift
Note: This fault code will only be set active.
FMI 13 is set when the TECU powers-up the first time and fails to recognize any valid shift
device connected to the vehicle within five seconds.
Possible Causes
FMI 13
OEM Wiring Harness between TECU and shift control device is disconnected
PBSC
FMI 14
OEM Wiring Harness between TECU and shift control device is disconnected
Shift Lever
The Service lamp may or may not come on depending on the failure.
TECU changes to AutoShift Fallback mode.
The engine will not crank.
286
Shift Control Device Not Configured Fault Fault Code 84 Isolation Procedures
Required Tools
Basic Hand Tools
ServiceRanger
287
Connector Views
Harness Front View
37 38
35 36
1
6
12
13
22
23 28
29 34
7
Harness Front View
(Push Button Shift Control 30-Way Connector)
A B C D E F G H J K
1
2
3
A1
A3
K1
K3
TECU
PBSC
28
27
F2
F1
31
25
J3
C1
B3
HIL High
HIL Low
Shift Power (Plus)
HIL High
HIL Low
Shift Power (Plus)
VDash Dimmer
Shift Lever
Controller
3
1
4
2
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
Park Pawl Actuator
17
16
15
31
TECU
2
3
4
1
Connector
288
STEP A
and FMIs with
2. Key on and observe the
Push Button Service lamp
If red Service lamp comes on Go to STEP B
If red Service lamp does not
turn on
Go to STEP C
If FMI 14 is present Call 1-800-826-HELP (4357).
Go to STEP V
STEP B
1. Key off and on while
observing the green mode
lamps on the PBSC
If green Mode lamps turn on Go to STEP F
If green Mode lamps do not
turn on
Replace PBSC. Go to STEP V
STEP C
1. Key off.
2. Disconnect the PBSC
30-way connector
3. Key on.
4. Measure the voltage
between pins J3 and C1 on
the 30-way connector
If voltage is within 0.6 volts of
battery voltage
Replace the PBSC. Go to
STEP V
If voltage is out of range Go to STEP D
289
STEP D
1. Key off.
cable.
3. Disconnect vehicle harness
38-way connector.
between pin J3 on the shift
control 30-way connector
and the pin 25 on the
vehicle harness 38-way
connector
If resistance between pins J3
and pin 25 is 0-0.3 ohms
Go to STEP E
If resistance is out of range Repair the vehicle harness
between the PBSC and the
transmission ECU. Go to
STEP V
STEP E
1. Key off.
cable.
38-way connector.
between the following:
Pin C1 on the shift
control 30-way
connector and pin
31 on the vehicle
harness 38-way
connector
Pin C1 on the shift
control and ground
If resistance between pins C1
and pin 25 is 0-0.3 ohms and
resistance between pin C1 and
(only if fault code is active). Go
to STEP V
STEP V
290
STEP F
1. Key off.
2. Disconnect the shift control
30-way connector
3. Key on.
4. Measure the AC voltage
between pins F1 and F2
If voltage is 0.1 volts AC or
greater
Replace the push button shift
control (PBSC). Go to STEP V
Note: Make sure the meter is
on the AC auto feature
or set to the AC 10 volts
scale
If voltage is 0.1 volts AC or less Go to STEP G
STEP G
1. Key off.
cable.
38-way connector.
Pin F1 on the shift
control 30-way
connector and pin
28 on the vehicle
harness 38-way
connector
Pin F1 on the shift
control 30-way
connector and
ground
If resistance between pins F1
Go to STEP H
STEP V
291
STEP H
1. Key off.
cable.
38-way connector.
Pin F2 on the shift
control 30-way
connector and pin
27 on the vehicle
harness 38-way
connector
Pin F2 on the shift
control 30-way
connector and
ground
If resistance between pins F2
Replace the Transmission ECU.
Go to STEP V
STEP V
292
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
code
page 17
testing.
Procedure page 19
293
Shift Control Device Incompatible Fault
SA 3
SPN 639
MID 130
SID 18
FMI 12
Overview
driver mode selection data. The TECU checks the vehicle for the type of PBSC device during the
first power-up to determine, if a compatible model is being used.
The HIL Link Fault is not active.
FMI 12 is set anytime the TECU powers-up and detects a non-compatible shift control device,
or it does not receive a component I.D. ten seconds after power-up.
Possible Causes
FMI 12
- Shift Control Device
TECU changes to AutoShift Fallback mode
The engine will not crank.
Required Tools
Basic Hand Tools
294
Shift Control Device Incompatible Fault Fault Code 85 Isolation Procedures
ServiceRanger
295
STEP A
and FMIs with
2. Select the Roadranger
Configurations menu and
view the Transmission
selection.
3. View the Push-button Type
field for one of the following
options:
EARNDM = Used
with EH-8E306A-
UPG transmissions
(shown on
transmission tag)
ERNDM = Used
with EH-8E306A-
UP transmissions
(shown on
transmission tag)
RNDML = Used
with EH-8E306A-
CD and EH-
8E306A-U
transmissions
(shown on
transmission tag)
If the Push-button Type field
matches the push-button
installed in the vehicle
Go to STEP B
If the Push-button Type field
does not match the push-button
installed in the vehicle
Change the Push-button Type
Field or Push-button to match
the transmission model number
shown on the transmission tag.
Use Step A.3. to determine
correct push-button for each
model.
296
STEP B
1. View the Hybrid Control
Module selection under the
Roadranger Configurations
option in ServiceRanger.
2. View the System
Configuration field for one
of the following options:
UPG = Used in EH-
8E306A-UPG
transmission
UP = Used in EH-
8E306A-UP
transmissions
CD or U = Used in
EH-8E306A-CD
and EH-8E306A-U
transmissions
3. Compare the HCM System
Configurations selection to
the TECU Push-button Type
selection.
If HCM System Configuration
and TECU Push-button Type
are the same
HELP (4357).
If HCM System Configuration
and TECU Push-button Type
are different
Install a HCM with the correct
configuration to match the
transmission tag. Go to STEP V
297
STEP V
1. Key off.
cable.
3. Key on.
page 17
code
page 17
error in testing.
Procedure page 19
298
299
Inverter CAN Message Fault (HCM)
SA 239
SPN 520223
FMI 2, 9
Overview
The Inverter communicates with the Battery Control Unit (BCU) located in the Power Electronics
Carrier (PEC) and the Hybrid Control Module (HCM) on the Controller Area Network (CAN) high-
speed proprietary data link. The data link is a two wire twisted pair with two 120 ohm resistors
located in the link.
The HCM CAN data link fault is not active.
FMI 9 is set when the HCM has not received a Inverter message for 30 consecutive message
cycles.
FMI 2 is only active in Product Diagnostic Mode and will set if 3 consecutive Inverter
messages are not received by the HCM.
page 25.
Possible Causes
FMI 9, 2
- Inverter
- CAN data link
remain powered.
300
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
27
28
5
4
HCM
Inverter
CAN - Low (Vehicle)
CAN - High
CAN - Low
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
10
20
30
40
1
11
21
31
301
STEP A
and FMIs with
2. Perform Electrical Pretest
and Hybrid Electrical
Pretest.
If no issues are found during the
Go to STEP B
Go to STEP V
STEP B
1. Key off
high-voltage
3. Disconnect Inverter 40-way
connector
between Inverter 40-way
If resistance between pins 5
and 4 is between 50-70 ohms
Replace Inverter. Go to
STEP V
scale)
If resistance is outside of range Repair CAN data link Harness.
Go to STEP V
WARNING
302
STEP V
1. Key off
cable
3. Key on
page 17
code
page 17
testing
Procedure page 19
303
Battery Control Unit CAN Message Fault (HCM)
SA 239
SPN 520234
FMI 2, 9
Overview
The Hybrid Control Module (HCM) communicate with the Inverter communicates with the Battery
Control Unit (BCU) located in the Power Electronics Carrier (PEC) and the HCM on the Controller
Area Network (CAN) high-speed proprietary data link. The data link is a two wire twisted pair with
two 120 ohm resistors located in the link.
The HCM CAN data link fault is not active.
FMI 2 is only active in Product Diagnostic Mode and will set if 3 consecutive BCU messages
are not received by the HCM.
FMI 9 is set when the HCM has not received a BCU 1 message for 30 consecutive message
cycles.
page 25.
Possible Causes
FMI 2, 9
- Inverter
- CAN data link from PEC to Inverter
- PEC
Fallback Mode When Faults is Set
remain powered
304
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
305
Connector Views
27
28
5
4
HCM
Inverter
CAN - Low (Vehicle)
CAN - High
CAN - Low
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
PEC Harness Connector View
(Deutsch 19 - Way)
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
35
34
2
1
PEC
CAN - High
CAN - Low
10
20
30
40
1
11
21
31
306
STEP A
and FMIs with
Pretest.
If no issues are found during the
Go to STEP B
Go to STEP V
STEP B
1. Key off
high-voltage
3. Disconnect PEC 19-way
connector
between PEC 19-way
scale)
Replace the Battery Control
Unit (BCU). Go to STEP V
WARNING
307
STEP C
1. Disconnect Inverter 40-way
connector.
between:
Inverter 40-way
connector pin 35
and PEC 19-way
connector pin 2.
Inverter 40-way
connector pin 34
and PEC 19-way
connector 1.
If resistance between pin 35
and 2 is between 0-0.2 ohms,
and resistance between 34 and
1 is between 0-0.2 ohms
Replace Inverter. Go to STEP V
scale)
If resistance is outside of range Repair CAN data link Harness
between Inverter and PEC. Go
to STEP V
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
308
309
24-volt Cranking Relay Fault
SA 239
SPN 520249
FMI 3, 4
Overview
The 24-volt Cranking Relay is wired into the Hybrid Control Module (HCM) on the coil side of the
relay. At key on, the HCM determines the starting method (High-Voltage Motor/Generator, or
Engine Starter) to use. If the HCM uses the Motor/Generator to start the engine, the clutch is
closed, the 24-volt cranking relay is de-energized, which disconnects the main battery power
supply to the Start Enable Relay. If the HCM decides to use the standard engine starter, the 24-volt
Cranking Relay is energized suppling battery power to the Start Enable Relay main feed, which
then powers the starter solenoid.
Engine speed is 0 RPM or unknown
FMI 3 if the HCM detects am open or short to vbatt in the control circuit of the 24-volt cranking
relay for 1 second or greater.
FMI 4 is set if the HCM detects a short to ground in the control circuit of the 24-volt cranking
relay for 1 second or greater.
page 25.
Possible Causes
FMI 3,4
- Vehicle harness from HCM to 24-volt Cranking Relay
- 24-volt Cranking Relay
- HCM
If the fault sets at power-up the engine will crank, provided the high-voltage batteries have a
sufficient State of Charge (SOC).
If the fault sets while driving, the vehicle will continue to operate
310
Required Tools
Basic Hand Tools
ServiceRanger
Connector Views
HCM
30
86
87
85
32
86
87
85
Crank Enable Plus

Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
12-Volt
Cranking Relay
24V Truck
Battery
2
4
V

P
l
u
s
4
Crank Enable Minus
26 Crank Enable Latch
AutoShift Start Enable Relay (30)
311
STEP A
and FMIs with
ServiceRanger using 9-pin
diagnostic connector.
2. Swap the 24V cranking
relay with another relay and
see if the fault returns
If the fault does not return with
new relay
Replace 24V cranking relay. Go
to STEP V
If the fault returns with new
relay
Go to STEP B
STEP B
Step A.
Note: The 24-volt Cranking
Relay must be wired
according to Eaton
Hybrid requirements
(shown on previous
page) for this test to
work properly. If wired
for correct wiring
schematic.
STEP C
1. Key off.
cable.
3. Disconnect the HCM
connector
between HCM vehicle
pins 32 and 4
If resistance between 32 and 4
is 40-120 ohms
Go to STEP D
If resistance is outside of range Repair the vehicle harness for
an open circuit. Go to STEP V
312
STEP D
1. Key on.
HCM vehicle harness
38-way connector pin 32
and ground at key on.
ground is 5 volts
code is active).Go to STEP V
ground is 24 volts
harness. Go toSTEP V
STEP E
1. Key off.
cable.
3. Disconnect the HCM
harness 38-way connector.
HCM vehicle harness
38-way connector pin 32
and ground.
code is active).Go to STEP V
If resistance is outside of range Repair the vehicle harness for a
313
STEP V
1. Key off.
cable.
3. Key on.
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
314
315
High Voltage Battery Fault
SA 239
SPN 520238
FMI 0, 22 - 31
Overview
FMI 0,22-31 are set for various internal High-Voltage Battery failures.
Possible Causes
FMI 0, 22-31
- PEC
The red Stop Hybrid lamp will display for FMI 0
The amber Check Hybrid lamp will display for FMI 22-29
Depending on the FMI the Inverter or HCM shuts the high-voltage system off
Required Tools
Basic Hand Tools
ServiceRanger
316
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
317
STEP A
and FMIs with
2. Key off.
3. Follow the Hybrid
Shutdown Procedure
found at front of book, to
high-voltage.
4. What FMIs are present If Fault Code 101, FMI 27 or 28
are listed with an active Fault
Code 101 FMI 26
STEP V
If Fault Code 101, FMI 27 or 28
are not listed with an active
Fault Code 101 FMI 26
Go to STEP B
If Fault Code 101 FMI 22-25 are
listed
STEP V
If Fault Code 101 FMI 29 is
listed
Go to STEP C
If Fault Code 101 FMI 30 or 31
are listed
Test complete. FMIs 30 and 31
require no action or
replacement.
STEP B
1. View the Data Monitor
parameter PID 133 Battery
SOC
If PID 133 Battery SOC is less
than 80 percent
STEP V
If PID 133 Battery SOC is
greater than 80 percent
HELP (4357).
WARNING
318
STEP C
1. View the Data Monitor
parameter PID 133 Battery
SOC
If PID 133 Battery SOC is
greater than 10 percent
STEP V
If PID 133 Battery SOC is less
than 10 percent
HELP (4357).
STEP V
1. Key off.
cable.
3. Key on.
page 17
code
page 17
testing.
Procedure page 19
319
Battery Control Unit Communication Fault
SA 239
SPN 520265
FMI 22 - 26
Overview
The High-Voltage Batteries each contain a cell controller that communicates over a twisted pair
data link to the Battery Control Unit (BCU). The Battery Control Unit located in the Relay Box
communicates with each battery to determine temperature, SOC, and voltage. This information is
then sent to the Inverter.
FMI 22 is set when the BCU fails to communicate over the CAN data link for 30 ms.
FMI 23 is set when the BCU fails to receive HCM data over the CAN data link for 2.5 seconds
or greater after communication is established.
FMI 24 is set when the BCU fails to receive Inverter data over the CAN data link for 2.5
seconds or greater after communication is established.
FMI 25 is set when the BCU fails to transmit anything over the data link for 2 seconds.
FMI 26 is set when the BCU detects an error on initial check.
Possible Causes
FMI 26
- Relay box
FMI 22, 25
- Relay box
- CAN data link between PEC and Inverter
FMI 23
- Relay box
- CAN data link between PEC and HCM
FMI 24
- Relay box
- Inverter
- CAN data link between PEC and Inverter
320
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
321
Connector Views
27
28
5
4
HCM
Inverter
CAN - Low (Vehicle)
CAN - High
CAN - Low
Front Harness View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
35
34
2
1
PEC
CAN - High
CAN - Low
10
20
30
40
1
11
21
31
322
STEP A
1. Key off
2. Key on
and FMIs with
Pretest
If no issues are found during
either Electrical Test
Go to STEP B
If issue was repaired during
Go to STEP V
STEP B
1. Key off
high-voltage
3. What Faults are present If Fault Code 103 FMI 26 is listed Replace PEC. Go to
STEP V
If Fault Code 103 FMI 22, 23, 24,
or 25 are listed with an active fault
code 111
111 on page 357
If fault code 88 or 89 are listed Go to procedure for Fault Code
88 on page 299 or 89 on
page 303
WARNING
323
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
If no codes Test complete
testing.
Procedure page 19
324
325
Battery Control Unit Fault
SA 239
SPN 520240
FMI 22 - 30
Overview
The High-Voltage Batteries each contain a cell controller that communicates over a twisted pair
data link to the Battery Control Unit (BCU). The Battery Control Unit located in the Relay Box
communicates with each battery to determine temperature, State of Charge (SOC), and voltage.
This information is then sent to the Inverter.
FMI 22-30 are set for various internal Battery Control Unit failures.
Possible Causes
FMI 22-30
- Relay box
326
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
327
STEP A
and FMIs with
2. Key off.
high-voltage
4. What FMIs are present If Fault Code 105, FMI 23-29 is
listed
Replace PEC. Go to STEP V
If Fault Code 105, FMI 30 is listed Go to STEP B
If Fault Code 105, FMI 22 is listed Key off and back on. If fault is still
present at key on, Replace PEC.
Go to STEP V
WARNING
328
STEP B
high-voltage
Motor / Generator
3. With the AC cable
disconnected at both ends,
measure resistance to cable
shielding at all three
terminals. Note: Cable
should be flexed while
measuring
If Open or OL on meter Replace PEC
If any resistance/continuity is
found
Replace AC High Voltage Cable.
Go to STEP V
WARNING
329
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
330
331
High Voltage Battery Leak Detection Fault
SA 239
SPN 520242
FMI 1
Overview
The Battery Control Unit (BCU) continuously monitors the vehicle to detect a high-voltage leak.
The circuit is connected to 3 locations on the DC high-voltage line with the opposite end connected
to the chassis through a resistor.
FMI 1 is set when resistance between high-voltage cable and inverter case is less than 82k
ohms for 1.2 seconds.
Possible Causes
FMI 1
- High-voltage cable insulation damage
- High-voltage component leaking
Required Tools
Basic Hand Tools
332
ServiceRanger
Megatest Meter AMB-45
injury or death.
WARNING
HAZARDOUS VOLTAGE
DANGER
HAZARDOUS VOLTAGE
333
STEP A
1. Key on
and FMIs with
If fault code 107 is active Go to STEP B
If fault code 107 is inactive Test complete. Go to STEP V
STEP B
1. Key off
high-voltage
3. Disconnect the Inverter DC
connector at the PEC
4. Measure the resistance to
shield at the DC cable
connector on both the
positive and negative
terminals
If Open or OL on meter Go to STEP I
found
Go to STEP C
WARNING
334
STEP C
high-voltage
2. Disconnect the DC
connector at the Inverter
3. With the DC cable
disconnected at both ends
measure the resistance to
cable shielding at both the
terminals
If Open or OL on meter Go to STEP D
found
Replace DC high-voltage cable
between the PEC and Inverter.
Go to STEP V
WARNING
335
STEP D
high-voltage
ground at the Inverter DC
connector on both positive
and negative terminals
If Open or OL on meter Possible error with testing. Go to
STEP V
found
Go to STEP E
STEP E
high-voltage
2. Disconnect the AC connector
at the Inverter
ground on all three terminals
at the AC cable
If Open or OL on meter Go to STEP F
found
Go to STEP G
WARNING
WARNING
336
STEP F
high-voltage
ground at all three terminals
at the Inverter AC connector
STEP V
found
WARNING
337
STEP G
high-voltage
Motor/Generator
3. With the AC cable
shielding at all three
terminals
If Open or OL on meter Go to STEP H
found
Replace AC High Voltage Cable.
Go to STEP V
WARNING
338
STEP H
high-voltage
ground at the Motor/
Generator AC connector
STEP V
found
Replace Motor/Generator. Go to
STEP V
STEP I
1. Is unit supplied with a DC/DC
converter or APG?
Yes Go to STEP J
No Replace PEC. Go to STEP V
WARNING
339
STEP J
high-voltage
2. Disconnect 24V positive and
negative cables from DC/DC
converter
3. Disconnect the PEC to DC/
DC converter DC cable at the
PEC
ground at the DC cable
terminals
If Open or OL on meter Possible error in testing. Go to
STEP V if vehicle does not have
an APG. Go to STEP M if vehicle
is equipped with APG
found
Go to STEP K
WARNING
340
STEP K
high-voltage
2. Disconnect the high-voltage
DC cable at the DC/DC
converter
shielding at positive and
negative terminals
If Open or OL on meter Go to STEP L
found
Replace High Voltage DC Cable.
Go to STEP V
WARNING
341
STEP L
high-voltage
ground at the DC/DC
Converter high-voltage DC
connector at both positive
and negative terminals
STEP V
found
Replace DC/DC Converter. Go to
STEP V
WARNING
342
STEP M
high-voltage
2. Disconnect the APG DC
high-voltage cable at the
PEC
ground at the DC cable
terminals
If Open or OL on meter Replace the PEC. Go to STEP V
found
Go to STEP N
WARNING
343
STEP N
high-voltage
2. Disconnect the high-voltage
DC cable at the APG
disconnected at both ends
measure the resistance from
terminals to cable shielding
at PEC cable end
If Open or OL on meter Go to STEP O
found
Replace DC High Voltage Cable.
Go to STEP V
WARNING
344
STEP O
high-voltage
ground at APG high-voltage
DC connector pins 1(+) and
4(-)
STEP V
found
Replace APG. Go to STEP V
WARNING
345
STEP V
1. Key off.
cable.
3. Key on.
4. Clear codes. Clear codes.
See Fault Code Removal/
Clearing on page 17
6. Check for codes. Clear
codes. See Fault Code
Removal/Clearing on
page 17
testing.
Procedure page 19
346
347
Battery Control Unit Power Supply Fault
SA 239
SPN 520268
FMI 3, 4
Overview
Battery Control Unit located in the Relay Box receives 24-volts ignition power and ground from the
Inverter.
The HCM Inverter enable voltage is greater than 7 volts and less than 16 volts.
FMI 3 is set when the BCU detects the Inverter enable voltage is greater than 16 volts for 1
second.
FMI 4 is set when the BCU detects the Inverter enable voltage is less than 7 volts for 1
second.
Possible Causes
FMI 4
- Relay Box
- Low-voltage harness from Inverter to PEC
- HCM
- Low-voltage harness from HCM to Inverter
- Inverter
FMI 3
- Relay Box
348
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
these instructions may result in severe personal injury or death
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
349
Connector Views
Inverter
Ground BC
VB_B
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
14
15
6
7
PEC
Ground BC
VB_B
Harness Front View

37 38
35 36
1
6
7
12
13
22
23
28
29
34
HCM
Inverter Enable 2 9 Inverter Enable
10
20
30
40
1
11
21
31
350
STEP A
and FMIs with
2. Key off
high-voltage
4. What Faults are present If Fault Code 108 FMI 3 or 4 are
listed with an active Fault Code
114
114 on page 375
listed with no active Fault Code
114
Go to STEP B
STEP B
connector.
2. Connect a multi meter to the
PEC 19-way connector pin 6
and pin 7.
3. Place multimeter where it can
be viewed, while standing
next to the truck.
4. Key on.
5. Observe multi meter voltage
reading.
23 to 25 volts
Replace the Battery Control Unit.
Go to STEP V
less than 7 volts
Go to STEP C
WARNING
351
STEP C
1. Key off.
40-way connector.
3. Measure resistance on the
following:
Inverter 40-way
connector pin 14 to
PEC 19-way
connector pin 6.
Inverter 40-way
connector pin 15 to
PEC 19-way
connector pin 7.
If resistance from pin 14 to pin 6
is 0 to 0.3 ohms and resistance
from pin 15 to pin 7 is 0 to 0.3
ohms
STEP V
If resistance is outside of range Replace the low-voltage harness
from the PEC to the Inverter. Go
to STEP V
STEP V
1. Key off
cable.
3. Key on
Removal/Clearing on
page 17
page 17
testing
Procedure page 19
352
353
Inverter Fault
SA 239
SPN 520220
FMI 21 - 29
Overview
The Inverter assembly is connected to the high-voltage DC cable from the PEC along with the
high-voltage AC cable from the Motor/Generator. It inverts the DC to AC voltage to power the
motor during electric assist and rectifies the AC back to DC to charge the high-voltage batteries
during coasting or regenerative braking. The Inverter is also the main controller for the high-
voltage system communicating to the Battery Control Module in the PEC along with
communicating to the HCM for overall system operation.
FMI 21-29 are set due to various internal failures of the Inverter.
Possible Causes
FMI 21-29
- Inverter
Depending on the internal failure the Inverter may continue to operate with the fault logged, or
shutdown the high- voltage system.
HCM continues to control the Hybrid vehicle in a diesel only mode for most failures.
354
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
355
STEP A
and FMIs with
2. Key off
high-voltage
4. What FMIs are present If Fault Code 110 is active Replace the Inverter. Go to
STEP V
If Fault Code 110 is inactive Test complete
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
testing
Procedure page 19
WARNING
356
357
Inverter Communication Fault
SA 239
SPN 520260
FMI 12, 19, 22- 28
Overview
The Inverter communicates with the Battery Control Unit (BCU) located in the PEC and the Hybrid
Control Module (HCM) on the CAN high-speed proprietary data link. The data link is a two wire
twisted pair with two 120 ohm resistors located in the link.
FMI 12 or 19 are set when the CAN message does not match or EEPROM check sum error
occurs at system power up.
FMI 22 is set when Inverter detects an internal CAN communication failure at power-up.
FMI 23, 24, 25, 27, or 28 are set when the Inverter fails to transmit, receive or obtain any
messages on the CAN data link.
FMI 26 is set when a specific message sent from the HCM is invalid.
Possible Causes
FMI 22
- Inverter
FMI 23, 24, or 25
- CAN data link
- Inverter
- Relay Box
FMI 26
- HCM
FMI 27
- Vehicle Harness
- Relay Box
- Inverter
The amber "Check Hybrid" lamp will display.
remain powered.
358
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
359
Connector Views
27
28
5
4
HCM
Inverter
CAN - Low (Vehicle)
CAN - High
CAN - Low
Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
(PEC - Low-Voltage Connector)
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
35
34
2
1
PEC
CAN - High
CAN - Low
10
20
30
40
1
11
21
31
360
STEP A
1. Key off
2. Key on
and FMIs with
and Hybrid Electrical Pretest
If no issues are found during
Go to STEP B
If issue was repaired during either
Electrical Test
Go to STEP V
STEP B
1. Key off
Procedure, found at front of
handled high-voltage
3. What FMIs are present for
active fault 111
If FMI 22 is listed Replace the Inverter. Go to
STEP V
If FMI 26 is listed Replace the HCM. Go to STEP V
If FMI 12, 23, 24, 25, 28 are listed Go to procedure for Fault Code
88
WARNING
361
STEP C
1. Key off
2. Remove 40-pin connector at
the Inverter
3. Check for short to ground
and 24-volt at pins 34 and 35
Short found to ground or 24V Replace the Vehicle Harness. Go
to STEP V
No short or open circuit found
and there is an active fault 103
FMI 26
No short or open circuits found Replace the Inverter. Go to
STEP V
STEP D
1. Key on
2. Key off and allow the system
to power down for at least 2
minutes.
3. Turn key to the on position If fault code 111 FMI 9 is not
active
Test complete. Go to STEP V
If fault code 111 FMI 9 is active Go to STEP E
STEP E
1. Key off
2. Remove the 40 pin connector
at the Inverter
3. Measure the voltage at Pin 1 If voltage at PIn 1 is 0 Replace the Inverter. Go to
STEP V
If voltage at Pin 1 is the same as
the battery voltage
362
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
testing
Procedure page 19
363
Inverter Voltage Fault
SA 239
SPN 520221
FMI 3, 4
Overview
The Inverter is connected to the Power Electronics Carrier through a high-voltage DC cable, which
supplies 340 volts from the batteries. During operation, the Inverter monitors the input voltage to
determine an over or under voltage concern.
FMI 4 is set when the Inverter input voltage measured at the capacitor is less than 200 volts for
1 second, while the main relays in the Relay Box are on.
FMI 3 is set when the Inverter input voltage measured at the capacitor is greater than 435 volts
for 0.05 ms.
Possible Causes
FMI 3,4
- Inverter
- PEC
- DC high-voltage cable
364
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
365
Connector Views
Inverter
340-Volt Pos (High Voltage)
340-Volt Neg (High Voltage) DC (-)
DC (+)
DC (-)
DC (+)
PEC
High Voltage DC Connector View
(Yazaki Connector)
1 2
DC(+)
DC(-)
340-Volt Neg (High Voltage)
High-Voltage DC Connector to PEC
DC(+)
DC(-)
366
STEP A
1. Key off
2. Key on
and FMIs with
high-voltage
5. What Faults are present If Fault Code 112 FMI 3 is listed Contact Eaton at 1-800-826-
HELP (4357).
If Fault Code 112, FMI 3 is listed
with other active Hybrid Fault
Codes beside 112
Go to procedure for active Hybrid
Fault Code(s).
If Fault Code 112 FMI 4 is listed Go to STEP B
WARNING
367
STEP B
1. Key off
2. Disconnect the DC high-
Inverter
3. Place the multi-meter on uF
option
high-voltage
5. Place the leads into the two
Inverter DC high-voltage
sockets making sure the
probes touch the terminals
6. Record the measurement
after 2 minutes
If the uF reading is 1104uF-
1656uF at 68F (20C)
Go to STEP C
If the uF reading is outside
1104uF-1656uF at 68F (20C)
STEP V
STEP C
1. Key off
voltage connector from the
PEC
each circuit on the DC cable
from the PEC connector to
the Inverter connector
If the resistance for each circuit is
1 ohm or less
STEP V
If resistance is out of range Replace the DC High-Voltage
Cable. Go to STEP V
WARNING
368
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
369
Inverter Current Fault
SA 239
SPN 520222
FMI 6, 14
Overview
The Inverter is connected to the Power Electronics Carrier (PEC) through a high-voltage DC cable
which supplies 340 volts from the batteries. During operation, the Inverter monitors the output
current to the Motor/Generator.
FMI 6 is set when the Inverter IGBT current is greater than 800 amps for 0.05 ms or the motor
cable is short.
FMI 14 is set when motor torque commanded is zero and current is reported by the Inverter.
Possible Causes
FMI 6
- Inverter
- Motor/Generator
- AC high-voltage cables
FMI 14
- Motor/Generator
- AC high-voltage cables
The red Stop Hybrid lamp will display for FMI 6 and a amber Check Hybrid for FMI 14
370
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
371
Connector Views
W
V
U
W
V
U
Inverter
Motor/
Generator
Phase 1
Phase 2
Phase 3
Phase 1
Phase 2
Phase 3
W U
V
E D
F
U
V
W
F
E D
D
E
D
E
Loose Disconnect
Loose Disconnect
Loose Disconnect
Loose Disconnect
372
STEP A
and FMIs with
2. Key off
high-voltage
4. What FMI(s) are present If Fault Code 113 FMI 6 is listed Go to STEP B
If Fault Code 113 FMI 14 is listed Go to STEP D
STEP B
1. Visually inspect the AC cable
for signs of abrasion, cuts, or
exposed wiring
cable at the Motor/Generator
and Inverter
high-voltage cable pins:
U-V
V-W
W-U
If resistance between each phase
is 5M or greater
Go to STEP C
An Auto Ranging Digital Volt/Ohm
Meter must be used
If resistance is outside of range Replace the AC High-Voltage
WARNING
373
STEP C
each AC high-voltage cable
pin to ground
If resistance between each pin
and ground is 5M or greater
STEP V
Cable. Go to STEP V
STEP D
cable from the Inverter and
Motor/Generator
following pins:
U-U
V-V
W-W
If resistance is less than 1 ohm
on each circuit
Replace the Motor/Generator. Go
to STEP V
used
374
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
testing
Procedure page 19
375
Inverter Power Supply Fault
SA 239
SPN 520261
FMI 1, 3, 4
Overview
The Inverter assembly uses a 24-volt supply provided from the HCM to power the internal control
board. The HCM provides this ignition power after it completes the power-up self check.
FMI 1 is set when the internal 24v to 12v converter is out of range.
FMI 3 is set when the Inverter ignition voltage is greater than 16 volts (12-volt system) and 32
volts (24-volt system) for 0.5 seconds.
FMI 4 is set when the Inverter ignition voltage is less than 7 volts (12-volt system) and 16 volts
(24-volt system) for 0.1 seconds.
Possible Causes
FMI 1
- Inverter
FMI 3
- Inverter
FMI 4
- HCM
- Inverter
- Power supply harness from HCM to Inverter
Electric Motor/Generator assist and regeneration are disabled, however, the high-voltage
relays will remain powered
376
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
377
Connector Views
STEP A
and FMIs with
Electrical Pretest
Go to STEP B
Electrical Pretest
Test Complete. Go to STEP V
2
7
9
6
HCM
Inverter
Inverter Enable
Ground 1
Inverter Enable
Ground 2
Front Harness View

37 38
35 36
1
6
7
12
13
22
23
28
29
34
10
20
30
40
1
11
21
31
378
STEP B
and FMIs with
2. Key off
high-voltage
If FMI 1 is listed Replace the Inverter
4. What FMIs are present If Fault Code 114 FMI 3 or 4 is
listed
Go to STEP C
If Fault Code 114 is not present Test Complete. Go to STEP V
STEP C
1. Key off
40-way connector
3. Connect a multi meter to the
Inverter 40-way connector
pin 9 and pin 6
4. Place multi meter where it
can be viewed while standing
next to the truck
5. Key on
6. Observe multi meter voltage
reading
If voltage is 23 to 25 volts (24-volt
system)
STEP V
If voltage is greater than 32 volts
(24-volt system)
Repair the vehicle charging
system. Refer to OEM for repair
procedure.
If voltage is outside of range Go to STEP D
WARNING
379
STEP D
1. Key off
2. Disconnect the negative
battery cable
4. Measure resistance from the
following:
Inverter 40-way
connector pin 9 to
HCM 38-way
connector pin 2.
Inverter 40-way
connector pin 6 to
ground.
If resistance from pin 1 to pin 2 is
0 to 0.3 ohms and resistance
from pin 6 to ground is 0 to OL
If resistance is outside of range Repair the open in the power or
ground harness. Go to STEP V
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
testing
Procedure page 19
380
381
Inverter Temperature Fault
SA 239
SPN 520223
FMI 0
Overview
The Inverter temperature sensor is a thermistor located inside the Inverter that changes in value
based on the temperature. The Inverter supplies a 5 volt reference voltage to the sensor and
measures the volt drop in the circuit. When the Inverter temperature is warm the sensor resistance
is low and the Inverter detects a low-voltage (0.1 volts equals 127C). When the Motor/Generator
is cold the sensor resistance is high and the Inverter detects a high-voltage (4.0 volts equal -56C).
FMI 0 is set with the Inverter temperature is greater than 97C (206F) for 100 ms or sensor
broken.
Possible Causes
FMI 0
- Inverter
- Liquid cooling system (low coolant, no coolant flow, coolant pump, radiator,
radiator fan, reservoir)
remain powered
Required Tools
Basic Hand Tools
382
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
383
STEP A
and FMIs with
pin diagnostic connector
high-voltage
3. Key on
option and view PID 120
Inverter Temperature in the
Power Electronics list
5. Observe PID 120 again after
20 minutes
If PID 120 Inverter Temperature
lowered from the first to second
reading
Go to STEP B
If PID 120 Inverter Temperature
remained constant
STEP V
STEP B
1. Key off
2. Observe the coolant level
after the system has cooled
to see if it is filled to the
proper level
If the coolant is within the
recommend limits
Go to STEP C
If the coolant is below the
recommended limits
Refer to OEM for coolant type
and fill procedure. Go to STEP V
WARNING
384
STEP C
1. Visually inspect the Hybrid
liquid cooling system radiator
for debris or obstruction to
airflow and inspect the
coolant lines for sharp bends
If the radiator is free of debris and
the coolant lines are not kinked
Go to STEP D
If the radiator is full of debris, the
airflow is obstructed, or the
coolant lines are kinked
Repair the concern. Go to
STEP V
STEP D
1. Key on
the 9-way connector in the
cab
the Cooling Pump option.
option
If the coolant pump turns on Go to STEP E
If the coolant pump fails to turn on Go to STEP F
STEP E
option.
Fan option
If the Heat Exchanger Fan turns
on
The 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. Go to STEP V
If the Heat Exchanger Fan fails to
turns on
Go to STEP G
385
STEP F
1. Key on
2. Disconnect the Coolant
Pump 2-way connector
the Cooling Pump option
option
5. Measure the voltage at the
to B.
concern
outside of range
Refer to OEM for Cooing Pump
power harness repair procedure.
STEP G
1. Key on
2. Disconnect the Heat
Exchanger Fan 2-way
connector
option
Fan option
5. Measure the voltage at the
to B.
Fan concern
outside of range
Fan power harness repair
procedure
386
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
page 17
testing
Procedure page 19
387
High Voltage Relays Fault
SA 239
SPN 521210, 521211, 521212
FMI 3, 4, 5
Overview
The High-Voltage Relays are located inside the Power Electronics Carrier (PEC) in the Relay Box
unit. There is one pre-charge relay on the positive side, an additional relay on the positive, and one
on the negative for a total of three. These relays are normally open when the system is off. The
relays are controlled through the Inverter.
FMI 3 is set when a short is detected to vehicle 24 volt on the control side of a high-voltage
relay.
FMI 4 is set when a short is detected to ground on the control side of a high-voltage relay.
FMI 5 is set when an open circuit is detected on the control side of a high-voltage relay.
Possible Causes
FMI 3, 4, 5
- Relay Box
- Inertia Switch
- Inverter
- Vehicle wiring between the Inverter and PEC
The amber Check Hybrid lamp will blink for FMI 10
The hybrid system will be offline
Transmission defaults to 1st start gear in diesel only mode
388
Required Tools
Basic Hand Tools
ServiceRanger
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
389
Connector Views
Inverter
DC (+)
DC (-)
DC (+)
PEC
Mating Connector View
(Deutsch 19 - Way)
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
1
2
1
2
Interlock negative
Interlock positive
Interlock negative
Interlock positive
21
22
17
9
23
32
13
11
33
31
15
19
Precharge Plus
Main Plus Plus
Precharge Minus
Main Minus Minus
Main Plus Minus
Main Minus Plus
Precharge Plus
Main Plus Plus
Precharge Minus
Main Minus Minus
Main Plus Minus
Main Minus Plus
10
20
30
40
1
11
21
31
390
STEP A
and FMIs with
high-voltage
3. What FMIs are present If Fault Code 116 FMI 3 is listed Go to STEP B
If Fault Code 116 FMI 4 is listed Go to STEP D
If Fault Code 116 FMI 5 is listed Go to STEP F
STEP B
1. Key off
2. Temporarily remove the
lockout bracket and pull the
'Service Switch' out
3. Disconnect the PEC 19-pin
connector
4. Measure the following
connectors according to the
SPN:
a. SPN 521210; pins 17
and 19 to 24-volt
b. SPN 521211; pins 9 and
11 to 24-volt
c. SPN 521212; pins 13
and 15 to 24-volt
Any resistance from PEC
connector pins to 24-volt
If meter reads OL or Open Circuit Go to STEP C
WARNING
391
STEP C
1. Key off
2. Connect the PEC 19-pin
connector
3. Disconnect the 40-pin
Inverter connector
SPN:
a. SPN 521210; pins 21
and 31 to 24-volt
b. SPN 521211; pins 22
and 32 to 24-volt
c. SPN 521212; pins 23
and 33 to 24-volt
Any resistance from the Inverter
connector pins to 24-volt
Repair vehicle harness. Go to
STEP V
If meter reads OL or Open Circuit Replace the Inverter. Go to
STEP V
STEP D
1. Key off
connector
Service Switch out.
SPN:
a. SPN 521210; pin 17 to
ground
b. SPN 521211; pin 9 to
ground
c. SPN 521212; pin 13 to
ground
Any resistance from the PEC
connectors to ground
If meter reads OL or Open Circuit Go to STEP E
392
STEP E
1. Key off
2. Reconnect the PEC 19-way
connector
40-way connector.
SPN:
a. SPN 521210; pin 21 to
ground
b. SPN 521211; pin 22 to
ground
c. SPN 521212; pin 23 to
ground
Any resistance from the Inverter
connectors to ground
Repair vehicle harness. Go to
STEP V
If meter reads OL or Open Circuit Replace the Inverter. Go to
STEP V
STEP F
1. Key off
connector
3. Ensure the key is in the Off
position
Service Switch out
PEC 19-way connector
terminal at the following pins:
SPN 521210; pins
17 to 19
SPN 521211; pins
9 to 11
SPN 521212; pins
13 to 15
and 19 is 112-122 ohms and the
resistance from pin 9 to 11 and
pin 13 to 15 are each 33-37 ohms
Go to STEP G
If resistance is out of range Reset inertia switch if Pin 13 to 15
is open or OL, retest circuit.
Replace PEC if circuit is still open
after switch reset or the other
circuits are out of range. Go to
STEP V
393
STEP G
1. Key off
2. Connect the PEC 19-way
connector
40-pin connector
position
Service Switch out
SPN 521210; pins
21 to 31
SPN 521211; pins
23 to 33
SPN 521212; pins
22 to 32
STEP V
Go to STEP V
STEP V
1. Key off
cable.
3. Key on
Removal/Clearing on
page 17
page 17
testing.
Procedure page 19
394
395
High Voltage Relays Fault
SA 239
SPN 520224
FMI 10, 14, 20, 29, 30
Overview
unit. There is one pre-charge relay on the positive side, an additional relay on the positive, and one
on the negative for a total of three. These relays are normally open when the system is off. The
relays are controlled through the Inverter.
FMI 10 is set when inverter capacitor voltage is less than 210 volts after 4 seconds from pre-
charge relay being closed or main positive relay is not on.
FMI 14 is set when the main negative relay is on and the inverter capacitor voltage decrease is
less than 10-volts / 5 seconds when initial capacitor voltage was greater than 200 volts and
motor speed is less than 500 RPM.
FMI 20 is set when the high-voltage DC cable interlock switch is open.
FMI 29 is set when battery voltage is present on the Inverter side of the main relays under
Main Positive Relay open status.
FMI 30 is set when battery voltage is present on the Inverter side of the main relays under
Main Negative Relay open status.
Possible Causes
FMI 10
- High-voltage fuse
- Red Service Switch
- DC high-voltage cable or interlock
- Inverter
- Inertia switch
FMI 14
- Inverter
- PEC
FMI 20
- DC cable interlock circuit
FMI 29
- Failed Main Positive relay
FMI 30
- Failed Main Negative relay
396
High Voltage Relays Fault Fault Code 116 Isolation Procedures
The amber Check Hybrid lamp will be illuminated for FMI 10, 14 and 20. The Red Stop
Hybrid lamp will be illuminated for FMI 29 and 30.
The hybrid system will be offline
Transmission defaults start gear to 1st in diesel only mode
Required Tools
Basic Hand Tools
ServiceRanger
397
Fault Code 116 Isolation Procedures Warnings and Cautions
injury or death.
DANGER
HAZARDOUS VOLTAGE
WARNING
HAZARDOUS VOLTAGE
398
Connector Views
Inverter
DC (+)
DC (-)
DC (+)
PEC
(Deutsch 19 - Way)
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
1
2
1
2
Interlock negative
Interlock positive
Interlock negative
Interlock positive
21
22
17
9
23
32
13
11
33
31
15
19
Precharge Plus
Main Plus Plus
Precharge Minus
Main Minus Minus
Main Plus Minus
Main Minus Plus
Precharge Plus
Main Plus Plus
Precharge Minus
Main Minus Minus
Main Plus Minus
Main Minus Plus
10
20
30
40
1
11
21
31
399
Check to see if the red Service Switch on the front of the PEC is pulled out. If the switch is
pushed in pull the switch out and turn the ignition key off. After 2 minutes turn the ignition
key on.
STEP A
and FMIs with
2. Check to see if the red
Service Switch on the front
of the PEC is pulled out. If
the switch is pushed in pull
the switch out and turn the
ignition key off. After 2
minutes turn the ignition key
on
3. What FMIs are present If Fault Code 116 FMI 10 is listed Go to STEP B
If Fault Code 116 FMI 14 is listed Go to STEP I
If Fault Code 116 FMI 20 is listed Go to STEP J
If Fault Code 116 FMI 29 or 30 is
listed
Go to STEP K
IMPORTANT
WARNING
400
STEP B
1. Key off
2. Remove the PEC air filter
cover
3. Reset the PEC Inertia Switch
(see TRSM2000 for
procedures)
4. Key on
and FMIs with
If Fault Code 116 FMI 10 is now
active
Go to STEP V
If Fault Code 116 FMI 10 is still
listed
Go to STEP C
STEP C
1. Key on
the 9-way diagnostic
connector in the cab
option and view Battery
Voltage PID 118 (SPN
520250 J1939) from the HV
Battery list
if Battery Voltage PID 118 (SPN
520250 J1939) is greater than
210 volts
Go to STEP D
if Battery Voltage PID 118 (SPN
520250 J1939) is less than 210
volts
Check main fuse in the PEC. If
fuse has not failed replace PEC.
Go to STEP V
401
STEP D
1. Key off
2. If the vehicle is not equipped
with a DC/DC Converter or
APG skip to Step E
3. Using high-voltage gloves
disconnect the DC cable for
the DC/DC Converter or APG
at the PEC bulkhead and cap
the connector and the
bulkhead terminal
Service Switch out.
5. Key on If fault code 116 FMI 10 is active
with the DC/DC Converter and
APG connector disconnected
Go to STEP E
If fault code 116 FMI 10 is not
active with the DC/DC Converter
and APG connector disconnected
Replace the Auxiliary Relays in
the PEC. Go to STEP V
STEP E
1. Key off
voltage cable at the PEC and
the Inverter
3. Measure the of each high-
voltage circuit on the cable
Resistance of each circuit is 0 -
0.3 ohms
Go to STEP F
If resistance is outside of range Replace the DC High-Voltage
Cable. Go to STEP V
402
STEP F
1. Key off
connector
position
Service Switch out
PEC 19-way connector
Pins 17 to 19
Pins 9 to 11
Pins 13 to 15
Go to STEP G
If resistance is out of range Replace PEC. Go to STEP V
STEP G
1. Key off
2. Connect the PEC 19-way
connector
40-pin connector
4. Inspect the connectors for
damage or corrosion
position
Service Switch out
Pins 21 to 31
Pins 23 to 33
Pins 22 to 32
Go to STEP H
Go to STEP V
403
STEP H
1. Key off
2. Check for short between
Inverter Pos (+) to Neg (-)
Short from Pos to Neg Replace the Inverter. Go to
STEP V
No continuity Replace PEC. Go to STEP V
STEP I
the 9-way diagnostic
connector in the cab
option
3. View the following
parameters in the HV-Battery
list:
Battery Pack
Voltage PID 118
(SPN 520250
J1939)
Battery Voltage PID
116 (SPN 520323
J1939)
If the voltage readings on PID
116 and PID 118 are within 10
volts of each other
If the voltage readings on PID
116 and PID 118 are greater than
10 volts of each other
STEP V
STEP J
1. Key off
voltage cables at the PEC
bulkhead and at the Inverter
between the two low voltage
interlock pins on each end of
the DC high-voltage cable
If resistance is 0 - 0.3 ohms Replace the Inverter. Go to
STEP V
If resistance is outside of range Replace the DC High-Voltage
Cable. Go to STEP V
404
STEP K
1. Key off
2. The PEC main fuse MUST
be removed before the PEC
to Inverter high-voltage cable
is disconnected from the
PEC. Reference Service
manual TRSM-2000 for the
main fuse removal procedure
3. Remove PEC from vehicle Replace PEC. Go to STEP V
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
Removal/Clearing on
page 17
testing
Procedure page 19
405
Battery Control Unit (BCU) Relay Cut Request Fault
SA 239
SPN 520251
FMI 3, 14, 29
Overview
unit. These relays are normally open when the system is off. The relays are controlled through the
Inverter and monitored through a 5-volt input from the Inverter. If the relays are open the voltage is
around 5 volts and when the relays are closed the voltage is around 1 volt.
FMI 3 is set when Battery Control Unit (BCU) relay ready CAN flag is active and the relay off
signal is set high for 0.02 seconds.
FMI 14 is set when the BCU relay cut request is by a different active BCU fault.
FMI 29 is set when the Relay Off signal line is active.
Possible Causes
FMI 3, 29
- Inverter
- Low-voltage wire harness
The Eaton service tool ServiceRanger may be used to clear the fault from TECU or HCM history.
The TECU and HCM automatically clear the faults from history after 200 hours of the fault staying
Inactive.
406
Required Tools
Basic Hand Tools
High-Voltage Gloves J48603
ServiceRanger
injury or death.
WARNING
HAZARDOUS VOLTAGE
DANGER
HAZARDOUS VOLTAGE
407
Connector Views
STEP A
and FMIs with
2. Key off
high-voltage
4. What FMIs are present If FMI 14 is listed Test complete. FMI 14 requires
no action or replacement
If FMI 3 or 29 are listed Go to STEP B
Inverter
Relay Off
8 9
1
2
3
4 5
6
7
10
11
12
13
14 15
16
17
18
19
13
3
5
PEC
Relay Off
10
20
30
40
1
11
21
31
WARNING
408
STEP B
1. View active faults to see if
any of the following are listed:
76, 78, 82, 101, 103, 105,
107, 108
If any of the faults are listed with
Fault Code 117 FMI 3
Go to test for faults that are active
If none of the faults are listed with
FMI 3
Go to STEP C
If none of the faults are listed with
FMI 29
Go to STEP D
STEP C
1. Key off
connector
40-way connector.
4. Measure the resistance from
the PEC 19-way connector
pin 5 to the Inverter 40-way
connector pin 13
If the resistance between pin 5
and pin 13 is 0 - 0.3 ohms
If resistance is outside of range Repair the HCM Low-Voltage
harness between the PEC and
Inverter. Go to STEP V
STEP D
1. Key off
2. Remove the 40-pin connector
from the Inverter
3. Use an ohm meter to
measure the resistance from
pin 3 to ground at the vehicle
harness
If the resistance between pin 3 to
ground is 0 to 0.3 ohms
If resistance is outside of range Repair 40-pin vehicle harness.
Go to STEP V
409
STEP V
1. Key off
cable
3. Key on
Removal/Clearing on
page 17
Removal/Clearing on
page 17
testing
Procedure page 19
410
411
Instrument Cluster Message
SPN 84
FMI 2, 9
Overview
Fault Code 166 is generated from missing park brake message.
See OEM cluster messages for any repairs.
412
Instrument Cluster Message Fault Code 166 Isolation Procedures
413
Front Box Test
Front Box Test
Overview
This symptom-driven test is performed if a - or flashing gear is displayed on the Gear Display,
and there are no active or inactive codes. Turn the key on and watch the Gear Display. If the Gear
Display shows - constantly, the Transmission ECU was not able to confirm front box control. If the
transmission displays a flashing gear when a forward or reverse mode is selected, the
transmission is not able to engage the gear position.
Note: This symptom-based test should only be performed if you were sent here from the
Diagnostic Procedure and you have no active fault codes.
Possible Causes
Low Power to Gear Select Motor
Electric Shifter
Gear Select Sensor
Yoke / Clutch / Main Shaft
Shift Bar Housing
Dragging Clutch
Torque Locked in Gear
There is no fallback mode for this symptom, however, the vehicle will either not crank if the - is
present or not engage a gear if the flashing gear is present when a non-neutral gear is selected.
Symptoms
Power-up no crank and the gear display shows -
Transmission will not engage a gear from neutral (flashing gear number is gear display).
Required Tools
Basic Hand Tools
ServiceRanger
414
Connector Views Front Box Test
Connector Views
STEP A
1. You should only perform this
symptom test if you were
sent here from the Diagnostic
Procedure and you have no
active fault codes
2. Key on
4. Observe Gear Display If Gear Display shows: N Go to STEP B
If Gear Display shows: - Go to STEP C
415
Front Box Test Isolation Procedures
STEP B
1. Depress service brake and
select D
2. Observe Gear Display If Gear Display shows a solid
gear
Test complete
If Gear Display shows a flashing
gear with no arrows
Go to STEP C
STEP C
1. Key off
2. Attempt to remove any type
of torque lock on the vehicles
drivetrain through one of the
following methods:
a. Remove the driveshaft
b. Lift the drive wheels off
the ground
c. Roll the vehicle in neutral
3. Key on
4. Observe gear display If Gear Display shows a solid N Go to STEP B
If Gear Display still shows a solid
-
Go to STEP D
STEP D
Electrical Pretest
Go to STEP E
Electrical Pretest
Go to STEP A
416
Isolation Procedures Front Box Test
STEP E
1. Key on
2. Listen for noise from the
Electric Shifter calibrating/
actuating then turn the key
off and listen for the same
noise again
If the Electric Shifter can be
heard calibrating/actuating
Go to STEP F
If the Electric Shifter cant be
heard calibrating
Go to STEP F
STEP F
1. Key off
2. Remove Electric Shifter from
Shift Bar Housing
Shift blocks are
fastened to shift
rails securely
Shift rails move into
each gear position
Electric shifter is
free from any
excessive lube
contamination
buildup
Two gear positions
can not be
engaged at the
same time
If no problem found and you could
not hear the electric shifter
actuation in the previous step
Replace the TECU. Go toSTEP V
If no problem found and you could
hear the electric shifter actuation
in the previous step
Replace the Electric Shifter. Go to
STEP V
If problem is found Repair as required. Go to STEP V
417
Front Box Test Isolation Procedures
STEP V
1. Key off
3. Place Shift Control into
neutral
4. Key on If Gear Display displays a solid
N
Test complete
If Gear Display does not display a
solid N
Return to STEP A to find
error in testing
418
Isolation Procedures Front Box Test
419
Engine Crank Test
Engine Crank Test
Overview
This symptom-driven test is performed if a N is displayed on the Gear Display with no active or
inactive codes and the vehicle will not crank.
The Hybrid Control Module (HCM) receives the input to crank from pin 20 on the HCM 38-way
Vehicle Connector, which is wired to the key switch. The HCM normally powers the High-Voltage
Motor/Generator to start the engine. If the Hybrid system is offline, the HCM will use the standard
24-volt starter by energizing the 24-volt Cranking relay. This relay then provides battery power to
pin 30 of the Start Enable Relay, which then powers the starter solenoid.
Symptom
Vehicle will not crank or there is a solid N in the gear display.
Possible Causes
24-volt Cranking Relay
Start Enable Relay
OEM Vehicle Harness
Engine Starter
24-volt batteries
Key switch input to pin 20 of the HCM
Required Tools
Basic Hand Tools
ServiceRanger
420
Engine Crank Test Wiring Schematic Engine Crank Test
Engine Crank Test Wiring Schematic
Harness Front View


37 38
35 36
1
6
12
13
22
23 28
29 34
7
TECU
HCM
30
86
87
85
26
87
86
85
30
32
Crank Enable Plus
Start Enable Latch

Harness Front View
37 38
35 36
1
6
7
12
13
22
23
28
29
34
Start Enable
Relay
24V Truck
Battery
2
4
V

P
l
u
s
4 Crank Enable Minus
4 Start Enable Minus
87
86
85
30

24V Cranking
Relay 26 Crank Enable Latch
Start Enable Plus 32
Starter solenoid
Key Switch
20
Off
Ignition
Crank
Engine Crank Request
421
Engine Crank Test
STEP A
active fault codes
2. Key on
Note: The ePTO lamp must be
off when using the key
switch to start the vehicle
If N is present on the Gear
Display
Go to STEP B
If N is not present on the Gear
Display
Refer to the Diagnostic
Procedure for the correct
Symptom based test to perform
STEP B
1. Key on
connector
option and view the Crank
Request parameter
If Crank Request reads 1 (Crank) Go to Step C.
If Crank Request reads 0 (No
Crank)
Go to Step E.
STEP C
1. Substitute a different start
enable and 24-volt cranking
relay
2. Attempt to crank engine If engine cranks Pinpoint which of the two relays
was at fault and replace it.Go to
STEP V
If engine does not crank Go to STEP D
422
Engine Crank Test
STEP D
1. Key on
Engine may crank
2. Jumper pin 87 of the start
enable relay connector to
battery power
If engine cranks Repair open circuit between pin
87 of the start enable relay and
battery. Refer to OEM for repair
procedures.
If engine does not crank Concern is with starter solenoid
or power harness to solenoid.
procedures
STEP E
1. Key off
cable
3. Disconnect HCM vehicle
4. Key in start position
5. Measure voltage from HCM
connector pin 20 to ground
If voltage is 23-25 volts Replace the HCM. Go to STEP V
If voltage is below 23 volts Repair the OEM vehicle harness.
Go to STEP V
STEP V
1. Key off
neutral
4. Key on If engine starts Test complete
If engine does not start Return to STEP A to find
error in testing.
WARNING
423
Hybrid Performance Test
Hybrid Performance Test
Overview
The Hybrid System uses a combination of diesel engine and electric power to provide varying
levels of torque during vehicle operation. If the Hybrid system has a fault, or if a hybrid component
is above the optimum operating temperature, the vehicle will reduce the amount of available Motor/
Generator torque.
Note: Some faults codes will affect the amount of torque available from the Motor/Generator and
will be noticeable to the driver.
Symptoms
Vehicle acceleration performance is not acceptable
Possible Causes
Hybrid liquid cooling system
PEC air cooling system restriction or poor air flow
Reduce engine power
Truckload capacity above the rated amount
Required Tools
Basic Hand Tools
ServiceRanger
424
Isolation Procedures Hybrid Performance Test
STEP A
1. Key on.
connector in the cab and
view the following Data
Monitor parameters under
the Hybrid (Engine and
Brake) list:
SPN 513 Actual
Engine Torque
SPN 518
Requested Engine
Torque
If actual torque is equal to
requested torque
Go to STEP B
If actual torque is less than
requested torque
Refer to OEM for engine power
concern. Go to STEP V
STEP B
option and view the following
parameter:
Battery
Temperature PID
115
If Battery temperature is below
40C
Refer to OEM for engine power
concern. Go to STEP V
If temperature if above 40C
inspect the battery cooling
system for the following.
Plugged intake or
exhaust ports
Restricted or
plugged air filter
Failed battery
cooling fan
Refer to the OEM for procedures
and specifications. Make
necessary and go to STEP V
425
Hybrid Performance Test Isolation Procedures
STEP V
1. Key off
3. Place Shift control into
neutral.
4. Key on If vehicle exhibits normal amount
of power
Test complete
If vehicle seems to produce lack
power
error in testing
426
Isolation Procedures Hybrid Performance Test
427
Gear Engagement Test
Gear Engagement Test
Overview
The Hybrid Control Module (HCM) normally commands the different gears shifts which are done
through the Transmission Electronic Control Unit (TECU). The HCM also controls the Electric
Clutch Actuator (ECA), which changes the position of the clutch.
Symptoms
Transmission will not engage a gear from Neutral and warning tone sounds (Solid N in Gear
Display).
Transmission will not engage a gear from Neutral (Flashing Gear in Gear Display). This
symptom is addressed in the Front Box Symptom test.
Transmission will not move from a stop (Solid Gear number in Gear Display).
Messages from the Body Controller to the HCM
Messages from the Engine, Chassis, or Body Controller to the TECU
Possible Causes
Transmission
Service Brake Switch
Boom/Outrigger switch
Required Tools
Basic Hand Tools
ServiceRanger
Signal Value Meaning Description
Prohibit Driving 0
1
Allow Driving
Prohibit Driving
Body Controller is
requesting the HCM not
allow gear engagement
from neutral.
Signal Value Meaning Description
Brake Switch 0
1
Not Applied
Applied
The ECU is confirming
the current state of the
service brake switch.
428
Isolation Procedures Gear Engagement Test
STEP A
active fault codes
If N is present on the Gear
Display
Go to STEP B
If N is not present on the Gear
Display
Refer to the Diagnostic
Procedure for the correct
symptom based test to perform
STEP B
1. Key on
2. Start engine
3. Depress service brake and
select D
If gear display shows a N and a
warning tone sounds
Go to STEP D
If Gear Display shows a flashing
gear with no arrows
Go to Front Box Test
If Gear Display shows a solid
gear, but vehicle will not move
Go to STEP C
STEP C
1. Key on.
2. Connect ServiceRanger and
view the following Data
Monitor parameter PID 154
Prohibit Driving
Prohibit Driving reads 0 (Allow
Driving)
HELP [4357]
Prohibit Driving reads 1 (Prohibit
Driving)
Ensure boom and outriggers are
fully retracted. Contact your OEM
for repair procedures. Go to
STEP V
429
Gear Engagement Test Isolation Procedures
STEP D
1. Key on
2. View the following Data
Monitor parameter while
depressing the service brake:
SPN 597 Service
Brake Status
If the service brake switch status
is depressed when you apply the
brakes
HELP [4357]
If the service brake switch does
not change status
Repair service brake wiring or
switch. Contact your OEM for
repair procedures. Go to STEP V
STEP V
1. Key off.
2. Reconnect all connectors.
neutral.
4. Key on. If the transmission will engage a
gear and move from a stop
Test complete.
If the transmission will not
engage a gear or move from a
stop
error in testing.
430
Isolation Procedures Gear Engagement Test
431
Wiring Diagrams
Wiring Diagram with Push Button Shift Controller
432
Wiring Diagram with Push Button Shift Controller Wiring Diagrams
433
Wiring Diagrams Wiring Diagram with Push Button Shift Con-
Hybrid Transmission ECU System Harness
Gear select
motor
Rail select
motor
Electric
shifter
A
B
A
B
Rail select
sensor
Gear select
sensor
Input shaft
speed sensor
Output shaft
speed sensor
18
19
20
10
11
12
7
8
23
24
A
B
C
A
B
C
35
37
36
38
B
C
A
17
31
25
D
For Transmission
Diagnostics
4-way
B - Service Bat. +
C - Service Bat. -
A - Service Ignition +
B
C
A
Transmission ECU
434
Wiring Diagram with Push Button Shift Controller Wiring Diagrams
435
Connector Pin Description
Hybrid and Transmission Connector Pins
TECU and HCM Connectors
Please note the location and orientation of the HCM and TECU connectors.
HCM - Vehicle Interface Connector
TECU - Vehicle Interface Connector
HCM - Hybrid System Interface Connector
37 38
35 36
1
6
7
12
13
22
23
28
29
34
37 38
35 36
1
6
7
12
13
22
23
28
29
34
37 38
35 36
1
6
12
13
22
23 28
29 34
7
436
Hybrid and Transmission Connector Pins Connector Pin Description
The backshell should always face down on the harness connectors.
437
Connector Pin Description Hybrid and Transmission Connector Pins
Transmission Controller 38-Way (Vehicle Interface Connector)
Description From Pin # To Pin # AWG
Not Used 1 Plug
J1939 Low (CAN) TECU 2 1939 Backbone B 18 TXL
J1939 High (CAN) TECU 3 1939 Backbone A 18 TXL
Start Enable Relay
Minus
TECU 4 AS Start Enable Relay 85 18 TXL
Not Used 5 Plug
Not Used 6 Plug
Not Used 7 Plug
Not Used 8 Plug
Not Used 9 Plug
J1587 Plus TECU 10 Splice into 1587 A 18 TXL
J1587 Minus TECU 11 Splice into 1587 B 18 TXL
Not Used 12 Plug
Not Used 13 Plug
Not Used 14 Plug
Not Used 15 Plug
Not Used 16 Plug
Not Used 17 Plug
Not Used 18 Plug
Not Used 19 Plug
Not Used 20 Plug
Not Used 21 Plug
Not Used 22 Plug
Not Used 23 Plug
Not Used 24 Plug
Shift Control Power
Minus
TECU 25 PBSC J3 18 TXL
Start Enable Latch TECU 26 AS Start Enable Relay 87 18 TXL
HIL Low (Proprietary
CAN)
TECU 27 PBSC F2 18 TXL
HIL High (Proprietary
CAN)
TECU 28 PBSC F1 18 TXL
Not Used 29 Plug
Not Used 30 Plug
Shift Control Power
Plus
TECU 31 PBSC C1 18 TXL
Start Enable Relay
Plus
TECU 32 AS Start Enable Relay 86 18 TXL
Not Used 33 Plug
Not Used 34 Plug
438
Ignition TECU 35 10A Fused Switched
Power from Ignition
Bus
12 GXL or
14SXL
Battery Minus TECU 36 Ground at Battery or
Starter
12 GXL
Not Used 37 Plug
Battery Plus TECU 38 30A Fused Non-
Switched
12 GXL
439
Hybrid Controller 38-Way (Vehicle Interface Connector)
Not Used 1 Plug
J1939 Low (CAN) HCM 2 1939 Backbone B 18 TXL
J1939 High (CAN) HCM 3 1939 Backbone A 18 TXL
24V Cranking Relay
Minus
HCM 4 24V Cranking
Relay
85 Plug
Not Used 5 Plug
Not Used 6 Plug
Not Used 7 Plug
Not Used 8 Plug
Not Used 9 Plug
J1587 Plus HCM 10 Splice into 1587 18 TXL
J1587 Minus HCM 11 Splice into 1587 18 TXL
Not Used 12 Plug
Not Used 13 Plug
Not Used 14 Plug
Not Used 15 Plug
Not Used 16 Plug
Not Used 17 Plug
PTO Signal HCM 18 PTO 18 TXL
Not Used 19 Plug
Engine Crank Request HCM 20 Crank Position on
Switch
18 TXL
Not Used 21 Plug
Not Used 22 Plug
Service Lamp HCM 23 4-pin Service
Connector
D 18 TXL
PTO Request (Non
J1939 BCU)
HCM 24 BCU 18 TXL
Not Used 25 Plug
24V Cranking Relay
Latch
HCM 26 24V Cranking
Relay
87 18 TXL
CAN Low (Proprietary
CAN)
HCM 27 HEV Backbone B 18 TXL
CAN High (Proprietary
CAN)
HCM 28 HEV Backbone A 18 TXL
Not Used 29 Plug
Not Used 30 Plug
Not Used 31 Plug
24V Cranking Relay
Plus
HCM 32 24V Cranking
Relay
86 18 TXL
Not Used 33 Plug
Not Used 34 Plug
440
Ignition HCM 35 Fused 10A to
Ignition Relay
12 GXL or
14SXL
Battery Minus HCM 36 Battery Ground 12 GXL
Not Used 37 Plug
Battery Plus HCM 38 Fused 30A Battery 12 GXL
441
Hybrid Controller 38-Way (Hybrid System Interface Connector)
Not Used 1 Plug
Inverter Enable HCM 2 Inverter 9 and 10 18 TXL
Not Used 3 Plug
Coolant Pump &
Battery Fan Relay
Minus
HCM 4 Coolant Pump
Relay & Battery
Fan Relay
85 18 TXL
High-Voltage Relay
Minus
HCM 5 High-Voltage Relay 4 18 TXL
PTO Power Minus HCM 6 PTO 18 TXL
Not Used 7 Plug
Not Used 8 Plug
Not Used 9 Plug
Not Used 10 Plug
DC/DC Converter
Temperature
HCM 11 DC/DC Converter 3 18 TXL
Not Used 12 Plug
ECA Ignition HCM 13 ECA H 18 TXL
Not Used 14 Plug
Not Used 15 Plug
Not Used 16 Plug
Service Battery Plus 17 Service Port A 18 TXL
Not Used 18 Plug
DC/DC Converter
Feedback Voltage
HCM 19 DC/DC Converter 1 18 TXL
Not Used 20 Plug
Not Used 21 Plug
Not Used 22 Plug
Not used 23 Plug
Not Used 24 Plug
Service Ignition HCM 25 Service Port C 18 TXL
Battery Cooling Fan
Relay Plus
HCM 26 Battery Cooling
Fan
86 18 TXL
Not Used 27 Plug
APG Enable HCM 28 APG C 18 TXL
Not Used 29 Plug
Not Used 30 Plug
Service Battery Minus HCM 31 Service Port B 18 TXL
Coolant Pump Relay
Plus
HCM 32 Coolant Pump
Relay
86 18 TXL
High-Voltage Relay
Plus
HCM 33 High-Voltage Relay 3 18 TXL
PTO Power Plus HCM 34 PTO 18 TXL
442
Heat Exchanger Plus HCM 35 HEF Relay 86 12 GXL or
14SXL
Not Used 36 Plug
Heat Exchanger Minus HCM 37 HEF Relay 85 18 TXL
Not Used 38 Plug
443
Push Button Shift Control Connector
Push Button 30-Way Connector
HIL High PBSC F1 TECU 28 18
HIL Low PBSC F2 TECU 27 18
Shift Control Power
Minus
PBSC J3 TECU 25 18
Shift Control Power
Plus
PBSC C1 TECU 31 18
Vdash PBSC B3 TECU Spliced 18
27
28
25
31
Transmission ECU Connector
(Vehicle Interface)
J1
Dimmer control input
Push Button Shift Control
Push Button Shift Control
Delphi 30-way connector
C2
F2 F1J3 C1 B3
Bulkhead connector
located at firewall
Push Button Shift Control (Delphi 30-Way Connector)
Transmission ECU Connector
(Vehicle Interface)
Back side
of gauges
Dash lights
37 38
35 36
1
6
7
12
13
22
23
28
29
34
A B C D E F G H J K
1
2
3
A1
A3
K1
K3
444
Inverter Connectors
Inverter 40-Way Connector
Relay Off (0) Inverter 3 Chassis Gnd 16 TXL
CAN High 1 Inverter 4 HEV Backbone A 16 TXL
CAN Low 1 Inverter 5 HEV Backbone B 16 TXL
GND1 Inverter 6 Chassis Gnd 16 TXL
GND2 Inverter 7 Chassis Gnd 16 TXL
V-Batt1 (24V) Inverter 9 PEC 2 16 TXL
V-Batt2 (24V) Inverter 10 PEC 2 16 TXL
Relay Off Inverter 13 PEC 5 16 TXL
Relay Box Enable 1 Inverter 14 PEC 6 16 TXL
GND (BC1) Inverter 15 PEC 7 16 TXL
REZGS1 Inverter 18 Resolver Ground Shield 1 16 TXL
REZGS2 Inverter 19 Resolver Ground Shield 2 16 TXL
REZGR Inverter 20 Resolver Ground R Shield 16 TXL
PRECHRG (+) Inverter 21 PEC 17 16 TXL
Main (+) (+) Inverter 22 PEC 9 16 TXL
Main (-) (+) Inverter 23 PEC 13 16 TXL
Relay Box Enable 2 Inverter 24 PEC 6 16 TXL
GND (BC2) Inverter 25 PEC 7 16 TXL
TM_S Inverter 26 Temp Sensor Shield 16 TXL
REZS1 Inverter 28 Resolver 2 16 TXL
Z
DETAIL Z
SCALE 1/1
A: Phase U
C: Phase W
B: Phase V
High-Voltage AC Amphenol Connector
Deutsch 40-way Connector
High-Voltage DC
Yazaki Connector
DC( - ) DC( + )
Breather
Mounting Bracket
Capscrews (2 x M5)
1
15
5 6
10
20
30
40
26
36 35
25
31
21
11
16
Ground Strap Bracket
Deutsch 40-way Connector
445
REZ_Plus Inverter 30 Resolver 4 16 TXL
PRECHRG (-) Inverter 31 PEC 19 16 TXL
Main (+) (-) Inverter 32 PEC 11 16 TXL
Main (-) (-) Inverter 33 PEC 15 16 TXL
CAN High 2 Inverter 34 PEC 1 16 TXL
CAN-Low 2 Inverter 35 PEC 2 16 TXL
TMGND Inverter 36 Temp Sensor 2 16 TXL
TM Inverter 37 Temp Sensor 1 16 TXL
REZ_Minus Inverter 40 Resolver 3 16 TXL
446
Power Electronics Carrier (PEC) Connectors
19-way Connector
CAN High PEC 1 Inverter 14 18
CAN Low PEC 2 Inverter 28 18
(Deutsch 19 - Way)
8 9
1
2
3
4 5
6
7
10
11
12
13
14
15
16
17
18
19
High Voltage DC Connector 1
to Inverter (Yazaki Connector)
to APG (Yazaki Connector)
to DCDC (Yazaki Connector)
Low Voltage Deutsch
19 - Way Connector
Caution: The PEC 19-way low-voltage connector
needs to have the back shell and strain
relief such that the unit will not allow
water entry from direct spray.
447
HV Relay (+) PEC 3 HCM 33 18
HV Relay (-) PEC 4 HCM 5 18
RelayOff PEC 5 Inverter 43 18
BCU (+) PEC 6 Inverter 16 18
BCU (-) PEC 7 Inverter 34 18
Main (+) + PEC 9 Inverter 30 18
Main (+) - PEC 11 Inverter 35 18
Main (-) + PEC 13 Inverter 31 18
Main (-) - PEC 15 Inverter 36 18
PreChg + PEC 17 Inverter 29 18
PreChg - PEC 19 Inverter 37 18
Battery Fan Plus PEC 12 Battery Fan Cooling Relay 87 12
Battery Fan Minus PEC 14 Battery Negative - 12
448
PEC High-Voltage (DC) Connector to Inverter
PEC High-Voltage (DC) Connector to DC/DC Converter
Inverter High-Voltage (AC) Connector
Inverter High-Voltage (DC) Connector
DC + PEC A Inverter A 15mm
DC - PEC B Inverter B 15mm
Loose Disconnect PEC 1 PEC 2 0.8 mm (18 AWG)
DC + PEC A DC/DC
Converter
A 14 AWG
DC - PEC B DC/DC
Converter
B 14 AWG
Loose Disconnect PEC 1 DC/DC
Converter
1 0.8 mm (18 AWG)
Loose Disconnect PEC 2 DC/DC
Converter
2 0.8 mm (18 AWG)
Phase 1 Inverter A Motor/Gen A 4 AWG
Phase 2 Inverter B Motor/Gen B 4 AWG
Phase 3 Inverter C Motor/Gen C 4 AWG
DC + Inverter A PEC A 15mm
DC - Inverter B PEC B 15mm
Loose Disconnect Inverter 1 Inverter 2 0.8 mm (18 AWG)
449
Electric Clutch Actuator (ECA) Connectors
ECA 3-Way Connector
ECA 8-Way Connector
Ignition ECA A Not Used Plug
Battery Minus ECA B Chassis Ground Battery - 12
Battery Plus ECA C Fused 50 amp
from Vbatt
Battery + 12
CAN High ECA A CAN Backbone A 18
CAN Low ECA B CAN Backbone B 18
CAN - Pass ECA C Not Used Plug
Signal ECA D Not Used Plug
CAN + Pass ECA E Not Used Plug
Engine Flywheel Speed
Sensor Plus
ECA F Speed Sensor + A 18
Engine Flywheel Speed
Sensor Minus
ECA G Speed Sensor - B 18
ECA Ignition ECA H HCM 13 18
HCM
28
27
A
B
A
B
F

G

F

G

50 AMP fuse
Battery power
(Non-switched power)
run to the Battery
Engine Flywheel Speed Sensor
(Eaton Supplied)
A

B

C

Metri-Pack 3-Way Connector
Metri-Pack 8-Way Connector
13
E
F
G
H
D
C
B
A
A
B
C
450
Motor/Generator Connectors
Views looking into connectors with wires exiting the opposite side.
Temperature Sensor
Resolver
High Voltage AC
Ampenol Connector
Temperature Sensor
Connector
Low Voltage Deutsch
Resolver Connector
Low Voltage Deutsch
Bottom View
Ground Strap
Bracket
Ground Strap
451
Motor/Generator Resolver Connector
Motor/Generator Temperature Sensor Connector
Motor/Generator High-Voltage (AC) Connector
Resolver Signal 3 Motor/Gen 1 EPS Inverter 38 18
Resolver Signal 2 Motor/Gen 2 EPS Inverter 28 18
Resolver Signal 1 Motor/Gen 3 EPS Inverter 40 Plug
Resolver Signal 4 Motor/Gen 4 EPS Inverter 30 Plug
Resolver - Motor/Gen 5 EPS Inverter 39 Plug
Resolver + Motor/Gen 6 EPS Inverter 29 18
Motor Temp Motor/Gen 1 EPS Inverter 37 18
Motor Temp Gnd Motor/Gen 2 EPS Inverter 36 18
Phase 1 Motor/Gen U Inverter U 4 AWG
Phase 2 Motor/Gen V Inverter V 4 AWG
Phase 3 Motor/Gen W Inverter W 4 AWG
452
Typical DC/DC Converter Circuit
Remove the 24-volt battery cables prior to working on the DC/DC converter.
DC(-)
DC(+)
24V DC(+)
24V DC(-)
High Voltage DC
Yazaki Connector
OEM Connection
Deutsch 4-Way OEM Connector
453
DC/DC Converter 4-Way Deutsch OEM Connector
Converter High-Voltage (DC) Connector
Converter 24-volt Studs
Ground DC/DC 4 Ground 18
Thermocouple DC/DC 3 HCM 11 18
Not Used DC/DC 2 Not Used Plug
Voltage Feedback DC/DC 1 HCM 19 18
DC + DC/DC A PEC A 14
DC - DC/DC B PEC B 14
Loose Disconnect DC/DC 1 PEC 1 18
Loose Disconnect DC/DC 2 PEC 2 18
24volt + DC/DC A Battery Positive
Post
A 2
24volt - DC/DC B Battery Negative
Post
B 2
454
www.eaton.com/greensolutions
Copyright Eaton Corporation, 2012.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.
Note: Features and specications
listed in this document are subject to
change without notice and represent
the maximum capabilities of the
software and products with all options
installed. Although every attempt has
been made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.

For specing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.

Eaton Corporation
Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger
Printed in USA
Roadranger: Eaton and trusted partners
providing the best products and services in the
industry, ensuring more time on the road.

Eaton Hybrid Drive System Model TRTS2500

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