Eaton Fault Code 21

Troubleshooting Guide
Eaton Hybrid Drive Systems MY08

TRTS1000 EN-US
October 2015
EH-8E306A-U
EH-8E306A-UPG
EH-8E306A-UP
EH-8E306A-CD
EH-8E306A-T
EH-6E606B-CD
Table of Contents TRTS1000
Table of Contents
General Information Electrical Pretest Procedures
Warnings & Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Power-Up Sequence Test. . . . . . . . . . . . . . . . . . . . . . 22
High-Voltage Warnings & Cautions . . . . . . . . . . . . 2 Electrical Pretest . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Insulated Rubber Glove Test and High-Voltage Hybrid Electrical Pretest. . . . . . . . . . . . . . . . . . . . . . . 29
Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Insulated Rubber Glove Test. . . . . . . . . . . . . . . . . . 3
Fault Isolation Procedures
High-Voltage Work Area Requirements . . . . . . . . . 3
Fault Code 1 - Motor/Generator Current Sensor. . . . . 33
High-Voltage Service Shutdown and Power-Up Fault Code 2 - Motor/Generator Temperature Sensor 38
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Code 3 - Motor/Generator Temperature . . . . . . 42
High-Voltage Service Shutdown Procedures . . . . . 5
Fault Code 4 - Motor/Generator Rotation Speed
High-Voltage Service Power-Up Procedure . . . . . . 5
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Diagnostic Tools/Service Publications . . . . . . . . . . . . . 6 Fault Code 5 - Motor/Generator AC Cable . . . . . . . . . 52
Eaton Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Code 6 - No HCM Operation . . . . . . . . . . . . . . . 57
SPX/OTC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Code 7 - Improper HCM Configuration . . . . . . . 60
Service Publications. . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Code 8 - Loss of Switched Ignition Power
Hybrid Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . 8 (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hybrid Component and Connector Locations. . . . . . . . 9 Fault Code 9 - Weak Battery Voltage . . . . . . . . . . . . . 66
Transmission Wiring Connections . . . . . . . . . . . . . 9 Fault Code 10 - Low Battery Voltage (HCM). . . . . . . . 69
Component Wiring Connections. . . . . . . . . . . . . . 11 Fault Code 11 - No TECU Operation . . . . . . . . . . . . . . 72
Fault Code Retrieval and Clearing. . . . . . . . . . . . . . . . 13 Fault Code 12 - Improper TECU Configuration . . . . . . 75
View Active and Inactive Faults . . . . . . . . . . . . . . 13 Fault Code 14 - Invalid Shifter Range. . . . . . . . . . . . . 78
Clear Inactive Faults . . . . . . . . . . . . . . . . . . . . . . . 13
Fault Code 16 - High Integrity Link (HIL) Test . . . . . . 83
Fault Code Isolation Procedure Index. . . . . . . . . . . . . 14 Fault Code 17 - Start Enable Relay . . . . . . . . . . . . . . . 89
Symptom-Driven Diagnostics Index. . . . . . . . . . . . . . 18 Fault Code 18 - ECA Communication . . . . . . . . . . . . . 94
Product Diagnostic Mode (PDM) . . . . . . . . . . . . . . . . 19 Fault Code 24 - J1939 HCM Message (TECU) . . . . . . 97
PDM only works with the following Inactive Fault Code 26 - Clutch Slip. . . . . . . . . . . . . . . . . . . . 101
codes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Fault Code 27 - Clutch Disengagement . . . . . . . . . . 105
Hybrid Light and Gear Display Descriptions. . . . . . . . 20 Fault Code 32 - Loss of Switched Ignition Power
Red “Service” Light . . . . . . . . . . . . . . . . . . . . . . . 20 (TECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Amber “Check Hybrid” Light . . . . . . . . . . . . . . . . 20 Fault Code 33 - Low Battery Voltage (TECU) . . . . . . 111
Red “Stop Hybrid” Light. . . . . . . . . . . . . . . . . . . . 20 Fault Code 34 - Weak Battery Voltage Fault (TECU) . 114
Blinking Amber “Check Hybrid” Light. . . . . . . . . . 20 Fault Code 35 - J1939 Communication Link (TECU) 117
“ST” in Gear Display. . . . . . . . . . . . . . . . . . . . . . . 20
Fault Code 36 - J1939 Engine Message (TECU). . . . 122
“PD” in Gear Display . . . . . . . . . . . . . . . . . . . . . . 20
Fault Code 37 - Power Supply (TECU) . . . . . . . . . . . 125
“CA” in Gear Display . . . . . . . . . . . . . . . . . . . . . . 21
“OS” in Gear Display . . . . . . . . . . . . . . . . . . . . . . 21 Fault Code 38 - Battery Fan Relay . . . . . . . . . . . . . . 129
“F” in Gear Display . . . . . . . . . . . . . . . . . . . . . . . . 21 Fault Code 39 - Heat Exchanger Relay . . . . . . . . . . . 135
Dash “-” in Gear Display. . . . . . . . . . . . . . . . . . . . 21 Fault Code 40 - Cooling Pump Relay . . . . . . . . . . . . 140
Double Stars “**” in Gear Display . . . . . . . . . . . . 21 Fault Code 47 - J1939 ABS Message (HCM) . . . . . . 146
Double Dashes “- -” in Gear Display. . . . . . . . . . . 21 Fault Code 48 - J1939 Transmission Message
Blank Gear Display . . . . . . . . . . . . . . . . . . . . . . . . 21 (HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
© 2015 Eaton. All rights reserved

TRTS1000 Table of Contents
Fault Isolation Procedures - continued

Fault Code 49 - J1939 Engine Message (HCM) . . . . 153 Fault Code 96 - Accelerator Pedal Offset . . . . . . . . . 293
Fault Code 50 - J1939 Body Controller Message Fault Code 97 - PTO Engagement . . . . . . . . . . . . . . 296
(HCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Fault Code 101 - High Voltage Battery 1 . . . . . . . . . 303
Fault Code 51 - Rail Position Sensor . . . . . . . . . . . . 159 Fault Code 102 - High Voltage Battery 2 . . . . . . . . . 307
Fault Code 52 - Gear Position Sensor . . . . . . . . . . . 164 Fault Code 103 - High Voltage Battery 1 Control
Fault Code 53 - DC/DC Converter. . . . . . . . . . . . . . . 169 Unit Communication . . . . . . . . . . . . . . . . . . . . . . . . 311
Fault Code 54 - DC/DC Converter Output Voltage . . 172 Fault Code 104 - High Voltage Battery 2 Control
Fault Code 56 - Input Shaft Speed Sensor . . . . . . . . 177 Unit Communication . . . . . . . . . . . . . . . . . . . . . . . . 314
Fault Code 58 - Output Shaft Speed Sensor. . . . . . . 181 Fault Code 105 - High Voltage Battery 1 Control
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Fault Code 59 - J1939 Communication Link (HCM). 185
Fault Code 106 - High Voltage Battery 2 Control
Fault Code 60 - CAN Communication Link (HCM) . . 190 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Fault Code 61 - Rail Select Motor . . . . . . . . . . . . . . 194 Fault Code 107 - High Voltage Battery Leak
Fault Code 63 - Gear Select Motor . . . . . . . . . . . . . . 197 Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Fault Code 64 - ECA Fault . . . . . . . . . . . . . . . . . . . . 201 Fault Code 108 - High Voltage Battery 1 Control
Fault Code 65 - ECA Speed Sensor . . . . . . . . . . . . . 204 Unit Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Fault Code 66 - ECA Battery Voltage . . . . . . . . . . . . 208 Fault Code 109 - High Voltage Battery 2 Control
Unit Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Fault Code 67 - ECA Ignition Voltage . . . . . . . . . . . . 211
Fault Code 110 - Inverter . . . . . . . . . . . . . . . . . . . . . 342
Fault Code 70 - Engine Failed to Respond (HCM) . . 215
Fault Code 111 - Inverter Communication . . . . . . . . 345
Fault Code 71 - Failed to Disengage a Gear . . . . . . . 218
Fault Code 112 - Inverter Voltage . . . . . . . . . . . . . . 349
Fault Code 72 - Failed to Select Rail. . . . . . . . . . . . . 222
Fault Code 113 - Inverter Current . . . . . . . . . . . . . . 353
Fault Code 73 - Failed to Engage a Gear. . . . . . . . . . 225
Fault Code 114 - Inverter Power Supply . . . . . . . . . 358
Fault Code 74 - Engine Failed to Respond (TECU) . . 228
Fault Code 115 - Inverter Temperature . . . . . . . . . . 362
Fault Code 75 - Power Down in Gear . . . . . . . . . . . . 231
Fault Code 116 - High Voltage Relays . . . . . . . . . . . 367
Fault Code 76 - High Voltage Battery 1 Potential
Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 Fault Code 117 - BCU Relay Cut Request. . . . . . . . . 374
Fault Code 77 - High Voltage Battery 2 Potential Fault Code 118 - Auxiliary High-Voltage Relay
Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Fault Code 78 - High Voltage Battery 1 Current . . . . 240 Fault Code 120 - APG Unit 1 AC Voltage . . . . . . . . . 385
Fault Code 79 - High Voltage Battery 2 Current . . . . 243 Fault Code 122 - APG UNIT 1 Output. . . . . . . . . . . . 388
Fault Code 82 - High Voltage Battery 1 Temperature 246 Fault Code 123 - APG Unit 1 High Voltage Battery. . 393
Fault Code 83 - Invalid Shifter Range. . . . . . . . . . . . 250 Fault Code 125 - APG Unit 1 Over Temperature. . . . 396
Fault Code 84 - Shift Control Device Not Configured 255 Fault Code 126 - APG Unit 1 Configuration . . . . . . . 399
Fault Code 85 - Shift Control Device Incompatible. . 261 Fault Code 127 - APG Unit 1 Ambient Air
Over Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Fault Code 86 - High Voltage Battery 2 Temperature 265
Fault Code 128 - APG Unit 1 Ambient Air
Fault Code 87 - CAN ECA Message (HCM). . . . . . . . 269 Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . 405
Fault Code 88 - CAN Inverter Message (HCM) . . . . . 273 Fault Code 129 - APG Unit 1 Communication . . . . . 408
Fault Code 89 - CAN BCU 1 Message (HCM) . . . . . . 277 Fault Code 131 - APG Unit 1 Configuration Error. . . 412
Fault Code 90 - CAN BCU 2 Message (HCM) . . . . . . 281
Fault Code 91 - APG Unit 1 CAN . . . . . . . . . . . . . . . 285
Fault Code 95 - 12-Volt Cranking Relay . . . . . . . . . . 289
2015.10.19 © 2015 Eaton. All rights reserved ii

Table of Contents TRTS1000
Symptom Procedures
Front Box Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Engine Crank Test . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Hybrid Performance Test . . . . . . . . . . . . . . . . . . . . . 424
ServiceRanger Test . . . . . . . . . . . . . . . . . . . . . . . . . 427
Gear Engagement Test . . . . . . . . . . . . . . . . . . . . . . . 432
ePTO Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Appendix
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
Hybrid Transmission ECU System Harness . . . . 445
Connector Pin Descriptions . . . . . . . . . . . . . . . . . . . 446

Hybrid and Transmission Connector Pins . . . . . 446
TECU and HCM Connectors . . . . . . . . . . . . . . . . 446
Transmission Controller 38-Way
(Vehicle Interface Connector). . . . . . . . . . . . . . . 447
Hybrid Controller 38-Way
(Vehicle Interface Connector). . . . . . . . . . . . . . . 448
Hybrid Controller 38-Way
(Hybrid System Interface Connector). . . . . . . . . 449
Inverter connectors . . . . . . . . . . . . . . . . . . . . . . 450
Inverter 56-Way Connector . . . . . . . . . . . . . . . . 451
Power Electronics Carrier (PEC) Connectors . . . 452
PEC 19-Way Connector . . . . . . . . . . . . . . . . . . . 453
PEC High-Voltage (DC) Connector to Inverter . . 453
PEC High-Voltage (DC) Connector to DC/DC
Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Inverter High-Voltage (AC) Connector . . . . . . . . 453
Inverter High-Voltage (DC) Connector . . . . . . . . 453
Electric Clutch Actuator (ECA) Connectors. . . . . 454
ECA 3-Way Connector . . . . . . . . . . . . . . . . . . . . 454
ECA 8-Way Connector . . . . . . . . . . . . . . . . . . . . 454
Motor/Generator Connectors . . . . . . . . . . . . . . . 455
Typical DC/DC Converter Circuit . . . . . . . . . . . . . 457
iii © 2015 Eaton. All rights reserved 2015.10.19

TRTS1000 General Information | Warnings & Cautions
Warnings & Cautions

Throughout this service manual there are paragraphs that Follow the specified procedures in the indicated order to
are marked with a title of Danger, Warning, or Caution. avoid personal injury:
These special paragraphs contain specific safety
information and must be read, understood, and heeded 1. If the high-voltage cones are around the vehicle
before continuing the procedure or performing the step(s). 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.
DANGER
HAZARDOUS VOLTAGE 2. Before working on a vehicle or leaving the cab
You will be severely injured or killed
if you do not follow the procedure. while the engine is running, you should place the
Components marked with
DANGER High Voltage should be shift lever in “N” set the parking brake, and block
avoided. Service must be
performed by qualified personnel only. the wheels.
3. For safety reasons, always engage the service
! Danger: Danger indicates you will be severely injured or brakes prior to selecting gear positions from “N.”
killed if do not follow the indicated procedure.
4. Before starting a vehicle always be seated in the
! Warning: Warning indicates an immediate hazard, which driver's seat, select “N” on the shift control, and set
could result in severe personal injury if you do not follow the parking brakes.
the indicated procedure.
5. In vehicles with ePTO, the engine and/or
! Caution: Caution indicates vehicle or property damage Motor/Generator can start in ePTO mode. Never
could occur if you do not follow the indicated procedure. perform any maintenance or work on vehicle, while
in this mode.
Note: Note indicates additional detail that will aid in the 6. 12-Volt Battery positive (+) and negative (-) must
diagnosis or repair of a component/system. be disconnected prior to any welding on any Hybrid
equipped vehicle.
! Caution: Follow the specified procedures in the indicated

order to avoid equipment malfunction or damage.
! Caution: Do not release the parking brake or attempt to

select a gear until the air pressure is at the
correct level.
! Caution: 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.
2015.10.19 © 2015 Eaton. All rights reserved 1

Warnings & Cautions | General Information TRTS1000
High-Voltage Warnings & Cautions 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
WARNING instructions may result in severe personal injury or death.
HAZARDOUS VOLTAGE
To reduce risk of possible serious
injury (Shock, Burn or Death): The rubber-insulated gloves that must be worn while
Components marked with High
Voltage should be avoided.
Service must be performed by
working on the high-voltage system are class 0 with leather
qualified personnel only. protectors. The rubber gloves should be tested before
EVERY use following the rubber insulation gloves testing
procedure found in “Diagnostic Tools/Service Publications”
DANGER
on page 6. Failure to follow these instructions may result in
HAZARDOUS VOLTAGE
if you do not follow the procedure.
severe personal injury or death.
DANGER High Voltage should be
avoided. Service must be Before inspecting or working on any high-voltage cables or
performed by qualified personnel only.
components the “High-Voltage Service Shutdown and
Power-Up Procedure” on page 4 should be followed. Failure
• Use CO2 or Dry Chemical Fire Extinguishers. to follow these instructions may result in severe personal
injury or death.
• The high-voltage wiring is covered in orange
insulation or convoluted tubing and marked with The Lockout and Tagout devices should only be removed by
warning labels at the connectors. the technician that placed the Lockout and Tagout devices
on the vehicle. Failure to follow these instructions may
• All Eaton® Hybrid Diesel/Electric vehicles will be result in severe personal injury or death.
marked 'Hybrid' on the outside of the vehicle, along
with the shift label on the dash. High-voltage rubber insulated gloves (class 0 with leather
protectors) must be worn when working on any
• Refer to OEM for specific location of chassis
high-voltage cables. The “High-Voltage Service Shutdown
mounted hybrid components.
and Power-Up Procedure” on page 4 must be followed prior
• Do NOT cut into the orange high-voltage cables. to removing any high-voltage cables. Failure to follow these
instructions may result in severe personal injury or death.
• Do NOT cut into or open the PEC.
• Do NOT cut into or open the DC/DC Converter. High-voltage cables and wiring are orange and contain a
warning label at the connectors. High-voltage components
• Do NOT cut into or open the Inverter. 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.
2 © 2015 Eaton. All rights reserved 2015.10.19

TRTS1000 General Information | Insulated Rubber Glove Test and High-Voltage Work Area
Insulated Rubber Glove Test and High-Voltage Work Area
Insulated Rubber Glove Test High-Voltage Work Area Requirements

Warning: The rubber-insulated gloves that must be worn Warning: A buffer zone must be set up and high-voltage
! while working on the high-voltage system are class 0 with ! insulated rubber gloves (class 0 with leather protectors) are
leather protectors. The rubber gloves should be tested required prior to working on any high voltage. Failure to fol-
before EVERY use following the rubber insulation gloves low these instructions may result in severe personal injury
testing procedure found in “Diagnostic Tools/Service Publi- or death.
cations” on page 6. Failure to follow these instructions may
The buffer zone is required only when working on the
result in severe personal injury or death.
high-voltage DC or AC systems and is called out both in the
The insulated rubber gloves that must be worn while “High-Voltage Service Shutdown and Power-Up Procedure”
working on the high-voltage system are class 0 rated. They on page 4 and the individual repair procedure.
must be inspected before each use and must always be
worn in conjunction with the leather outer glove. Any hole • Position the vehicle in the service bay.
in the insulated rubber glove is a potential entry point for • Position 4 orange cones around the corners of the
high-voltage. vehicle to mark off a 3' (1m) perimeter around the
vehicle.
• Roll the glove up from the open end until the lower
portion of the glove begins to balloon from the • Do not allow any unauthorized personnel into the
resulting air pressure. If the glove leaks any air it buffer zone during repairs involving high voltage.
must not be used. Only personnel trained for service on the
high-voltage system are to be permitted in the
• The gloves should not be used if they exhibit any
buffer zone.
signs of wear and tear.
• The leather gloves must always be worn over the
rubber insulating gloves to protect them.
• The rubber insulating gloves must be class 0 and
meet all of the American Safety Testing Materials
standards.

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

WARNING
HAZARDOUS VOLTAGE
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.
DANGER
HAZARDOUS VOLTAGE
if you do not follow the procedure.
DANGER High Voltage should be
avoided. Service must be
performed by qualified personnel only.
A buffer zone must be set up and ASTM Class 0 electrical

insulating rubber gloves with leather protectors are
required prior to working on high-voltage. Failure to follow
these instructions may result in severe personal injury or
death.
The rubber-insulated gloves that must be worn while

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

components this “High-Voltage Service Shutdown
Procedure” should be followed. Failure to follow these
instructions may result in severe personal injury or death.
The lockout tagout devices should only be removed by the

technician that placed the lockout tagout devices on the
vehicle. Failure to follow these instructions may result in
severe personal injury or death.
ASTM Class 0 electrical insulating rubber gloves with

leather protectors must be worn when working on any
high-voltage cables. This “High-Voltage Service Shutdown
Procedure” must be followed prior to removing any
high-voltage cables. Failure to follow these instructions
may result in severe personal injury or death.
High-voltage cables and wiring are orange and contain a

warning label at the connectors. High-voltage components
are marked with a label. ASTM Class 0 electrical insulating
rubber gloves with leather protectors must be used when
working on any of these components. Failure to follow
these instructions may result in severe personal injury
or death.

TRTS1000 General Information | High-Voltage Service Shutdown and Power-Up Procedure
High-Voltage Service Shutdown 9. Turn ignition key off and proceed to repair or
troubleshooting step.
Procedures
Note: The voltage drops to zero when the key is off.
1. Follow “High-Voltage Work Area” procedure.
2. Locate the red PEC Service Switch on the front of
the PEC and push switch off.
High-Voltage Service Power-Up
Procedure
3. Remove the Service Switch Cover and install the
Lockout Bracket (J48506). 1. Install all high-voltage connectors into their locked
positions.
4. Fasten tag to the Lockout Bracket.
2. If you are the person working on the vehicle,
5. Ensure the PEC Service Switch can not move from
remove the Lockout Bracket and tag.
the off position.
3. Reinstall the Lockout Bracket over the Service
6. Allow the system to set for a minimum of 5
Switch.
minutes to discharge high voltage.
4. Pull the Service Switch out and let vehicle set for 2
7. Connect ServiceRanger and view the Data Monitor
minutes.
PID 116 called “High-Voltage Battery Potential.”
Use SPN 520323 for J1939 connection “Battery 5. Start vehicle when appropriate.
Voltage RB” (Relay Box).
8. The voltage should be 30 volts or less. If the
voltage is above 30 volts, do not work on the
vehicle and contact Eaton® at 1-800-826-HELP
(4357).

Diagnostic Tools/Service Publications | General Information TRTS1000
Diagnostic Tools/Service Publications
Eaton Tools
• Visit Roadranger.com
Tool Description
ServiceRanger version 3 ServiceRanger PC based Diagnostic Tool
SPX/OTC Tools
• Contact SPX / OTC at (800) 328-6657
Tool Description
J49818 Eaton Hybrid Tool Safety Kit - Basic PPE (Items listed below can be ordered separately)
J48603 ASTM Class 0 electrical insulating rubber gloves with leather protectors (1000 volt)
J48605 Hybrid Safety Cones (set of 4)
J48506 Lockout Switch Plate
J48906 Lockout Tags (per 25)
Tool Description
J49819 Eaton Hybrid Tool Safety Kit - Basic Plus PPE (Items listed below can be ordered separately)
J48603 ASTM Class 0 electrical insulating rubber gloves with leather protectors (1000 volt)
J48605 Hybrid Safety Cones (set of 4)
J48506 Lockout Switch Plate
J48906 Lockout Tags (per 25)
J48907 Orange Magnetic Sign
J48608 Hybrid Non-Conductive Safety Pole
J48908 Glove Bag

TRTS1000 General Information | Diagnostic Tools/Service Publications
Misc. Service Tools Items listed below are ordered separately
J48624 Nexiq USB-Link Communication Adapter
J43318-A* Pin Adapter Kit - Interface Harness Diagnostics
J48735* Alignment Pins - Hybrid Motor/Gen to Transmission Main Case
AMB-45* Digital Megohmmeter - High-Voltage Leakage Detection
J49111* Clutch Alignment Tool
J46708* Fluke Digital Multimeter
J48505 Input Shaft Turning Socket
J48507 Lifting Fixture - Power Electronics Carrier
J48502 Jack Adapter Plate - Hybrid Drive Unit
5019 Transmission Jack - Low Lift
5078 Transmission Jack - High Lift
J48577 Engine/Transmission Stand Adapter Plate - Hybrid Drive Unit
J29109-A Engine/Transmission Stand - 6000 lb. Rating
Tool Description
J48893 Hybrid PPE / Service Tool Kit (includes J49819 kit and items from Miscellaneous Service Tools
highlighted with *)
Service Publications
• Visit Roadranger.com
TRSM1000 Service Manual (covers external components on transmission and Hybrid components)
TRSM0110 Service Manual (covers internal transmission repairs only)
TRTS1000 Troubleshooting Guide
TRDR1000 Drivers Instructions
TRDR1110 First Responder Guide
CLMT-0365 Eaton 365 mm Clutch Installation Procedure

Hybrid Diagnostic Procedure | General Information TRTS1000
Hybrid Diagnostic Procedure
Key ON
Is Red "Stop Hybrid" or Go to “Hybrid Light and

Amber “Check Hybrid” Yes Gear Display Descriptions”
light blinking? (page 20)
Note: If ServiceRanger fails No
to communicate, go to Retrieve Active Faults
“ServiceRanger Test” with ServiceRanger
(page 427)
Go to "Fault Code Isolation Procedure

Active Codes? Yes
Index" (page 14)
No
Go to “Hybrid Light and
Does Gear Display
No Gear Display Descriptions”
Show an "N"?
(page 20)
Yes
Go to “Engine Crank Does Engine Crank?
No
Test” (page 420)
Yes
If equipped, does
Go to "ePTO Test” No vehicle operate
(page 436) normal in ePTO mode?
Yes
Go to "Gear Engagement Test” If a mode other than neutral is selected does
if solid “N” is displayed No transmission engage a gear? NOTE: Service
(page 432) Brake must be applied prior to selecting a gear
Go to “Front Box Test” is Yes

flashing gear number is
displayed (page 416) Will vehicle move Go to “Gear Engagement
No
from a stop? Test” (page 432)
Yes
Go to "Hybrid
Performance Test" No Is vehicle acceleration
(page 424) performance acceptable? Inactive Faults = Go
to "Product
Yes Diagnostic Mode (PDM)"
(page 19)
Clear faults and
operate vehicle based Active Faults = Go to
on customers "Fault Code Isolation
concern Procedure Index"
(page 14)
No Fault = Test
Complete

TRTS1000 General Information | Hybrid Component and Connector Locations
Hybrid Component and Connector Locations

Transmission Wiring Connections
Rail Position Sensor
Output Shaft Speed Sensor
Electronic Clutch Actuator

Top: 3-Way Connector
Bottom: 8-Way Connector
Transmission Electronic Control Unit (TECU)

Left: 38-Way Vehicle Connector Hybrid Control Module (HCM)
Right: 38-Way System Connector Left: 38-Way System Connector
Right: 38-Way Vehicle Connector

Hybrid Component and Connector Locations | General Information TRTS1000
Gear Position Sensor

High-Voltage 3-Way AC Connector
Transmission Diagnostic Port
Motor/Generator
Temperature Connector
Input Shaft Speed Sensor Motor/Generator

Resolver Connector

TRTS1000 General Information | Hybrid Component and Connector Locations
Component Wiring Connections

High Voltage DC Connector
Top: DC(-)
Bottom: (DC(+)
(-) (+)
12V DC(-)
DC/DC Converter
Coolant Ports
OEM Connection
12V DC(+)
HIgh Voltage 3-Way AC Connector
Coolant Port Outlet

Coolant Port Inlet
Inverter
Low Voltage 56-Way Connector High-Voltage DC Connector to PEC

Hybrid Component and Connector Locations | General Information TRTS1000
Air Exhaust 19-Pin Low-Voltage Connector

(not shown) Power Electronics Carrier (PEC)
Air Intake
Red Service Switch with Cover
DC Connector to
APG (Optional)
DC Connector to DC/DC
DC Connector Converter (Optional)
to Inverter

TRTS1000 General Information | Fault Code Retrieval and Clearing
Fault Code Retrieval and Clearing

All Eaton® hybrid systems require ServiceRanger for all
diagnostics. To view fault codes or to clear them, follow the
procedures below.
View Active and Inactive Faults

1. Connect ServiceRanger to the 9-Way Diagnostic
Connector.
2. Go to the “Tools” menu and select the
“Communication” tab.
3. Select the appropriate communication device for
J1587 and J1939.
4. Select “Connect” on the main page.
5. Select the “View Fault Codes” tab.
Note: Initial use requires all steps; however subsequent
uses require only Step 4 and Step 5.
Clear Inactive Faults

Connector.
2. Go to the “Tools” menu and select the
“Communication” tab.
3. Select the appropriate communication device for
J1587 and J1939.
4. Select “Connect” on the main page.
5. Select the “View Fault Codes” tab.
6. Select the “Clear Faults” button.
Note: Initial use requires all steps, however
subsequent uses require only Step 4 and Step 5.

Fault Code Isolation Procedure Index | General Information TRTS1000
Fault Code Isolation Procedure Index

Fault Code FMI Description Page Number
1 0, 6 Motor/Generator Current Sensor page 33
2 3 Motor/Generator Temperature Sensor page 38
3 0 Motor/Generator Temperature page 42
4 0, 2, 22–27 Motor/Generator Rotation Speed Sensor page 48
5 22–29 Motor/Generator AC Cable page 52
6 12 No ECU Operation (HCM) page 57
7 13 Improper ECU Configuration (HCM) page 60
8 4 Loss of Switched Ignition Power (HCM) page 63
9 14 Weak Battery Voltage (HCM) page 66
10 4 Low Battery Voltage (HCM) page 69
11 12 No ECU Operation (TECU) page 72
12 13 Improper ECU Configuration (TECU) page 75
14 2, 3, 4 Invalid Shifter Range page 78
16 2 High Integrity Link (HIL) page 83
17 3, 4 Start Enable Relay page 89
18 9, 2 ECA Communication page 94
24 9 J1939 HCM Message (TECU) page 97
26 10, 23 Clutch Slip page 101
27 7, 13 Clutch Disengagement page 105
32 2 Loss of Switched Ignition Power (TECU) page 108
33 4 Low Battery Voltage (TECU) page 111
34 14 Weak Battery Voltage (TECU) page 114
35 2 J1939 Communication Link page 117
36 14 J1939 Engine Message (TECU) page 122
37 5 Power Supply (TECU) page 125
38 3, 4, 14 Battery Fan Relay page 129
39 3, 4, 5 Heat Exchanger Relay page 135

TRTS1000 General Information | Fault Code Isolation Procedure Index
40 3, 4, 5, 14 Cooling Pump Relay page 140
47 9, 2 J1939 ABS Message (HCM) page 146
48 9, 2 J1939 Transmission Message (HCM) page 149
49 9, 2 J1939 Engine Message (HCM) page 153
50 9, 2 J1939 Body Controller Message (HCM) page 156
51 2, 3, 4 Rail Position Sensor page 159
52 2, 3, 4 Gear Position Sensor page 164
53 12, 14 DC/DC Converter page 169
54 2, 4 DC/DC Converter Output Voltage page 172
56 2, 3, 4, 5, 10 Input Shaft Speed Sensor page 177
58 2, 3, 4, 5 Output Shaft Speed Sensor page 181
59 9, 2 J1939 Communication Link (HCM) page 185
60 9, 2 CAN Communication Link (HCM) page 190
61 5, 6 Rail Select Motor page 194
63 5, 6 Gear Select Motor page 197
64 12, 21–28 ECA page 201
65 2, 5 ECA Speed Sensor page 204
66 3, 4, 14 ECA Battery Voltage page 208
67 3, 4, 5 ECA Ignition Voltage page 211
70 0, 1, 2, 7 Engine Failed to Respond (HCM) page 215
71 7 Failed to Disengage Gear page 218
72 7 Failed to Select Rail page 222
73 7 Failed to Engage Gear page 225
74 7 Engine Failed to Respond (TECU) page 228
75 14 Power Down In Gear page 231
76 3, 4, 16, 18 High-Voltage Battery 1 Potential Voltage page 234
77 3, 4, 16, 18 High-Voltage Battery 2 Potential Voltage page 237
78 6 High-Voltage Battery 1 Current page 240
79 6 High-Voltage Battery 2 Current page 243
82 0, 16 High-Voltage Battery 1 Temperature page 246
83 12, 13 Invalid Shifter Range page 250

Fault Code Isolation Procedure Index | General Information TRTS1000
84 13 Shift Control Device Not Configured page 255
85 12 Shift Control Device Incompatible page 261
86 0, 16 High-Voltage Battery 2 Temperature page 265
87 9, 2 CAN ECA Message (HCM) page 269
88 9, 2 CAN Inverter Message (HCM) page 273
89 9, 2 CAN BCU 1 Message (HCM) page 277
90 9, 2 CAN BCU 2 Message (HCM) page 281
91 9 APG Unit 1 - CAN Fault page 285
95 3, 4 12-Volt Cranking Relay page 289
96 2 Accelerator Pedal Offset page 293
97 7, 14 PTO Engagement page 296
101 0, 22–31 High-Voltage Battery 1 page 303
102 22–31 High-Voltage Battery 2 page 307
103 22–26 High-Voltage Battery 1 Control Unit Communication page 311
104 22–26 High-Voltage Battery 2 Control Unit Communication page 315
105 22–30 High-Voltage Battery 1 Control Unit page 319
106 22–30 High-Voltage Battery 2 Control Unit page 323
107 1 High-Voltage Battery Leak Detection page 326
108 3, 4 High-Voltage Battery 1 Control Unit Power Supply page 336
109 3, 4 High-Voltage Battery 2 Control Unit Power Supply page 340
110 22–29 Inverter page 344
111 22–26 Inverter Communication page 347
112 3, 4 Inverter Voltage page 351
113 6 Inverter Current page 355
114 3, 4 Inverter Power Supply page 360
115 0 Inverter Temperature page 364
116 10, 14 High-Voltage Relays page 369
117 3, 14 BCU Relay Cut Request page 376
118 3, 4, 5 Auxiliary High-Voltage Relay Control Circuit page 381
120 3, 4 APG Unit 1 - AC Voltage page 387
122 6, 14, 15 APG Unit 1 - Output page 390

TRTS1000 General Information | Fault Code Isolation Procedure Index
123 3, 4, 14 APG Unit 1 - High Voltage Battery page 395
125 0 APG Unit 1 - Over Temperature page 398
126 22–27 APG Unit - Configuration page 401
127 0 APG Unit 1 - Ambient Air Over Temperature page 404
128 3 APG Unit 1 - Ambient Temperature Sensor page 407
129 9 APG Unit 1 - Communication page 410
131 13 APG Unit 1 - Configuration Error page 414

Symptom-Driven Diagnostics Index | General Information TRTS1000
Symptom-Driven Diagnostics Index
Symptom Isolation Procedure Page Number
Power up no crank and gear display shows a dash Front Box Test page 418
“-”
Power up no crank and gear display shows a “N” Engine Crank Test page 422
Power up no crank and gear display shows a Power Up Sequence Test page 22
double dash (-- ), double star, (**), or blank
Power up vehicle cranks and gear display shows Refer to OEM for gear display issue N/A
(-- ), (**), or blank
Vehicle acceleration performance is not acceptable Hybrid Performance Test page 426
ServiceRanger doesn’t communicate with vehicle ServiceRanger Test page 429
Transmission will not engage a gear from neutral Gear Engagement Test page 434
and warning tone sounds (solid “N” in gear
display)
Transmission will not move from a stop (solid gear Gear Engagement Test page 434
number in gear display)
Transmission will not engage a gear from neutral Front Box Test page 418
(flashing gear number in gear display)
Red “Service” light on the Push Button Shift Fault Code Retrieval and Clearing page 13
Control is on and blinking
Amber “Check Hybrid” light is on Fault Code Retrieval and Clearing page 13
Red “Stop Hybrid” light is on Fault Code Retrieval and Clearing page 13
ePTO mode does not operate as expected ePTO Test page 438

TRTS1000 General Information | Product Diagnostic Mode (PDM)
Product Diagnostic Mode (PDM)

Product Diagnostic Mode (PDM) is used to help diagnose PDM only works with the following
Inactive codes that may have set during normal driving.
This diagnostic mode increases the sensitivity of the fault Inactive codes:
sensing capabilities. 8, 9, 10, 13, 14, 16, 17, 18, 24, 33, 34, 35, 36, 38, 39, 40,
43, 44, 46, 47, 48, 49, 50, 51, 52, 56, 57, 58, 59, 60, 61, 63,
This procedure tests loose, degraded and intermittent 87, 88, 89, 90, 95
connections. See “Fault Code Isolation Procedure Index” on
page 14. Use the Index as a guide to the wiring and
connectors associated with the Inactive fault codes. Flex the
wiring harness and connectors in an attempt to recreate the
fault after activating PDM.
PDM is only to be used by a trained service technician in an

authorized dealer.
To enter PDM mode:

Note: The vehicle will not start in Product Diagnostic Mode
(PDM). Turn the key off and allow the system to
power down to exit PDM.
1. Vehicle must be stationary, engine must not be
running, vehicle parking brake must be set.
Connector.
3. Select the “View Fault Codes” screen.
4. Perform 2 key clicks of the ignition switch starting
in the on position and ending in the on position.
Note: An "88" may show up in the dash at key on,
which is a normal power-up test of the
display.
5. The gear display flashes a solid “PD” (Product
Diagnostic Mode) and the mode is activated.
6. Flex the wiring harness and connectors and
attempt to recreate the fault.
7. If a fault becomes Active during PDM,
ServiceRanger will display the fault with a status of
Active.
8. If a fault is detected, exit PDM mode and perform
the corresponding fault code troubleshooting
procedure. See “Fault Code Isolation Procedure
Index” on page 14.
Note: Active codes set during PDM mode will not
be stored as Inactive.
9. To exit PDM mode, power the system down by
turning the key off.

Hybrid Light and Gear Display Descriptions | General Information TRTS1000
Hybrid Light and Gear Display Descriptions

All Eaton® hybrid systems use a combination of 3 lights to Blinking Amber “Check Hybrid” Light
indicate failures of different operating systems and the
The majority of vehicles have a red Stop Switch on the front
ability of the vehicle to drive. These lights include the red
of the Power Electronics Carrier (PEC). If this switch is
“Service” light, amber “Check Hybrid” light, and the red
pushed in, the amber “Check Hybrid” light will blink.
“Stop Hybrid” light.
• To reset, pull switch out and turn key off for 2
minutes. Continue to the diagnostic test for the
Red “Service” Light fault that is currently Active.
• Light is located on the Push Button Shift Control • If the light remains on, go to “Hybrid Diagnostic
and reads “Service”. Procedure” on page 8 and start with step 3
• Light is turned on and off by the Transmission “Retrieve Active Faults with ServiceRanger.”
Electronic Control Unit (TECU) for automated • There should be an Active Fault Code 76 FMI 4, or
transmissions faults over the High Integrity Fault Code 116, FMI 10.
Link (HIL).
• Light also comes on momentarily at key on as part “ST” in Gear Display
of the TECU self-test.
A “ST” in the gear display indicates a driver-triggered snap-
shot was recorded. Snapshot is a diagnostic tool that is
Amber “Check Hybrid” Light used to capture specific data at the time a fault occurs. It is
triggered through two different means listed below:
• Light is located near the middle of the dash. It is
amber and reads “Check Hybrid.” • Fault code triggered - Specific faults will trigger the
HCM or TECU to capture a snapshot file for later
• Light is turned on and off indirectly by the Hybrid retrieval. This method will not display an “ST” in
Control Module (HCM) and directly by the Body the gear display.
Controller over J1939.
• Driver triggered - If the driver chooses to capture a
• Light is turned on when a hybrid system fault snapshot of an event, he needs to decide if he
is Active. wants TECU or HCM data. To capture a TECU
• When the amber light is on, the vehicle can still be snapshot select, Low and the Up button twice. To
driven; however, the vehicle may operate without capture a HCM snapshot select, Drive or Low and
hybrid electric assist. the Up button and the Down button.
Red “Stop Hybrid” Light “PD” in Gear Display

A “PD” in the gear display indicates the TECU and HCM are
• Light is located near the middle of the dash. The in a special diagnostic mode called Product Diagnostic
light is red and reads “Stop Hybrid”. Mode (PDM).For more details on the mode and its
• Light is turned on and off indirectly by the HCM and operation, see “Product Diagnostic Mode (PDM)” on
directly by the Body Controller over J1939. page 19.
• Light is turned on when a hybrid system fault

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

TRTS1000 General Information | Hybrid Light and Gear Display Descriptions
“CA” in Gear Display Blank Gear Display

“CA” in gear display indicates HCM is detecting a clutch A blank gear display indicates the display has lost power, or
abuse situation. the TECU isn’t communicating with the gear display. See
“Symptom-Driven Diagnostics Index” on page 18.
• If the HCM detects a clutch abuse situation it will
first tone the Push Button Shift Control and flash a
“CA” in the gear display.
• If the clutch abuse situation continues, the hybrid
system will allow only an electric launch in addition
to continuing the tone and the “CA.”
• If the clutch abuse continues while driving, the
hybrid system will open the clutch when vehicle
speed is below 5 MPH and allow the clutch to cool.
“OS” in Gear Display

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

depress the service brake pedal to slow the vehicle;
or,
• The HCM will either upshift the vehicle or reduce
torque to prevent the motor from going overspeed.
“F” in Gear Display

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

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

Two stars “**” in the gear display indicates the gear display
has power, but no communication on the data link. See
“Symptom-Driven Diagnostics Index” on page 18.
Double Dashes “- -” in Gear Display

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

Power-Up Sequence Test | Electrical Pretest Procedures TRTS1000
Power-Up Sequence Test

Overview
This test must be performed only when experiencing a
“vehicle won’t crank” with a double dash “- -”, double
star“**”, or blank gear display. The Electrical Pretest must
be performed prior to this procedure (see “Electrical
Pretest” on page 25.)
Detection
The power-up self-check is performed automatically at
every key on. Turn key on and watch the “Service” light. If
power up stops with the “Service” light constantly on, or it
never comes on, self-check has failed.
Fallback
There is no fallback for this concern and the vehicle does
not crank if the Transmission Electronic Control Unit
(TECU) or Power Supply Harness has failed.
Possible Causes
This may be caused by any of the following:
• TECU Power Supply
• TECU
Additional Tools
• Basic hand tools
• Battery load tester
• Eaton® Test Adapter Kit J43318
• Digital Volt/Ohm Meter J46708

TRTS1000 Electrical Pretest Procedures | Power-Up Sequence Test
Component Identification
see “Wiring Diagrams” on page 446.

Power-Up Sequence Test | Electrical Pretest Procedures TRTS1000
Power-Up Sequence Test

Purpose: Perform the Electrical Pretest.
A
1. Perform the “Electrical Pretest” on page 25.
2. Is problem still present after the Electrical Pretest?
• Yes, replace the Transmission Electronic
Control Unit (TECU), then return to the
“Hybrid Diagnostic Procedure” on page 8.
• No, test is complete. Return to the “Hybrid
Diagnostic Procedure” on page 8.

Electrical Pretest | Electrical Pretest Procedures TRTS1000
Electrical Pretest
Overview
This test must be performed prior to diagnosing certain
specific faults. This test verifies the quality of the standard
battery system and the main power and ground supplies to
the Hybrid Control Module (HCM), Transmission Electronic
Control Unit (TECU), and Electronic Clutch Actuator (ECA).
Note: This test is called out in the procedures where it is

required.
Detection
There is no detection process specifically for the basic
electrical supply; however, failures of this type are generally
detected by the transmission or driver as some other type
of fault code or symptom.
Fallback
A weak power supply can cause many issues such as shift
performance, power up or failure to crank.
Possible Causes
Low-voltage can be caused by the following:
• Low batteries
• Charging System
• Power harness connections or fuses to TECU, HCM
or ECA
Additional Tools
• ServiceRanger

Front View Front View

(TECU - Vehicle Interface Connector) 1 (HCM - Vehicle Interface Connector)
6 29 34
7 23 28
12
36 35 37 38
22 13 22
13
38 37 35 36
28 23 7 12
34 29 1 6
ECA -Pack 8-Way Connector

ECA - 3-Way Connector
C B A A B C D
H G F E
NOTE: Refer to the Eaton Hybrid Component and Connector Location page for Connector Locations
TECU
Battery
TECU Power 38
Neg (-)
TECU Ground 36
TECU Ignition 35
Plus (+)
Ignition Relay
HCM 87
ECA
HCM Ignition (Vehicle) 35
C ECA Power
HCM Ground (Vehicle) 36
B ECA Ground
HCM Power (Vehicle) 38
Clutch Ignition (System) 13 H

TRTS1000 Electrical Pretest Procedures | Electrical Pretest
Electrical Pretest
Purpose: Verify chassis battery voltage. Purpose: Verify ECA battery voltage and ignition
A B status.
1. Key off. 1. Key on.

2. Inspect starter/battery and Inline fuse holder 2. Connect ServiceRanger to 9-Way Diagnostic
connections on Electronic Clutch Actuator (ECA), Connector in the cab.
Hybrid Control Module (HCM) and Transmission
3. Select the “Data Monitor” option and view the
Electronic Control Unit (TECU) for integrity.
following parameters under the hybrid (clutch
Note: ECA, HCM and TECU use a 30-amp fuse. actuator) list:
Refer to OEM for locations.
- PID 132 “Clutch Actuator Battery Voltage.”
3. Measure voltage across batteries. - PID 160 “Clutch Actuator Ignition Switch Status.”
• If voltage is 11–13 volts on a 12-volt system,
Note: If the clutch parameters can not be viewed on
proceed with battery load test. Repair or
ServiceRanger, check the power supply to the
replace batteries as required. Go to Step B. ECA with a voltmeter.
• If voltage is outside of range, repair or replace
• If PID 132 is within 0.6 volts of battery voltage
batteries and charging system as required.
and PID 160 reads "1", go to Step C.
Repeat this step.
• If either voltage is out of range, repair main
Connection Measurement power or ignition supply to the ECA. Repeat
this step.
Starter Battery to ECA
Parameter Reading
Starter Battery to HCM
PID 132 “Clutch Actuator
Starter Battery to TECU Battery Voltage”
PID 160 “Clutch Actuator

Ignition Switch Status”

Purpose: Verify HCM battery voltage and ignition Purpose: Verify TECU battery and switched
C status. D voltage.
1. Select the “Data Monitor” option and view the 1. Select the “Data Monitor” option and view the
following parameters under the HCM list: following parameters under the hybrid
(Transmission) list:
- PID 165 “Battery Potential Voltage.”
- PID 168 “Battery Potential Voltage.”
- PID 166 “Ignition Switch Status.”
- PID 158 “Battery Potential Voltage Switched.”
Note: If the “Battery Potential Voltage” or “Ignition
Switch Status” can not be viewed on Note: If the “Battery Potential Voltage” or “Battery
ServiceRanger, check the power supply to Potential Voltage Switched” can not be
the HCM with a voltmeter. viewed on ServiceRanger, check the power
supply to the TECU with a voltmeter.
• If PID 165 is within 0.6 volts of battery voltage
and PID 166 reads "1", go to Step D. • If PID 168 is within 0.6 volts of battery voltage
and PID 158 is within 0.6 volts of ignition
• If either voltage is out of range, repair the main
voltage, test is complete. Return to the fault
power or ignition supply to the HCM. Repeat
or symptom procedure that referenced this
this step.
step.
Parameter Reading • If either voltage is out of range, repair main

power or ignition supply to the TECU. Repeat
PID 165 “Battery Potential this step.
Voltage”
Parameter Reading
PID 166 “Ignition Switch
Status” PID 168 “Battery Potential
Voltage”
PID 158 “Battery Potential

Voltage Switched”

TRTS1000 Electrical Pretest Procedures | Hybrid Electrical Pretest
Hybrid Electrical Pretest

Overview
This test must be performed prior to diagnosing select
hybrid faults. This test verifies the power supply for the
Inverter and Battery Control Unit (BCU).
Note: The Electrical Pretest must be performed before the

Hybrid Electrical Pretest.
Note: This test will be called out in the procedures where it
is required.
Detection
There is no detection process specifically for the basic
electrical supply; however, failures of this type are generally
detected by the hybrid system or driver as some other type
of fault code or symptom.
Fallback
Loss of ignition power causes the hybrid system to be
inoperable. The vehicle runs under diesel power only.
Possible Causes
Low-voltage can be caused by Power Harness connections
from Inverter or BCU.
Additional Tools
• ASTM Class 0 electrical insulating rubber gloves
with leather protectors J48603
• Lockout bracket J48506
• Lockout tags
• ServiceRanger

Hybrid Electrical Pretest | Electrical Pretest Procedures TRTS1000
Deutsch 19 - Way Mating Connector View

Delphi 56-Way Mating Connector View (PEC - Low Voltage Connector)
(Inverter - Low Voltage Connector) 1
14
19 8 9
28
15 18 7 2 10
17 6 1 3 11
16 5 4 12
42 29
15 14 13
56
43
Inverter PEC
Chassis Ground 1 1
Chassis Ground 2 2
HCM
Inverter Enable 15 (Pin 2)
Relay Box Enable 16 6
Ground B 34 7
DC/DC DC/DC Converter

Converter 4-Way OEM Connector
4 3
1 2
4
Ground

TRTS1000 Electrical Pretest Procedures | Hybrid Electrical Pretest
Hybrid Electrical Pretest

Purpose: Verify Inverter ground continuity. Purpose: Verify voltage at Inverter 56-Way
A B Connector.
1. Perform the Electrical Pretest (see “Electrical 1. Connect a multimeter to the Inverter 56-Way
Pretest” on page 25.), then continue to step 2. Connector Pin 15 and Pin 1.
! Warning: See “High-Voltage Service Shutdown and 3. Observe multimeter voltage reading:
Power-Up Procedure” on page 4. Follow the proce-
• If voltage is 11–13 volts, go to Step C.
dures to avoid shock, burn or death from improp-
erly handled high-voltage. • If voltage is outside of range, repair the
Harness from the HCM, then repeat this step.
3. Disconnect the Inverter 56-Way Connector.
4. Measure resistance from Pin 1 to battery negative
and then from Pin 2 to battery negative: Connection Measurement
• If resistance is 0–0.3 ohms from Pin 1 to Pin 15 to Pin 1
battery negative and from Pin 2 to battery
negative, go to Step B.
• If resistance is outside of range, repair the
Inverter Ground Harness, then repeat this step.
Purpose: Verify continuity of Inverter to PEC

Connection Measurement
C Ground Wire.
Pin 1 to battery
negative 1. Key off.
Pin 2 to battery 2. Reconnect the Inverter 56-Way Connector.
negative
3. Disconnect the PEC 19-Way Connector.
4. Measure resistance from PEC Pin 7 to battery
negative:
• If resistance from Pin 7 to battery negative is
0–0.3 ohms, go to Step D.
Inverter to PEC Ground Wire, then repeat
this step.
Pin 7 to battery
negative

Hybrid Electrical Pretest | Electrical Pretest Procedures TRTS1000
Purpose: Verify voltage at PEC 19-Way Connector. Purpose: Verify continuity of DC/DC Ground Wire.
D E
1. Connect a multimeter to the PEC 19-Way 1. Key off.
Connector Pin 6 and Pin 7.
2. Reconnect PEC 19-Way Connector.
2. Key on.
3. Disconnect DC/DC Converter 4-Way Connector.
3. Observe multimeter voltage reading.
4. Measure resistance from DC/DC Converter 4-Way
• If voltage is 11–13 volts, and vehicle has ePTO Connector Pin 4 to battery negative:
feature on Push Button, go to Step E.
• If resistance between Pin 4 and battery
• If vehicle does not have ePTO feature, test is negative is 0–0.3 ohms, test is complete.
complete. Reconnect PEC 19-Way Connector. Reconnect the 4-Way Connector. See “Fault
See “Fault Code Isolation Procedure Index” on Code Isolation Procedure Index” on page 14.
page 14.
• If voltage is outside of range, repair the Power Ground Harness from the DC/DC Converter to
Supply Harness from the Inverter, then repeat battery negative, then repeat this step.
this step.
Pin 4 to battery
6 to 7 negative

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

J1939: SA 239 SPN 520225 FMI 0, 6
Overview Conditions to Set Fault Code Inactive

The High-Voltage Motor/Generator Assembly is connected Only Inactive faults can be cleared from the Transmission
to the Inverter Assembly through an AC High-Voltage Cable Electronic Control Unit (TECU) or HCM history using
that contains 3 separate cables. During operation, the ServiceRanger. The TECU automatically clears the faults
Inverter monitors the amperage in the AC cables through a from history after 200 hours and the HCM automatically
current sensor, which is mounted inside the Inverter. The clears the faults from history after the fault has stayed
inductive sensor produces an output based on amperage Inactive for 200 hours.
present in the cables.
Possible Causes
Detection This fault code can be caused by any of the following:
The Inverter ignition voltage is greater than 7 volts and less • FMI 0, 6
than 16 volts.
- Inverter
Conditions to Set Fault Code Active - Motor/Generator
Conditions to Set Fault: - AC cable
• FMI 6 is set when Inverter detects current input
from the Motor/Generator greater than 100 amps
for 150 MS.
• FMI 0 is set when the Inverter detects current input
from the Motor/Generator greater than 200 amps
for 0.3 MS.
Fallback
When Fault Code 1 is set the following conditions occurs:
• Amber “Check Hybrid” light illuminates.
• Fault is stored in Hybrid Control Module (HCM)
memory.
• Electric Motor/Generator Assist and Regeneration
are disabled; however, the high-voltage relays
remain powered.
• HCM continues to control the hybrid vehicle in a
diesel-only mode.
• Transmission defaults start gear to 1st.

Fault Code 1 - Motor/Generator Current Sensor | Fault Isolation Procedures TRTS1000
C A
F F
C A
E D E D
B
High-Voltage AC Harness Connector View High-Voltage AC Motor/Gen Connector View

(Amphenol Connector) (Amphenol Connector)
Inverter Motor/
Generator
Phase 3 C C Phase 3
Phase 2 B B Phase 2
Phase 1 A A Phase 1

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

Purpose: Check for fault code status and continuity Purpose: Verify continuity of high-voltage circuitry
A of high-voltage circuitry. B to ground.
1. Review and follow the “Warnings & Cautions” on 1. Measure resistance of each circuit to ground in the
page 1. AC High-Voltage Cable:
2. Retrieve Active fault codes and FMIs with Ser- • If resistance between each circuit and ground
viceRanger using the 9-Way Diagnostic Connector. is 5M ohms or greater, go to Step C.
3. Key off. • If resistance is outside of range, replace the
AC High-Voltage Cable, then go to Step V.
! Danger: See “High-Voltage Service Shutdown and
dures to avoid shock, burn or death from improp- Connection Measurement
erly handled high-voltage.
Pin A to ground
4. Remove the AC Cable from the Motor/Generator
and Inverter.
Pin B to ground
5. Measure resistance of each circuit in the
AC High-Voltage Cable Pins A-A, B-B and C-C: Pin C to ground
• If resistance for each circuit is less than
1 ohm, go to Step B.
• If resistance is outside of range, replace the
Pin A to Pin A
Pin B to Pin B
Pin C to Pin C

Fault Code 1 - Motor/Generator Current Sensor Test | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of high-voltage circuitry. Purpose: Verify continuity of Motor/Generator

C D phases.
1. Key off. 1. Measure resistance of each Motor/Generator phase

at the following Pins: A-B, B-C and C-A:
2. Measure the resistance between the following
AC High-Voltage Cable Pins A-B, B-C and C-A: • If resistance of each phase is less than
10 ohms, replace the Inverter, then
• If resistance of each phase is 5M or greater,
go to Step V.
go to Step D.
Motor/Generator, then go to Step V.
Pin A to Pin B
Pin A to Pin B
Pin B to Pin C
Pin B to Pin C
Pin C to Pin A
Pin C to Pin A

TRTS1000 Fault Isolation Procedures | Fault Code 1 - Motor/Generator Current Sensor Test
Purpose: Verify repair.

V
1. Key off.
2. Reconnect all connectors and the negative
battery cable.
3. Key on.
4. Clear codes, see “Clear Inactive Faults” on page 13.
5. Drive the vehicle and attempt to reset the code.
6. Check for codes, see “View Active and Inactive
Faults” on page 13.
• If no codes, test is complete.
• If Fault Code 1 appears, find error in testing,
go to Step A.
• If a code other than 1 appears, see “Fault Code
Isolation Procedure Index” on page 14.

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

J1939: SA 239 SPN 520226 FMI 3

The Motor/Generator Temperature Sensor is a thermistor Only Inactive faults can be cleared from the Transmission
located inside the Motor/Generator that changes in value Electronic Control Unit (TECU) or HCM history using
based on the temperature. The Inverter supplies a 5-volt ServiceRanger. The TECU automatically clears the faults
reference voltage to the sensor and measures the volt drop from history after 200 hours and the HCM automatically
in the circuit. When the Motor/Generator temperature is clears the faults from history after the fault has been
warm, the sensor resistance is low and the Inverter detects Inactive for 200 hours.
low-voltage (0.2 volts equals 536 °F [280 °C]). When the
Motor/Generator is cold the sensor resistance is high and Possible Causes
the Inverter detects high voltage (4.1 volts equals or 32 °F This fault code can be caused by any of the following:
[0 °C]). • FMI 3
Detection - Motor/Generator
The following preconditions must be met before the system - Short/open Temperature Sensor wires between
detects the fault: the Motor/Generator and the Inverter
• Inverter ignition voltage is greater than 7 volts and - Inverter
less than 16 volts.
Additional Tools
Conditions to Set Fault Code Active • Basic hand tools
The following conditions must be met to set the fault code
Active: • ASTM Class 0 electrical insulating rubber gloves
• FMI 3 is set when the sensor voltage is greater than
4.1 volts for 10 seconds, while the Inverter • Lockout bracket J48506
temperature is over 35 °C or 95 °F, or if the sensor • Lockout tags
output voltage is less than 0.2 volts for 10 seconds. • Eaton® Test Adapter Kit J43318
Fallback • Digital Volt/Ohm Meter J46708
When Fault Code 2 is set the following conditions occur: • ServiceRanger
• Fault is stored in Hybrid Control Module
(HCM) memory.
• High-Voltage Motor/Generator Assist is available,
but at a reduced amount.

TRTS1000 Fault Isolation Procedures | Fault Code 2 - Motor/Generator Temperature Sensor
Delphi 56-Way Mating Connector View 1

Temperature Sensor
14 (Harness View - Front Side)
28
15
42 29 2 1
56
43
Inverter Motor/Generator
Temperature Sensor
TM Ground 38 2 Temp Sensor
TM 50 1 Temp Sensor

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

Purpose: Check for fault code status and continuity Purpose: Verify continuity of Inverter and
A of Motor/Generator Temperature Sensor circuit B Motor/Generator Temperature Sensor circuit.
1. Review and follow the “Warnings & Cautions” on 1. Key off.

page 1.
2. Retrieve Active fault codes and FMIs with Ser-
3. Reconnect the Motor/Generator 2-Way
viceRanger using the 9-Way Diagnostic Connector.
Temperature Sensor Connector.
3. Key off.
4. Measure resistance at the following:
4. Disconnect the Temperature Sensor Connector at
- Inverter 56-Way Connector Pin 50 to Pin 38
the Motor/Generator.
- Inverter 56-Way Connector Pin 50 to ground
! Warning: See “High-Voltage Service Shutdown and
Power-Up Procedure” on page 4. Follow Note: Gently flex the Inverter 56-Way Harness
the procedures to avoid shock, burn or near the Connector while monitoring the
death from improperly handled resistance values.
high-voltage.
• If resistance is 0.8K–301.7K ohms between
5. Measure resistance at the Motor/Generator 2-Way Pin 50 and Pin 38 and resistance between
Temperature Sensor Connector from Pin A to Pin B: Pin 50 and ground is 10K ohms or greater,
replace the Inverter, then go to Step V.
• If resistance is 0.8K ohms to 301.7K ohms,
go to Step B. • If resistance is outside of range, repair the
open or short to ground in the harness
between the Inverter 56-Way Connector and
the Motor/Generator 2-Way Connector, then
go to Step V.
Pin A to Pin B
Pin 50 to Pin 38
Pin 50 to ground

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

V
1. Key off.
2. Key on.
battery cable.
4. Clear codes, see “Fault Code Retrieval and
Clearing” on page 13.
5. Drive vehicle and attempt to reset the code.
go to Step A.

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

J1939: SA 239 SPN 520227 FMI 0

The Motor/Generator temperature is measured through a Only Inactive faults can be cleared from the Transmission
thermistor sensor, which is located internal to the unit. The Electronic Control Unit (TECU) or HCM history using
sensor changes value based on the temperature. The ServiceRanger. The TECU automatically clears the faults
Inverter supplies a 5-volt reference voltage to the sensor from history after 200 hours and the HCM automatically
and measures the volt drop in the circuit. clears the faults from history after they have been Inactive
for 200 hours.
When the Motor/Generator temperature is warm the sensor
resistance is low and the Inverter detects a low-voltage (0.2 Possible Causes
volts equals 536 °F [280 °C]). When the Motor/Generator is This fault code can be caused by any of the following:
cold, the sensor resistance is high and the Inverter detects
a high voltage (4.1 volts equals 32 °F [0 °C]). • FMI 0 (FMI 0 is set when the temperature sensor
value is greater than 365 °F [185 °C] for 1 second):
Detection - Motor/Generator
Inverter ignition voltage is greater than 7 volts and less than - Inverter
16 volts.
- Liquid cooling system (low coolant, no coolant
Conditions to Set Fault Code Active flow, Coolant Pump, Radiator, Radiator Fan,
When the Motor/Generator temperature is warm the sensor reservoir)
resistance is low and the Inverter detects a low-voltage (0.2
volts equals 536 °F [280 °C]). When the Motor/Generator is Additional Tools
cold the sensor resistance is high and the Inverter detects a • Basic hand tools
high-voltage (4.1 volts equals 32 °F [0 °C ]). • ASTM Class 0 electrical insulating rubber gloves
Fallback
When Fault Code 3 is set the following conditions occur: • Lockout bracket J48506
• Amber “Check Hybrid” light illuminates. • Lockout tags
• Fault is stored in Hybrid Control Module (HCM) • Eaton® Test Adapter Kit J43318
memory. • Digital Volt/Ohm Meter J46708
• Electric Motor/Generator Assist and Regeneration • ServiceRanger
are disabled; however, high-voltage relays remain
powered.
diesel-only mode.

TRTS1000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature
Delphi 56-Way Mating Connector View 1

Temperature Sensor
14 (Harness View - Front Side)
28
15
42 29 2 1
56
43
Inverter Motor/Generator
Temperature Sensor
TM Ground 38 2 Temp Sensor
TM 50 1 Temp Sensor

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

Purpose: Check for Active or Inactive fault code Purpose: Verify level of hybrid system coolant.
A status. B
page 1.
2. Observe the coolant level after the system has
2. Retrieve Active fault codes and FMIs with Ser- cooled down to ensure if is filled to the proper level:
• If coolant is within the recommended limits,
! Warning: See “High-Voltage Service Shutdown and 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.
3. Key on. When refilling the system it should be
pressurized or vacuum bleed of air to
4. Find initial temperature by selecting the “Data ensure the coolant flows properly during
Monitor” option and view PID 113 normal operation.
“Motor/Generator Temperature” in the “Power
Electronics” list.
5. View PID 113 again after 20 minutes:
• If PID 113 “Motor/Generator Temperature”
dropped from the first reading, go to Step B.
• If PID 113 “Motor/Generator Temperature”
remained the same, go to Step H. Purpose: Verify integrity of hybrid cooling system
C components.
Time Temperature 1. Key off.
Initial check 2. Visually inspect the hybrid liquid cooling system

radiator for debris, obstruction to airflow, or sharp
bends in the coolant lines:
20 minute
• 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 coolant lines are bent
sharply, repair the concern, then go to Step V.

TRTS1000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature Test
Purpose: Verify operation of hybrid Coolant Pump. Purpose: Verify voltage at hybrid Coolant Pump.
D F
1. Key on. 1. Key on.
2. Connect ServiceRanger to the 9-Way Connector in 2. Disconnect the Coolant Pump 2-Way Connector.
the cab.
3. Select the “Advanced Products Function” option
3. Select the Advanced Product Functions option and and select “Cooling Pump.”
select the “Cooling Pump” option.
4. Enable the Cooling Pump option.
4. Enable the “Cooling Pump” option:
5. Measure voltage at the 2-Way Connector from
• If the Coolant Pump turns on, go to Step E. Pin A to Pin B:
• If the Coolant Pump does not turn on, • If voltage between Pin A and Pin B is ±0.2 volts
go to Step F. of battery voltage, refer to OEM for Coolant
Pump concern.
• If voltage between Pin A and Pin B is outside
of range, refer to OEM for repair procedures
on Cooling Pump Power Harness or
damaged fuse.
Purpose: Verify operation of hybrid Heat

E Exchanger Fan.
Pin A to Pin B
1. Select the Advanced Product Functions option and
select the “Heat Exchanger Fan” option.
2. Enable the Heat Exchanger Fan option:
• If the Heat Exchanger Fan turns on, the system
needs to be purged of air, allowing the coolant
to flow. Bleed the air by using a coolant system
pressurizing tool or a vacuum tool, then
go to Step V.
• If the Heat Exchanger Fan does not turn on,
go to Step G.

Fault Code 3 - Motor/Generator Temperature Test | Fault Isolation Procedures TRTS1000
Purpose: Verify voltage at hybrid Heat Exchanger Purpose: Verify continuity of Inverter circuitry.
G Fan. H
1. Key on. 1. Key off.
2. Disconnect the Heat Exchanger Fan 2. Disconnect the Inverter 56-Way Connector.
2-way connector.
3. Measure resistance between Pin 38 and Pin 50, and
3. Select the “Advanced Products Function” option Pin 50 to ground of the Inverter 56-Way Connector.
and select the “Heat Exchanger Fan.”
• If resistance is 0.8K–301.7K ohms between
4. Enable the Heat Exchanger Fan option. Pin 50 and Pin 38 and resistance between
Pin 50 and ground is 10K ohms or greater,
replace the Inverter, then go to Step V.
Pin A to Pin B:
• If resistance is outside the range, go to Step I.
• If voltage between Pin A and Pin B is ±0.2 volts
of battery voltage, refer to OEM for Heat
Exchanger Fan concern.
• If voltage between Pin A and Pin B is outside of
range, refer to OEM for repair procedures on Pin 50 to Pin 38
Heat Exchanger Fan Power Harness or
damaged fuse.
Pin 50 to ground
Pin A to Pin B

TRTS1000 Fault Isolation Procedures | Fault Code 3 - Motor/Generator Temperature Test
Purpose: Verify continuity of Temperature Sensor Purpose: Verify repair.

I circuit. V
1. Key off. 1. Key off.
2. Disconnect the Motor/Generator Temperature 2. Reconnect all connectors and negative
Sensor 2-Way Connector located on the right side battery cable.
of the Motor/Generator.
3. Key on.
3. Measure resistance between the 2-Way
Temperature Sensor Connector from Pin A to Pin B:
• If resistance is 0.8K–301.7K ohms, repair the
shorted HCM System Harness between the 6. Check for codes, see “View Active and Inactive
Inverter 56-Way Connector and Faults” on page 13.
Motor/Generator 2-Way Connector.
• If resistance is outside the range, replace the
go to Step A.
Connection Measurement Isolation Procedure Index” on page 14.
Pin A to Pin B

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

J1939: SA 239 SPN 520228 FMI 0, 2, 22–27
Overview Fallback
The Motor/Generator Rotation Speed Sensor is mounted to When Fault Code 4 is set the following conditions occur:
the back of the Motor/Generator around the Input Shaft. • Amber “Check Hybrid” light illuminates.
The sensor (two-piece design) is a rotor mounted to the
Input Shaft and a Sensing Ring mounted to the motor • Fault is stored in Hybrid Control Module
housing. The Sensing Ring is supplied with low-voltage (HCM) memory.
during operation. The rotor turns inducing a voltage • Electric Motor/Generator Assist and Regeneration
fluctuation into the Sensing Ring, which is then converted are disabled; however, the high-voltage relays
into a digital signal for Motor/Generator RPM. Voltage remain powered.
output and frequency is low at idle and increases with RPM. • HCM continues to control the hybrid vehicle in a
diesel-only mode.
Detection
Fault is detected when: • Transmission defaults start gear to 1st.
• Inverter ignition voltage is greater than 7 volts and Conditions to Set Fault Code Inactive
less than 16 volts. Only Inactive faults can be cleared from the Transmission
• FMI 2 does not set if there is an Active Electronic Control Unit (TECU) or HCM history using
Transmission Input Shaft Speed Sensor fault. ServiceRanger. The TECU automatically clears the faults
from history after 200 hours. The HCM automatically clears
Conditions to Set Fault Code Active the faults from history after the fault has been Inactive for
The following conditions must be met to set the fault 200 hours.
code Active:
• FMI 0 is set when the Motor/Generator speed Possible Causes
exceeds the normal allowable range. This fault code can be caused by any of the following:
• FMI 2 is set when the Motor/Generator speed is • FMI 0

different than Transmission Input Shaft Speed by - Long extended grades may require intermittent
more than 100 RPM for at least 10 seconds. use of the service brakes to slow the vehicle
• FMI 22, 24, 25 are set when the combination of • FMI 22, 24, 25, 27
analog-to-digital converter signals are a mismatch. - Inverter
• FMI 27 is set when the Inverter detects an error • FMI 2, 23, 26
during the initial check.
- Inverter
• FMI 23 is set when there is an analog-to-digital
converter output error signal for 100 MS. - Motor/generator
• FMI 26 is set when the rotation sensor speed is - Resolver Harness between the Motor/Generator
greater than 6000 min-1 for 10 MS. and Inverter
Additional Tools
• Lockout tags
• ServiceRanger

TRTS1000 Fault Isolation Procedures | Fault Code 4 - Motor/Generator Rotation Speed Sensor
Delphi 56-Way Mating Connector View 1 Resolver Harness View

(Front Side)
14
28
15
5 3 1
42 29
6 4 2
56
43
Motor/Generator
Resolver
Inverter
REZ S3 53 1 Resolver
REZ Minus (-) 55 5 Resolver
REZ Plus (+) 56 6 Resolver

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

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of Resolver and Inverter
A status. B components.
1. Review and follow the “Warnings & Cautions” on 1. Disconnect the 56-Way Low-Voltage Connector
page 1. at the Inverter.
2. Retrieve Active fault codes and FMIs with Ser- 2. Measure Resolver resistance at the 56-Way
viceRanger using the 9-Way Diagnostic Connector. Harness Connector between the following pins:
3. Key off. - Pin 55 to Pin 56
- Pin 53 to Pin 54
- Pin 51 to Pin 52
dures to avoid shock, burn or death from improp- Note: Gently flex the Inverter 56-Way Connector
erly handled high-voltage. Harness near the Connector while monitoring
the resistance values.
4. Which FMIs are present?
Resistance ranges for the pins are:
• If FMI 22, 24, 25, or 27 are listed, replace - Pins 55 to Pin 56: 10.5–8.6 ohms
the Inverter, then go to Step V.
- Pins 53 to Pin 54: 34–28 ohms
• If FMI 2, 23, or 26 are listed, go to Step B. - Pins 51 to Pin 52: 27–23 ohms
• If FMI 0 is listed, Using ServiceRanger select • If the above resistances are found, and
the Advanced Product Functions and FMI 2 is Active, contact Eaton at
download the TECU and HCM snapshots then 1-800-826-HELP (4357).
contact Eaton® at 1-800-826-HELP (4357).
• If the above resistances are found, and
FMI 26 or 23 are Active, replace the Inverter,
then go to Step V.
• If resistance is outside of range for any of the
readings, go to Step C.
Pin 55 to Pin 56
Pin 53 to Pin 54
Pin 51 to Pin 52

TRTS1000 Fault Isolation Procedures | Fault Code 4 - Motor/Generator Rotation Speed Sensor Test
Purpose: Verify continuity of Resolver Harness Purpose: Verify repair.

C circuitry. V
1. Disconnect the 6-Way Motor/Generator 1. Key off.
Resolver Connector.
2. Measure the Resolver resistance at the 6-Way battery cable.
Harness Connector between the following pins:
3. Key on.
- Pin 5 to Pin 6
- Pin 1 to Pin 3 4. Clear codes, see “Clear Inactive Faults” on page 13.
- Pin 2 to Pin 4 5. Drive the vehicle and attempt to recreate the code.
Note: An auto-ranging digital Volt/Ohm Meter must 6. Check for codes, see “View Active and Inactive
be used. Faults” on page 13.
Resistance ranges for the pins are: • If no codes, test is complete.
- Pins 5 to Pin 6: 10.5–8.6 ohms
• If Fault Code 4 appears, contact Eaton at
- Pins 1 to Pin 3: 34–28 ohms 1-800-826-HELP (4357).
- Pins 2 to Pin 4: 27–23 ohms
• If the above resistances are found, repair the Isolation Procedure Index” on page 14.
open harness between the Inverter 56-Way
Connector and the Motor/Generator 6-Way
Resolver Connector, then go to Step V.
Pin 5 to Pin 6
Pin 1 to Pin 3
Pin 2 to Pin 4

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

J1939: SA 239 SPN 520229 FMI 22–29
Overview Fallback
The Motor/Generator AC Cables are connected from the When Fault Code 5 is set the following conditions occur:
Motor/Generator to the Inverter. These cables carry up to • Red “Stop Hybrid” light illuminates.
500 volts AC 3 phase when the vehicle is in operation.
Detection (HCM) memory.
The following preconditions must be met before the system • Inverter shuts high-voltage system off.
detects the fault: • HCM continues to control the hybrid vehicle in a
• Inverters ignition voltage is greater than 7 volts and diesel-only mode.
less than 16 volts. • If FMI 28, or 29 is present at power up, the vehicle
• FMI 25–27 require the Motor/Generator RPM to be does not crank.
greater than 500 RPM.
• FMI 28 requires the Motor/Generator RPM to be Conditions to Set Fault Code Inactive
less than 500 RPM. Only Inactive faults can be cleared from the Transmission
Electronic Control Unit (TECU) or HCM history using
• FMI 29 requires the Motor/Generator RPM to be ServiceRanger. The TECU automatically clears the faults
less than 50 RPM. from history after 200 hours. The HCM automatically clears
the faults from history after the fault code has been Inactive
Conditions to Set Fault Code Active for 200 hours.
The following conditions must be met to set the fault
code Active: Possible Causes
• FMI 22, 23, 24 are set when the 2-phase motor This fault code can be caused by any of the following:
current is more than 360 amps for 0.9 MS. • FMI 22, 23, 24
• FMI 25, 26, 27 are set when the Inverter detects a - Inverter
single open wire and motor current is less than 8
amps for 200 MS at speeds greater than or equal to - Motor/generator
500 RPM and current command from the Inverter - AC cable
is greater than 20 amps.
• FMI 25, 26, 27, 28, 29
• FMI 28 is set when Motor/Generator current is less
than 8 amps for 200 MS at speed less than 500 - Motor/generator
RPM and current command is greater than 20 - AC cable
amps.
• FMI 29 is set during initialization. The Inverter Additional Tools
determines if the AC Cable is connected between • Basic hand tools
the motor and Inverter by sending out 20 amps for • ASTM Class 0 electrical insulating rubber gloves
200 MS and checking the feedback. with leather protectors J48603
• Lockout tags
• ServiceRanger

TRTS1000 Fault Isolation Procedures | Fault Code 5 - Motor/Generator AC Cable
C A
F F
C A
E D E D
B
High-Voltage AC Harness Connector View High-Voltage AC Motor/Gen Connector View

(Amphenol Connector) (Amphenol Connector)
Inverter Motor/
Generator
Phase 3 C C Phase 3
Phase 2 B B Phase 2
Phase 1 A A Phase 1

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

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of high-voltage cable.
A status. B
page 1.
2. Remove the AC high-voltage cable at the
2. Retrieve Active fault codes and FMIs with Ser- Motor/Generator and Inverter.
3. Measure the resistance between the following
3. Key off. AC cable pins:
- Pin A to Pin B
- Pin B to Pin C
Power-Up Procedure” on page 4. Follow
the procedures to avoid shock, burn or - Pin C to Pin A
death from improperly handled
• If resistance between each phase is 5M ohms
high-voltage.
or greater, replace the Inverter, then go to
4. Which faults are present? Step V.
• If Fault Code 5 FMI 22, 23, or 24 are Active, • If resistance is outside of range, replace the
go to Step B. AC high-voltage cable, then go to Step V.
• If Fault Code 5 FMI 25, 26, 27, 28, or 29 are

Active, go to Step C.
Pin A to Pin B
Pin B to Pin C
Pin C to Pin A

TRTS1000 Fault Isolation Procedures | Fault Code 5 - Motor/Generator AC Cable Test
Purpose: Verify continuity of high-voltage cable. Purpose: Verify continuity of high-voltage cable.
C D
1. Disconnect the AC high-voltage cable from the 1. Measure the resistance of each Motor/Generator
Inverter and Motor/Generator. phase at the following pins:
2. Measure the resistance of the AC High-Voltage - Pin A to Pin B
Cable from the Inverter Connector to the - Pin B to Pin C
Motor/Generator Connector on each of the - Pin C to Pin A
following pins:
Note: An auto-ranging digital Volt/Ohm Meter must
- Pin A to Pin A
be used.
- Pin B to Pin B
- Pin C to Pin C • If the resistance of each phase is 10 ohms or
less, replace the Inverter, then go to Step V.
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.
• If resistance is outside of range, replace the Connection Measurement
Pin A to Pin B
Connection Measurement Pin B to Pin C
Pin A to Pin A Pin C to Pin A
Pin B to Pin B
Pin C to Pin C

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

V
1. Key off.
battery cable.
3. Key on.
go to Step A.

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

J1939: SA239 SPN 629 FMI 12, 14

The Hybrid Control Module (HCM) is mounted to the Only Inactive faults can be cleared from the Transmission
transmission and it contains all of the software to control Electronic Control Unit (TECU) or HCM history using
both the hybrid power electronics as well as the ServiceRanger. The TECU automatically clears the faults
transmission operation. from history after 200 hours. The HCM automatically clears
the faults from history after the fault has been Inactive for
Detection 200 hours.
The following preconditions must be met before the system
detects the fault: Possible Causes
• HCM ignition voltage is greater than 7 volts and This fault code can be caused by any of the following:
less than 16 volts. • FMI 12, 14: HCM
Conditions to Set Fault Code Active Additional Tools

The following conditions must be met to set the fault code • Basic hand tools
Active:
• ServiceRanger
• FMI 12 is set at key on if the HCM detects an
internal failure.
• FMI 14 is set when HCM can not complete write of
EEPROM during shut down.
Fallback
When Fault Code 6 is set the following conditions occur:
• Amber “Check Hybrid” light illuminates if the HCM
sets the fault after power up.
• If the fault occurs at power up the vehicle may
not crank.

Fault Code 6 - No HCM Operation | Fault Isolation Procedures TRTS1000
Note: No Schematic for this code.
Note: For component location refer to the OEM service literature.

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

Purpose: Check for Active and Inactive fault code
A status.
1. Retrieve Active fault codes and FMIs with

ServiceRanger using the 9-Way Diagnostic
Connector:
• If Fault Code 6 is Active, replace the Hybrid
Control Module (HCM).
• If Fault Code 6 is Inactive, test is complete.

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

J1939: SA 239 SPN 629 FMI 13
Overview
The Hybrid Control Module (HCM) is mounted to the
transmission and contains all of the software to control
both the hybrid power electronics as well as the
transmission operation.
Detection
detects the fault:
• HCM ignition voltage is greater than 7 volts and
less than 16 volts.
Conditions to Set Fault Code Active

code Active:
• FMI 13 is set at key on if the HCM data is not read
from memory within 1 second.
Fallback
• Fault is stored in HCM memory.
• If this fault occurs at power up, the vehicle does not
crank.
Only Inactive faults can be cleared from the Transmission
ServiceRanger. The TECU automatically clears faults from
history after 200 hours. The HCM automatically clears
faults from history after the fault has been Inactive for
200 hours.
Possible Causes
This fault code can be caused by any of the following:
• FMI 13: Improper ECU configuration software
Additional Tools
• ServiceRanger

TRTS1000 Fault Isolation Procedures | Fault Code 7 - Improper HCM Configuration
Note: For component location refer OEM service literature.

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

Purpose: Check for Active or Inactive fault code
A status.

Connector.
2. Turn ignition off for 2 seconds.
3. Key on:
• If Fault Code 7 is Active, replace the Hybrid
Control Module (HCM).

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

J1939: SA 239 SPN 158 FMI 4

The Hybrid Control Module (HCM) is mounted to the Only Inactive faults can be cleared from the TECU or HCM
transmission and contains all of the software to control history using ServiceRanger. The TECU automatically clears
both the hybrid power electronics as well as the the faults from history after 200 hours. The HCM
transmission operation. The HCM ignition power is a fused, automatically clears a fault from history after that fault has
single 12-volt feed that runs through the HCM 38-Way been Inactive for 200 hours.
Vehicle Connector.
Possible Causes
The following preconditions must be met before the system • FMI 4
detects the fault:
- Ignition Power Supply to HCM
• Output Shaft speed must be greater than 0 RPM.
- HCM
The following conditions must be met to set the fault Additional Tools
code Active: • Basic hand tools
• FMI 4 is set when the HCM loses ignition power • Eaton® Test Adapter Kit J43318
during operation for 2 seconds or greater. • Digital Volt/Ohm Meter J46708
Note: When troubleshooting an Inactive code refer to the • ServiceRanger
“Product Diagnostic Mode (PDM)” on page 19.
Fallback
• Amber “Check Hybrid” light illuminates only if the
vehicle is moving.
• Red “Service” light illuminates and an “F” flashes
in the gear display, if the fault occurs prior to
power up.
- Fault is stored in Transmission Electronic
Control Unit (TECU) memory due to lack of
communication with the HCM.
• If fault occurs while the vehicle is moving, the
transmission remains in place and the clutch opens
when the vehicle comes to an idle. The clutch
closes and the vehicle will operate in 1st and
reverse from stop.
• If this fault occurs at power up, the vehicle does
not crank.

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

Typical Relay Switch
(HCM - Vehicle Interface Connector)
29 34
23 28
37 38
13 22
35 36
30
7 12 86
1 6
85 87
87
Vehicle 86
Ignition Ignition
Relay
Ground 85
30
HCM
12V Plus
Ignition 35
12V Truck
Battery

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

Purpose: Check for Active or Inactive fault code Purpose: Verify repair.
A status and perform electrical pretest. V
page 1.
2. Retrieve Active fault codes and FMIs with Ser- battery cable.
3. Key on.
3. Perform the “Electrical Pretest” on page 25:
• If Fault Code 8 is Active after performing the
Electrical Pretest, replace the Hybrid Control
Module (HCM), then go to Step V. 6. Check for codes, see “View Active and Inactive
• If Fault Code 8 is Inactive after performing the
Electrical Pretest, go to Step V. • If no codes, test is complete.
go to Step A.

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

J1939: SA 239 SPN 168 FMI 14

transmission and contains all of the software to control Electronic Control Unit (TECU) or HCM history using
both the hybrid power electronics as well as the ServiceRanger. The TECU automatically clears the faults
transmission operation. The HCM main battery power is from history after 200 hours. The HCM automatically clears
fused 12-volt feed that runs through the HCM 38-Way a fault from history after that fault has been Inactive for
Vehicle Connector with the main ground wire returning to 200 hours.
the battery negative terminal.
Possible Causes
detects the fault:
- Power Supply Harness to the HCM
less than 16 volts. - Low batteries or bad main power connection
• HCM System Battery Voltage Low Fault is Inactive. - Charging system

The following conditions must be met to set the fault • Basic hand tools
code Active: • Eaton® Test Adapter Kit J43318
• FMI 14 is set when the HCM battery voltage drops • Digital Volt/Ohm Meter J46708
below 9 volts for 10 seconds.
• ServiceRanger
Note: When troubleshooting an Inactive code refer to the
Fallback
• Red “Hybrid Stop” lamp will display if there are
additional fault codes caused by the low or weak
voltage. This feature was added with HCM Software
1107 and higher.

TRTS1000 Fault Isolation Procedures | Fault Code 9 - Weak Battery Voltage
Harness Front View Typical Relay Switch

29 34
23 28
37 38
13 22
35 36
30
7 12 86
1 6
85 87
Ignition
Relay
30
HCM
HCM Ground 36
12V Plus
VBATT 38
12V Truck
Battery

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

A status and perform Electrical Pretest. V
page 1.
2. Key on.
battery cable.
• If Fault Code 9 is Inactive after performing the
Electrical Pretest, clear codes (see “Clear • If no codes, test is complete.
Inactive Faults” on page 13.) Go to Step V.
go to Step A.

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

J1939: SA 239 SPN 168 FMI 4

transmission and contains the software that controls both Electronic Control Unit (TECU) or HCM history using
the hybrid power electronics as well as the transmission ServiceRanger. The TECU automatically clears the fault
operation. The HCM main battery power is a fused, 12-volt from history after 200 hours. The HCM automatically clears
feed and runs through the HCM 38-Way Vehicle Connector a fault from history after it has been Inactive for 200 hours.
with the main ground wire returning to the battery
negative terminal. Possible Causes
Detection • FMI 4
detects the fault: - Power Supply Harness to the HCM.
• HCM ignition voltage is greater than 7 volts and - Low batteries or bad main power connection.
less than 16 volts. - Charging system.

code Active:
• FMI 4 is set when the HCM battery voltage drops
below 7 volts for more than 1 second. • Digital Volt/Ohm Meter J46708
• ServiceRanger
“Product Diagnostic Mode (PDM)” on page 19
Fallback
• Red “Hybrid Stop” lamp will display if there are
additional fault codes caused by the low or weak
voltage. This feature was added with HCM Software
1107 and higher.

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

29 34
23 28
37 38
13 22
35 36
30
7 12 86
1 6
85 87
Ignition
Relay
30
HCM
HCM Ground 36
12V Plus
VBATT 38
12V Truck
Battery

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

page 1.
2. Key on.
battery cable.
• If Fault Code 10 is Inactive after performing
the Electrical Pretest, see “Clear Inactive • If no codes, test is complete.
Faults” on page 13. Go to Step V.
go to Step A.
• If a code other than 10 appears, see “Fault
Code Isolation Procedure Index” on page 14.

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

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

The Transmission Electronic Control Unit (TECU) is Only Inactive faults can be cleared from the TECU or HCM
mounted to the transmission and contains all of the history using ServiceRanger. The TECU automatically clears
software to control the transmission; however, the hybrid the faults from history after 200 hours. The HCM
Control Module (HCM) controls the operation of the TECU automatically clears a fault from history after it has been
during hybrid operation. Inactive for 200 hours.
Detection Possible Causes

The following preconditions must be met before the system This fault code can be caused by any of the following:
detects the fault: • FMI 12: Electric Shifter
• TECU ignition voltage is greater than 7 volts and
less than 16 volts. Additional Tools
The following conditions must be met to set the fault • ServiceRanger
code Active:
• FMI 12 is set if the TECU detects an intermittent
failure in the Electronic Shifter position.
Fallback
• Red “Service” light illuminates and an “F” flashes
in the gear display (only if the fault occurs after
power up).
• Fault is stored in TECU memory.
• If the fault code occurs after power up, the
transmission remains in the current gear and the
clutch opens.

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

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

A status.

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

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

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

mounted to the transmission and contains all of the history using ServiceRanger. The TECU automatically clears
software to control the transmission operation; however, the fault from history after 200 hours. The HCM
the Hybrid Control Module (HCM) controls the operation of automatically clears the fault from history after it has been
the TECU during hybrid operation. Inactive for 200 hours.

detects the fault: • FMI 13: Improper TECU configuration software
• TECU is powered and ignition voltage is greater
than 7 volts and less than 16 volts. Additional Tools
code Active:
• FMI 13 is set when the TECU is not reading valid
information from memory, including the
transmission table and calibration values within 1
second of power up.
Fallback
• Red “Service” light illuminates and “F” flashes in
the gear display.
• If the fault occurs at power up the vehicle does
not crank.

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

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

A status.

Connector:
• If Fault Code 12 is Active, replace the
Transmission Electronic Control Unit (TECU).

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

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

connected to the shift device, which transmits driver mode history using ServiceRanger. The TECU automatically clears
selection data. The only compatible shift devices are the faults from history after 200 hours. The HCM automatically
Eaton® Push Button Shift Control (PBSC) and clears a fault from history after it has been Inactive for
OEM-supplied shift lever (if equipped with park). The TECU 200 hours.
checks the vehicle for the type of shift device during the
first power up. Possible Causes
Detection • FMI 2: Shifter is in between detent positions or
The following preconditions must be met before the system sensor is out of calibration.
detects the fault:
• FMI 3: Sensor input is shorted high or sensor
• TECU ignition voltage is greater than 7 volts and ground in open
less than 16 volts.
• FMI 4: Sensor input is open circuit or shorted
• TECU System Battery Voltage Low Fault is Inactive. to ground
• TECU is being powered up for the first time and no
shift device has been configured. Additional Tools
The following conditions must be met to set the fault • Eaton Test Adapter Kit
code Active: • Digital Volt/Ohm Meter
• FMI 2 is set when the shifter is not returning a • ServiceRanger
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
Fallback
• “F” appears in the gear display.
• TECU changes to AutoShift control.
• Engine does not crank.

TRTS1000 Fault Isolation Procedures | Fault Code 14 - Invalid Shifter Range
Harness Front View
(TECU - Vehicle Interface Connector) 1 4-way Park Pawl Actuator
6 Connector
7 3
12
2
36 35
22 13
38 37
1
4
28 23
34 29
Park Pawl
TECU
Actuator
Shift Return (Minus) 17 1 Park Pawl Actuator
Shift Control Input 1 16 3 Park Pawl Actuator
Shift Control (Plus) 31 2 Park Pawl Actuator

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

Purpose: Verify supply voltage at Shift Lever. Purpose: Verify voltage of Shift Lever in neutral po-
A B sition.
1. Review and follow the “Warnings & Cautions” on 1. With the Actuator/Shift Lever in neutral, check
page 1. voltage on the following pins:
2. Disconnect the 4-Way Connector to the - Pin 3 to ground
Park Pawl Actuator. - Pin 4 to ground
3. Key on. • If voltage is between 2.25–2.75,

go to Step C.
4. Check for 12-volt supply at 4-Way Connector at
Pin 1 and Pin 2: • If voltage is outside the range, replace the Park
Pawl Mechanism Sensor, then go to Step V.
• If voltage between Pin 1 and Pin 2 is ±0.2 volts
of battery voltage, go to Step B.
• If voltage is outside the range, go to Step D. Connection Measurement
Pin 3 to ground
Pin 4 to ground
Pin 1 to Pin 2

TRTS1000 Fault Isolation Procedures | Fault Code 14 - Invalid Shifter Range Test
Purpose: Verify continuity of TECU Harness. Purpose: Verify continuity of TECU Harness.
C D
1. Disconnect the TECU Vehicle Harness 1. Disconnect the TECU Vehicle Harness
38-way connector. 38-way connector.
2. Check continuity between: 2. Check continuity between:
- 38-Way Connector Pin 15 and 4-Way Connector - 38-Way Connector Pin 17 and 4-Way Connector
Pin 4 Pin 1
- 38-Way Connector Pin 16 and 4-Way Connector - 38-Way Connector Pin 31 and 4-Way Connector
Pin 3 Pin 2
• If continuity is complete, replace the • If continuity is complete, replace the
Transmission Electronic Control Unit (TECU), Transmission Electronic Control Unit (TECU),
then go to Step V. then go to Step V.
• If an open is found, repair the Vehicle Harness, • If an open is found, repair the Vehicle Harness,
then go to Step V. then go to Step V.
Connection Measurement Connection Measurement
Pin 15 to Pin 4 Pin 17 to Pin 1
Pin 16 to Pin 3 Pin 31 to Pin 2

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

V
1. Key off.
2. Reconnect all connectors.
3. Key on.
4. Clear Codes, see “Clear Inactive Faults” on page 13.
go to Step A.
• If a fault code other than 14 appears, see
“Fault Code Isolation Procedure Index” on
page 14.

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

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

The High Integrity Link (HIL) is a high-speed twisted pair Only Inactive faults can be cleared from the TECU or HCM
500K proprietary data link that connects the Transmission history using ServiceRanger. The TECU automatically clears
Electronic Control Unit (TECU) to the Push Button Shift faults from history after 200 hours. The HCM automatically
Control (PBSC). Each module contains an internal 120 ohm clears faults from history after that fault has been Inactive
resistor. The HIL carries information such as driver mode for 200 hours.
selection and fault information to illuminate the
“Service” light. Possible Causes
Detection • FMI 2
detects the fault: - HIL Data Link
• TECU ignition voltage is greater than 7 volts and - PBSC

less than 16 volts. - TECU
• TECU System Battery Voltage Low Fault is Inactive. - Power Supply Harness from TECU to PBSC
• TECU driver interface configuration is set to HIL.
Additional Tools
FMI 2 is set when the TECU loses communication for 5 • Eaton® Test Adapter Kit J43318
seconds or more with the PBSC.
Note: When troubleshooting an Inactive code refer to the • ServiceRanger
Fallback
When Fault Code 16 sets the following conditions occur:
• An “F” appears in the gear display.
• Push Button Mode Light flashes next to the
selected mode and the “Service” light remains off.
• Push Button lights come on and then remains off if
the data link fails at power up.
• Operation mode changes to AutoShift
Fallback mode.
• If the code is Active during power up, transmission
does not engage a gear.
• If the fault is Active while driving, transmission
remains in the current gear. It then shifts into the
default gear once the vehicle stops. Clutch opens at
idle and closes if the throttle is pressed. The vehicle
moves into the default start gear only.

Fault Code 16 - High Integrity Link (HIL) Test | Fault Isolation Procedures TRTS1000
Harness Front View Harness Front View
TECU - Vehicle Interface Connector 1 Push Button Shift Control Connector
6
7
12
K J H G F E D C B A
36 35
1 K1 A1
22 13
2
38 37
3 K3 A3
28 23
34 29
TECU PBSC
HIL Low 27 F2 HIL Low
HIL High 28 F1 HIL High
Shift Power (+) 31 C1 Shift Power (+)
Shift Power (-) 25 J3 Shift Power (-)

Fault Code 16 - High Integrity Link (HIL) Test

Purpose: Check for Active or Inactive fault code Purpose: Verify voltage at Push Button Shift Con-
A status. C troller.

page 1.
2. Disconnect the 30-Way Push Button Shift
2. Retrieve Active fault codes and FMIs with Ser- Control Connector.
3. Key on.
3. Key on and observe the red Push Button
4. Connect voltmeter leads to Pin F1 and Pin F2.
“Service” light.
Note: Make sure the Volt/Ohm Meter is on the
• If the red “Service” light turns on,
proper scale (around 10 volts AC).
go to Step C.
• If the red “Service” light does not turn on, • If the voltage is 0.10 volts AC or greater,
go to Step B. replace the Shift Control (only if fault code
is Active), then go to Step V.
• If the voltage is out of range, go to Step F.
Pin F1 to Pin F2
Purpose: Verify voltages at Vehicle Harness.
B
1. Disconnect Shift Control 30-Way Connector.
2. Key on.
3. Measure voltage on 30-Way Connector between
Pin J3 and Pin C1.
• If voltage is within 0.6 volts of battery voltage,
go to Step C.
• If out of range, go to Step D.
Pin J3 to Pin C1

Purpose: Verify continuity from Vehicle Harness to Purpose: Verify continuity from Push Button Shift
D Push Button Shift Controller. E Controller circuits to ground.

2. Disconnect negative battery cable. 2. Measure the resistance between:
3. Disconnect Vehicle Harness 38-Way Connector. - Shift Control 30-Way Connector Pin C1
and Vehicle Harness 38-Way Connector Pin 31.
Note: On Peterbilts, disconnect gear display. - Shift Control 30-Way Connector Pin C1
4. Measure resistance between: and ground.
- Shift Control 30-Way Connector Pin J3 and • If resistance between Pin C1 and Pin 31 is
Vehicle Harness 38-Way Connector Pin 25. 0–0.3 ohms and resistance between Pin C1
and ground is 10K ohms or greater, replace
• If resistance between Pin J3 and Pin 25 is
0–0.3 ohms, go to Step E.
(Only if Fault Code is Active).
• If any of the above conditions are not met,
repair the Vehicle Harness between the Shift
repair the Vehicle Harness between the TECU
Control and TECU, then go to Step V.
and Shift Control, then go to Step V.
Pin J3 to Pin 25
Pin C1 to Pin 31
Pin C1 to ground

Purpose: Verify continuity from Push Button Shift Purpose: Verify continuity from Vehicle Harness to
F Controller circuits to ground. G Push Button Shift Controller.

2. Disconnect negative battery cable. 2. Measure resistance between:
3. Disconnect Vehicle Harness 38-Way Connector. - Shift Control 30-Way Connector Pin F2 and
Vehicle Harness 38-Way Connector Pin 27.
4. Measure resistance between: - Shift Control 30-Way Connector Pin F2
- Shift Control 30-Way Connector Pin F1 and ground.
and Vehicle Harness 38-Way Connector Pin 28.
• If resistance between Pin F2 and Pin 27 is
- Shift Control 30-Way Connector Pin F1
0–0.3 ohms and resistance between Pin F2
and ground.
and ground is 10K ohms or greater, replace
• If resistance between Pin F1 and Pin 28 is Transmission Electronic Control Unit (TECU)
0–0.3 ohms and if resistance between Pin F1 (Only if Fault Code is Active). Go to Step V.
and ground is 10K ohms or greater,
go to Step G.
• If any of the above conditions are not met, Control and TECU, then go to Step V.
Control and TECU, then go to Step V.
Connection Measurement Pin F2 to Pin 27
Pin F1 to Pin 28 Pin F2 to ground
Pin F1 to ground


V
1. Key off.
2. Reconnect all connectors and negative
battery cable.
3. Key on.
6. Check for codes see “View Active and Inactive
go to Step A.

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

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

The Start Enable Relay is wired into the Transmission Only Inactive faults can be cleared from the TECU or HCM
Electronic Control Unit (TECU) on the coil side of the relay. history using ServiceRanger. The TECU automatically clears
At key on, the HCM determines which starting method to the faults from history after 200 hours. The HCM
use (high-voltage Motor/Generator or Engine Starter). If the automatically clears a fault from history after it has been
HCM uses the standard engine Starter, the 12-volt Cranking Inactive for 200 hours.
Relay is energized supplying battery power to the Start
Enable Relay main feed, which then powers the Possible Causes
Starter Solenoid. This fault code can be caused by any of the following:
• FMI 3, 4
Detection
The following preconditions must be met before the system - Loose or corroded connections, bent or burnt
detects the fault: pins, short to ground, open, or short to VBATT
on the circuit.
• Transmission Electronic Control Unit (TECU)
ignition voltage is greater than 7 volts and less than - Start Enable Relay
16 volts. - TECU

code Active:
• FMI 3 is set when the TECU detects an open or
short in the control circuit of the Start Enable Relay • Digital Volt/Ohm Meter J46708
for 1 second or greater. • ServiceRanger
• 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.
Fallback
• Red “Service” light illuminates and an “F” flashes in
the gear display.
• If the fault sets at power up the engine still cranks,
provided the high-voltage batteries have a
sufficient State of Charge (SOC).
• If the fault sets while driving, the vehicle continues
to operate.

Fault Code 17 - Start Enable Relay | Fault Isolation Procedures TRTS1000
Front Harness View
(TECU - Vehicle Interface Connector) 1
6
7
12
36 35
22 13
30
38 37
86
28 23
34 29 87
85
TECU Start Enable

Relay
Start Enable Minus 4 85
Start Enable Plus 32 86

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

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of Transmission
A status. C Harness circuits.

page 1.
2. Disconnect negative battery cable.
3. Disconnect the Transmission Harness
38-way connector.
View FMIs present.
4. Measure resistance between Vehicle Harness
3. Exchange the current Start Enable Relay with
38-Way Connector Pin 32 and Pin 4:
another relay and see if fault returns:
• If resistance between Pin 32 and Pin 4 is
• If fault does not return with new relay, replace
40–120 ohms, go to Step D.
the Start Enable Relay (only if fault code is
Active), then go to Step V. • If resistance is outside of range, repair the
Vehicle Harness for an open circuit, then
• If fault returns with new relay, go to Step B.
go to Step V.
Pin 32 to Pin 4
Purpose: Verify FMI set.

B
1. Which FMIs were listed from Step A?
• If FMI 3 is listed, go to Step C.
• If FMI 4 is listed, go to Step E.

Fault Code 17 - Start Enable Relay Test | Fault Isolation Procedures TRTS1000
Purpose: Verify voltages at Transmission Harness. Purpose: Verify continuity of Transmission

D E Harness circuits to ground.

2. Measure voltage between Vehicle Harness 38-Way 2. Disconnect battery cable.
Connector Pin 32 and ground:
Note: The voltage reads 5 volts for only 38-Way Connector.
1–2 seconds. 4. Measure the resistance between Vehicle Harness
• If the voltage between Pin 32 and ground is 38-Way Connector Pin 32 and ground:
5 volts, replace the Transmission Electronic • If the resistance between 32 and ground is 10K
Control Unit (TECU) (only if fault code is ohms or greater, replace the Transmission
Active), then go to Step V. Electronic Control Unit (TECU) (only if fault
• If the voltage between Pin 32 and ground is code is Active), then go to Step V.
12 volts, repair the short to VBATT on the • If the resistance is outside of range, repair the
harness. Voltage should remain at 5 volts for Vehicle Harness for a short to ground, then
1–2 seconds after initial key on. Go to Step V. go to Step V.
Connection Measurement Connection Measurement
Pin 32 to ground Pin 32 to ground

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

V
1. Key off.
battery cable.
3. Key on.
go to Step A.

Fault Code 18 - ECA Communication | Fault Isolation Procedures TRTS1000
Fault Code 18 - ECA Communication

J1939: SA 239 SPN 520200 FMI 2, 9

The Electric Clutch Actuator (ECA) controls the position of Only Inactive faults can be cleared from the Transmission
the clutch assembly. The ECA communicates with the Electronic Control Unit (TECU) or HCM history using
Hybrid Control Module (HCM) over the proprietary ServiceRanger. The TECU automatically clears faults from
Controller Area Network (CAN) data link to change position, history after 200 hours. The HCM automatically clears a
show faults or transmit other operation information. fault from history after that fault has been Inactive for
200 hours.
Detection
The following preconditions must be met before the system Possible Causes
detects the fault: This fault code can be caused by any of the following:
• HCM ignition voltage is greater than 7 volts and • FMI 9
less than 16 volts. - CAN Data Link from the ECA to the link
• ECA ignition voltage is greater than 8.5 volts. - ECA
• HCM CAN data link error is Inactive. - HCM
• FMI 9 is set when the ECA loses communication on • Eaton® Test Adapter Kit J43318
the CAN Data Link for 2 seconds. • Digital Volt/Ohm Meter J46708
• ServiceRanger
Fallback
• Red “Stop Hybrid” light illuminates.
• ECA maintains current clutch position or moves to
the last position commanded by the HCM. Upon
approaching idle, the clutch opens and remains in
this state.
• If the fault occurs at power up, the vehicle does
not crank.

TRTS1000 Fault Isolation Procedures | Fault Code 18 - ECA Communication
Harness Front View
29 34 ECA 8-Way Harness Connector
23 28
37 38 B D
A C
13 22 H G E
F
35 36
7 12
1 6
HCM ECA
CAN - Low (Vehicle) 27 2B CAN - Low
CAN - High (Vehicle) 28 2A CAN - High

Fault Code 18 - ECA Communication Test | Fault Isolation Procedures TRTS1000
Fault Code 18 - ECA Communication Test

A status. V
1. Retrieve Active fault codes and FMIs with 1. Key off.
Connector.
battery cable.
3. Key on.
• If Fault Code 18 FMI 9 is Active, see “Fault
Code 87 - CAN ECA Message (HCM)” on
page 269. 5. Drive the vehicle and attempt to reset the code.
• If Fault Code 18 FMI 9 is Inactive, test is 6. Check for codes, see “View Active and Inactive
complete. Go to Step V. Faults” on page 13.
• If Fault Code 18 appears, go to Step A. Find
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 24 - J1939 HCM Message (TECU)
Fault Code 24 - J1939 HCM Message (TECU)

J1587: MID 130 SID 231 FMI 9
J1939: SA 3 SPN 525 FMI 9

The Transmission Electronic Control Unit (TECU) Only Inactive faults can be cleared from the TECU or HCM
communicates with the Hybrid Control Module (HCM) over history using ServiceRanger. The TECU automatically clears
the J1939 data link during vehicle operation to exchange faults from history after 200 hours. The HCM automatically
requested gear and current gear information. clears a fault from history after it has been Inactive for 200
hours.
Detection
• TECU ignition voltage is greater than 7 volts and • FMI 9
less than 16 volts. - J1939 Data Link
• No J1939 data link fault currently Active in - HCM
the TECU.
Additional Tools
• FMI 9 is set when the TECU fails to receive • Digital Volt/Ohm Meter J46708
transmission data (such as a requested gear) for 2 • ServiceRanger
seconds or greater from the HCM, and it is still
communicating with other modules on J1939.
Note: When troubleshooting an Inactive code refer to the)
Fallback
When Code 24 is set the following conditions occur:
• Red “Service” light illuminates, and an “F” flashes
in the gear display.
Fallback mode.
• If the fault sets at power up, the engine does
not crank.
• If the fault sets while driving, the vehicle remains in
current gear. When the vehicle stops the clutch
opens and remains in this position.
• Amber “Check Hybrid” light may display on the
dash due to an Active Fault Code 48.

Fault Code 24 - J1939 HCM Message (TECU) | Fault Isolation Procedures TRTS1000

(TECU - Vehicle Interface Connector) (HCM - Vehicle Interface Connector)
1 29
6 34
7 23
12 28
36 35 37 38
22 13
13 22
38 37 35 36
28 23 7 12
34 29 1 6
J1939 Low 2 2 J1939 Low
TECU
HCM
J1939 High 3 3 J1939 High

TRTS1000 Fault Isolation Procedures | Fault Code 24 - J1939 HCM Message (TECU) Test
Fault Code 24 - J1939 HCM Message (TECU) Test

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of Vehicle Harness.
A status and perform Electrical Pretest. B
Connector.
3. Disconnect HCM Vehicle Harness
38-Way Connector.
• If no issues found during the Electrical Pretest,
4. Measure resistance between HCM Vehicle Harness
go to Step B.
• If issue was repaired during the Electrical
Pretest, go to Step V.
proper scale (around 200 ohm scale).
between 50–70 ohms, replace the Hybrid
Control Module (HCM), then go to Step V.
• If resistance is outside of range, repair J1939
Data link Harness, then go to Step V.
Pin 2 to Pin 3

Fault Code 24 - J1939 HCM Message (TECU) Test | Fault Isolation Procedures TRTS1000

V
1. Key off.
battery cable.
3. Key on.
go to Step A.

TRTS1000 Fault Isolation Procedures | Fault Code 26 - Clutch Slip
Fault Code 26 - Clutch Slip

J1939: SA 239 SPN 522 FMI 10, 23
Overview Possible Causes

The mechanical clutch assembly is controlled through the This fault code can be caused by any of the following:
Electric Clutch Actuator (ECA) which is mounted on the • FMI 10
clutch housing. The Hybrid Control Module (HCM) controls
the ECA position and monitors several variables to - Clutch Assembly
determine if there is a slip concern in the clutch when it is in
• FMI 23
the closed position.
Additional Tools
Detection
The following preconditions must be met before the system • Basic hand tools
detects the fault: • ServiceRanger
less than 16 volts.
• ECA ignition voltage is greater than 7 volts and less
than 16 volts.
• There is no Active fault code 18 or 87 present.

code Active:
• 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.
• FMI 23 is set when the HCM detects a clutch
overheat situation.
Note: A “CA” appears if the clutch is allowed to slip and
create heat beyond a set point. Do not use the
throttle as a hill hold device as it causes clutch
damage and a “CA.”
Fallback
• Red “Stop Hybrid” light or amber “Check Hybrid”
light illuminates.
Conditions to Set Fault Code Inactive

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

Fault Code 26 - Clutch Slip | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 26 - Clutch Slip
Fault Code 26 - Clutch Slip

Purpose: Check for Active or Inactive fault code Purpose: Verify fault codes present.
A status. C
1. Retrieve Active fault codes and FMIs with 1. Is Fault Code 27 FMI 13 Active?
• If Fault Code 27 FMI 13 is Active, see “Fault
Connector.
Code 27 - Clutch Disengagement” on
2. Which FMIs are present? page 105.
• If FMI 10 is listed, go to Step B. • If Fault Code 27 FMI 13 is Inactive,
go to Step D.
• If FMI 23 is listed, FMI 23 is set due to
excessive clutch heat. This can occur when the
throttle is being used as a hill hold or a worn
clutch is slipping on long/steep grades.
Contact Eaton at 1-800-826-HELP (4357).
Purpose: Verify operation of the clutch.

D
1. Key on.
Purpose: Verify fault codes present.
B 2. Start engine.
3. Drive the vehicle under load in highest gear
possible. At a steady speed, quickly and fully press
1. Is Fault Code 64 Active?
and hold the throttle:
• If Fault Code 64 is Active, see “Fault Code 64 -
• If Fault Code 26 is Active, replace the Clutch.
ECA Fault” on page 201.
See CLMT-0365 for installation procedures.
• If Fault Code 64 is Inactive, go to Step C. Go to Step V.
Go to Step V.

Fault Code 26 - Clutch Slip | Fault Isolation Procedures TRTS1000

V
1. Key off.
2. Key on.
battery cable.
go to Step A.

TRTS1000 Fault Isolation Procedures | Fault Code 27 - Clutch Disengagement
Fault Code 27 - Clutch Disengagement

J1939: SA 239 SPN522 FMI 7, 13

The mechanical clutch assembly is controlled through the This fault code can be caused by any of the following:
Electric Clutch Actuator (ECA) that is mounted on the clutch • FMI 7
housing. The Hybrid Control Module (HCM) controls the
ECA position and monitors several variables to determine - Clutch Assembly
if their is a slip concern in the clutch when it is in the - ECA
closed position.
• FMI 13
Detection - Clutch Assembly
- Cross-Shafts
detects the fault:
• HCM ignition voltage is greater than 7 volts and Additional Tools
less than 16 volts.
• ECA ignition voltage is greater than 7 volts and less
• ServiceRanger
than 16 volts.

code Active:
• FMI 7 is set when the engine torque is greater than
400 N•m, 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 13 is set when the ECA fails to calibrate during
power up due to a mechanical binding issue and
there are no other ECA faults present.
Fallback
• If this fault occurs while driving, the vehicle
continues to operate and the transmission will shift
to neutral once the vehicle stops.

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

Fault Code 27 - Clutch Disengagement | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 27 - Clutch Disengagement Test
Fault Code 27 - Clutch Disengagement Test

Purpose: Check for Active or Inactive fault code Purpose: Verify integrity of the Cross-Shaft
A status. C Assembly.

2. Remove Electric Clutch Actuator from
Connector.
Transmission Housing.
2. If Fault Code 64 is listed:
3. Attempt to rotate the Cross-Shaft and Yoke
• If Fault Code 27 FMI 7 or 13 are listed with an Assembly by hand.
Active Fault Code 64, see “Fault Code 64 - ECA
• If the Cross-Shaft Assembly rotates by hand
Fault” on page 201.
from the Release Bearing to the Transmission
• If Fault Code 27 FMI 7 is listed with no Active Case, replace the Clutch. See CLMT0365 for
fault code 64, go to Step B. installation procedure. Go to Step V.
• If Fault Code 27 FMI 13 is listed with no Active • If the Cross-Shaft Assembly does not rotate by
Fault Code 64, go to Step C. hand, replace the Cross-Shaft, bushings, and
grease. Repeat this step.
Purpose: Verify FMI set.

B Purpose: Verify repair.
V
1. Key on.
1. Key off.
2. Start engine.
2. Key on.
3. Launch vehicle and drive until 6th gear is obtained.
Then slow down to a stop. 3. Clear codes, see “Clear Inactive Faults” on page 13.
4. Repeat the launch 5 times. 4. Reconnect all connectors and the negative
battery cable.
5. Is FMI 7 Active?
• If FMI 7 is Active, replace the Clutch. See
CLMT0365 for installation procedure. 6. Check for codes, see “View Active and Inactive
Go to Step V. Faults” on page 13.
• If FMI 7 is Inactive, test is complete. • If no codes, test is complete.
Go to Step V.
go to Step A.

Fault Code 32 - Loss of Switched Ignition Power (TECU) | Fault Isolation Procedures TRTS1000
Fault Code 32 - Loss of Switched Ignition Power (TECU)

J1939: SA 3 SPN 43 FMI 2
J1587: MID130 PID 43 FMI 2

mounted to the transmission and it contains all of the history using ServiceRanger. The TECU automatically clears
software to control the transmission operation; however, faults from history after 200 hours. The HCM automatically
the Hybrid Control Module (HCM) controls the operation of clears a fault from history after it has been Inactive for
the TECU during hybrid operation. Ignition power is fused 200 hours.
and provided from the Key Switch. Application of this input
initiates the power-up sequence. Possible Causes
Detection • FMI 2
detects the fault: - Ignition power supply to TECU
• Output Shaft Speed must be greater than 0 RPM. - TECU

• FMI 2 is set when the TECU loses ignition power • Digital Volt/Ohm Meter J46708
during operation for 2 seconds or greater.
• ServiceRanger
Fallback
• Red “Service” light displays and an “F” flashes in
the gear display.
Fallback mode.
• If the fault sets at power up, engine does not crank.
• If the fault sets while driving, the vehicle remains
in the current gear and the clutch opens when the
vehicle approaches idle. If the throttle is pressed,
the default start gear engages and the clutch will
close.
• No lights are illuminated on the Push Button if the
fault occurs prior to power up or while in neutral.
Only the current Mode light will be illuminated if the
fault occurs while driving.The Push Button starts to
tone when the vehicle approaches a stop and
continues until power is returned.

TRTS1000 Fault Isolation Procedures | Fault Code 32 - Loss of Switched Ignition Power (TECU)
Front View Typical Relay Switch

6
7
12
36 35
22 13
38 37
30
28 23 86
34 29
85 87
87
Vehicle 86
Ignition Ignition
Relay
Ground 85
30
TECU
12V Plus
Ignition 35
12V Truck
Battery

Fault Code 32 - Loss of Switched Ignition Power (TECU) | Fault Isolation Procedures TRTS1000
Fault Code 32 - Loss of Switched Ignition Power (TECU)

2. Key on.
Connector.
2. Perform the Electrical Pretest (see “Electrical
Pretest” on page 25). 4. Reconnect all connectors and the negative
battery cable.
• If Fault Code 32 is Active after performing
Electrical Pretest, replace the Transmission 5. Drive the vehicle and attempt to reset the code.
Electronic Control Unit (TECU) (only if fault
code is Active), then go to Step V.
the Electrical Pretest, clear codes
(see “Clear Inactive Faults” on page 13), • If Fault Code 32 appears, go to Step A. Find
then go to Step V. error in testing.
• If a code other than 32 appears, go to “Fault

TRTS1000 Fault Isolation Procedures | Fault Code 33 - Low Battery Voltage (TECU)
Fault Code 33 - Low Battery Voltage (TECU)

J1587: MID 130 PID 168 FMI 4
J1939: SA 3 SPN168 FMI 4

The Transmission Electronic Control Unit (TECU) is This fault code can be caused by any of the following:
mounted to the transmission and contains the software to • FMI 4 has several areas that may cause this fault:
control the transmission operation; however, the Hybrid
Control Module (HCM) controls the operation of the TECU - Power supply to TECU
during normal hybrid mode operation. The HCM main - Low batteries or bad main power connection
battery power is a fused 12-volt feed that runs through the - Charging system
HCM 38-Way Vehicle Connector with the main ground wire
returning to the battery negative terminal. - TECU
Detection Additional Tools

detects the fault: • Eaton® Test Adapter Kit J43318
• TECU ignition voltage is greater than 7 volts and • Digital Volt/Ohm Meter J46708
less than 16 volts.
• ServiceRanger
code Active:
• FMI 4 is set when the TECU battery voltage drops
below 7 volts for more than 1 second.
Fallback
• TECU switches to AutoShift Fallback mode.
• No lights 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
maintains the current gear. The clutch opens when
the vehicle stops.

200 hours.

Fault Code 33 - Low Battery Voltage (TECU) | Fault Isolation Procedures TRTS1000
Front View
6
7
12
36 35
22 13
38 37
28 23
34 29
TECU 12V Truck

Battery
TECU Ground 36 Ground
TECU Power 38 12V Plus

TRTS1000 Fault Isolation Procedures | Fault Code 33 - Low Battery Voltage (TECU)
Fault Code 33 - Low Battery Voltage (TECU)

A status and perform Electrical Pretest.

Connector.
Pretest” on page 25):
Electrical Pretest, replace Transmission
Electronic Control Unit (TECU) (only if Fault
Code is Active), then go to Step V.
the Electrical Pretest, clear codes (see “Clear
Inactive Faults” on page 13.) Go to Step V.

V
1. Key off.
2. Key on.
battery cable.
go to Step A.

Fault Code 34 - Weak Battery Voltage Fault (TECU) | Fault Isolation Procedures TRTS1000
Fault Code 34 - Weak Battery Voltage Fault (TECU)

J1587: MID 130 PID 168 FMI 14
J1939: SA 3 SPN 168 FMI 14

mounted to the transmission and contains the software that • FMI 14 has several areas that may cause this fault:
controls transmission operation. The Hybrid Control
Module (HCM) controls the operation of the TECU during - Power supply to TECU
normal hybrid mode operation. The HCM main battery - Low batteries or bad main power connection
power is a fused 12-volt feed that runs through the HCM - Charging system
38-Way Vehicle Connector with the main ground wire
returning to the battery negative terminal. - TECU

detects the fault: • Eaton® Test Adapter Kit J43318
• TECU ignition voltage is greater than 7 volts and • Digital Volt/Ohm Meter J46708
less than 16 volts.
• ServiceRanger
• TECU System Battery Voltage Low Fault is Inactive.

code Active:
• FMI 14 is set when the TECU battery voltage drops
below 9 volts for 10 seconds.
Fallback
• 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.

200 hours.

TRTS1000 Fault Isolation Procedures | Fault Code 34 - Weak Battery Voltage Fault (TECU)
Front View
6
7
12
36 35
22 13
38 37
28 23
34 29
TECU 12V Truck

Battery
TECU Ground 36 Ground
TECU Power 38 12V Plus

Fault Code 34 - Weak Battery Voltage Fault (TECU) | Fault Isolation Procedures TRTS1000
Fault Code 34 - Weak Battery Voltage Fault (TECU)

2. Key on.
Connector.
Pretest” on page 25): 4. Reconnect all connectors and the negative
battery cable.
Electrical Pretest, replace Transmission 5. Drive the vehicle and attempt to reset the code.
Electronic Control Unit (TECU) (only if Fault
the Electrical Pretest, clear codes (see “Clear
Inactive Faults” on page 13.) Go to Step V. • If Fault Code 34 appears, go to Step A. Find
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 35 - J1939 Communication Link (TECU)
Fault Code 35 - J1939 Communication Link (TECU)

J1587: MID 130 SID 231 FMI 2
J1939: SA 3 SPN 639 FMI 2

J1939 is a high-speed twisted pair 250K data link with one This fault code can be caused by any of the following:
120 ohm resistor at each end of the link. The Transmission • FMI 2
Electronic Control Unit (TECU) is connected to the J1939
data link at the 38-Way Connector. This link is used to - J1939 Data Link
transmit information to the Hybrid Control Module (HCM) - TECU
as well as communicate with or receive data from the other
modules on the network such as the Electronic Control Unit Additional Tools
(ECU). • Basic hand tools
Detection • Eaton® Test Adapter Kit J43318
The following preconditions must be met before the system • Digital Volt/Ohm Meter J46708
detects the fault: • ServiceRanger
less than 16 volts.
• TECU Battery Voltage Low fault is Inactive.

code Active:
• FMI 2 is set when the TECU loses communication
with all modules on the J1939 data link for 5 or
more seconds.
Fallback
the gear display.
• The operation mode changes to AutoShift
Fallback mode.
• If the fault sets at power up, the engine will
not crank.
current gear and the clutch opens when vehicle
speed approaches idle.

200 hours.

Fault Code 35 - J1939 Communication Link (TECU) | Fault Isolation Procedures TRTS1000
Front Harness View
6
7 9-way Diagnostic Connector
12
36 35 E D
C
22 13 A B
F
38 37
G J
H
28 23
34 29
J1939 Low TECU 2 D J1939 Low
TECU 9-way Diagnostic

Connector
J1939 High TECU 3 C J1939 High

Fault Code 35 - J1939 Communication Link (TECU)

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of Vehicle Interface
A status. B circuits.

Connector.
3. Disconnect TECU Vehicle Harness
2. Key on.
38-way connector.
3. Select the “Vehicle Components” screen and view
4. Measure resistance between TECU Vehicle Harness
the various modules reporting on the J1939 link:
• If the TECU is not reporting on J1939, but the
HCM is listed, go to Step B.
• If neither the HCM nor the TECU are reporting
on J1939, go to Step C. • If resistance between Pin 2 and Pin 3 is
between 50–70 ohms, replace Transmission
Electronic Control Unit (TECU), then
go to Step V.
J1939 Data link Harness, then go to Step V.
Pin 2 and Pin 3

Fault Code 35 - J1939 Communication Link (TECU) | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of Transmission Purpose: Verify continuity of Transmission

C Harness diagnostic connector. D Harness diagnostic connector circuits to ground.

2. Measure resistance between the diagnostic 2. Measure the resistance between the following
connector 9-Way Pin C and Pin D. 9-Way Diagnostic Connector Pins:
• If resistance between Pin C and Pin D is - Pin C to ground
between 50–70 ohms, go to Step D. - Pin D to ground
• If resistance is 70 ohms or greater, one or • If resistance between Pin C to ground and Pin
more of the terminating resistors on the J1939 D to ground are both 10K ohms or greater,
Data Link Harness is missing or out of range, attempt to communicate with another vehicle
or there is an open in the link. Go to Step V. to ensure ServiceRanger is working. If
ServiceRanger fails to communicate with
• If resistance is 50 ohms or less, there is an another vehicle, call 1-800-826-HELP (4357).
additional terminating resistor present.
Repair the OEM J1939 Data Link Harness, then • If resistance is outside of range, repair J1939
go to Step V. Data Link Harness for a short to ground, then
go to Step V.
Pin C and Pin D
Pin C to ground
Pin D to ground

Purpose: Verify repair

V
1. Key off.
2. Key on.
battery cable.
go to Step A.

Fault Code 36 - J1939 Engine Message (TECU) | Fault Isolation Procedures TRTS1000
Fault Code 36 - J1939 Engine Message (TECU)

J1587: MID 130 SID 231 FMI 14
J1939: SA 3 SPN 639 FMI 14

J1939 is a high-speed twisted pair 250K data link with one Only Inactive faults can be cleared from the TECU or HCM
120 ohm resistor at each end of the link. The Transmission history using ServiceRanger. The TECU automatically clears
Electronic Control Unit (TECU) is connected to the J1939 faults from history after 200 hours. The HCM automatically
data link at the 38-Way Connector. This link is used to clears a fault from history after it has been Inactive for
transmit information to the Hybrid Control Module (HCM) 200 hours.
and communicate with other modules on the network such
as the Engine Control Unit (ECU). Possible Causes
Detection • FMI 14
detects the fault. - J1939 data link
• TECU ignition voltage is greater than 7 volts and - ECU

less than 16 volts.
Additional Tools
• TECU Battery Voltage Low fault is Inactive.
• TECU J1939 data link fault is Inactive.
• Eaton® Test Adapter Kit
Conditions to Set Fault Code Active • Digital Volt/Ohm Meter
code Active:
• FMI 14 is set when the TECU fails to receive engine
ECU data like engine torque for 5 seconds or
greater, and it is still communicating with other
modules on J1939.
Fallback
When Fault Code 36 is set the following conditions occur.
the gear display.
• If the fault occurs while moving, the TECU goes
into AutoShift Fallback mode.
• Once the vehicle stops, start and reverse gears can
be selected and the transmission operates in
AutoSelect mode.
• If the fault occurs at power up, the vehicle
will crank.

TRTS1000 Fault Isolation Procedures | Fault Code 36 - J1939 Engine Message (TECU)
Front View
6
7
12
36 35
22 13
38 37
28 23
34 29
J1939 Low TECU 2
Engine ECM
TECU
J1939 High TECU 3
(refer to OEM engine wiring

diagram for pin outs)

Fault Code 36 - J1939 Engine Message (TECU) | Fault Isolation Procedures TRTS1000
Fault Code 36 - J1939 Engine Message (TECU)

A status.

Connector:
• If Fault Code 36 is Active, concern is either the
ECU or the Data Link from Engine ECU to
J1939 Data Link Backbone. Refer to OEM for
repair procedure.

TRTS1000 Fault Isolation Procedures | Fault Code 37 - Power Supply (TECU)
Fault Code 37 - Power Supply (TECU)

J1587: MID 130 SID 251 FMI 5
J1939: SA 3 SPN 610 FMI 5

mounted to the transmission and contains the software that • FMI 5
controls the transmission operation; however, the Hybrid
Control Module (HCM) controls the operation of the TECU - Power supply to TECU
during normal hybrid mode. The TECU main battery power - Low batteries or bad main power connection
is a fused, 12-volt feed that runs through the TECU 38-Way - Broken or corroded battery interconnect
Vehicle Connector with the main ground wire returning to straps may also be the cause of high
the battery negative terminal. resistance readings
detects the fault: • Basic hand tools
• TECU ignition voltage is greater than 7 volts and • Eaton® Test Adapter Kit J43318
less than 16 volts. • Digital Volt/Ohm Meter J46708
• TECU only runs this test if the Electric Shifter is • ServiceRanger
being cycled from N to gear.
Note: Changing the start gear from N allows this test to
run.

code Active:
• 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.
Fallback

clears a fault from history after that fault has been Inactive
for 200 hours.

Fault Code 37 - Power Supply (TECU) | Fault Isolation Procedures TRTS1000
Front View
6
7
12
36 35
22 13
38 37
28 23
34 29
TECU Power 38
Positive (+)
TECU
12V Battery
TECU Ground 36 Negative (-)
Warning! - Do Not Load Test at Diagnostic Port
4-Way Diagnostics Port
B A
C D
4-way
4-Way Diagnostic Port B - Service Bat. +

(Located at the left rear C - Service Bat. -
corner of the transmission.) A - Service Ignition +

TRTS1000 Fault Isolation Procedures | Fault Code 37 - Power Supply (TECU)
Fault Code 37 - Power Supply (TECU)

Purpose: Check for Active or Inactive fault code Purpose: Verify voltages at Transmission Harness
A status and perform Electrical Pretest. C diagnostic connector.
1. Retrieve Active fault codes and FMIs with 1. Locate diagnostic port on Transmission Harness.
2. Key on.
Connector.
3. Measure voltage between Pin B and Pin C.
Pretest” on page 25). • If voltage between Pin B and Pin C is within
• If Fault Code 37 is Active after performing the 0.6 volts of battery voltage, go to Step D.
Electrical Pretest, go to Step B. • If voltage is outside of range, repair battery
• If Fault Code 37 is Inactive after performing power supply to TECU. Fuse may be blown.
the Electrical Pretest, clear codes, see “Clear Repeat test.
Inactive Faults” on page 13. Go to Step V.
Pin B to Pin C
Purpose: Verify voltage at Transmission Harness

B Diagnostic Connector.
1. Locate diagnostic port on Transmission Harness.

Purpose: Verify voltages at Transmission Harness
2. Key on.
3. Measure voltage between Pin C and the battery
D diagnostic connector.
negative post.
1. Key on.
• If voltage between Pin C and battery negative
post is 0.70 volts or less, go to Step C. 2. Measure voltage between Pin A and Pin C.
• If voltage is outside of range, repair battery • If voltage between Pin A and Pin C is within
ground supply to TECU, then 0.6 volts of battery voltage, go to Step E.
go to Step V. • If voltage is outside of range, repair Ignition
Power Supply to ECU. Fuse may be blown.
Repeat test.
Pin C to negative Connection Measurement
Pin A to Pin C

Fault Code 37 - Power Supply (TECU) | Fault Isolation Procedures TRTS1000
Purpose: Verify integrity of Vehicle Interface

E Harness connections.
1. Key off.
3. Disconnect the Vehicle Harness 38-Way Connector.
4. Inspect main power 38-Way Connector Terminals
Pin 36 and Pin 38, inline 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, then go to Step V.

V
1. Key off.
2. Clean and reconnect all connectors.
3. Key on.
5. Drive vehicle and attempt to reset the code.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 38 - Battery Fan Relay
Fault Code 38 - Battery Fan Relay

J1939: SA 3 SPN 520243 FMI 3, 4, 5, 14

The Battery Fan Relay is normally an open relay connected Only Inactive faults can be cleared from the TECU or HCM
to the Hybrid Control Module (HCM) on the control side. history using ServiceRanger. The TECU automatically clears
When the HCM powers the control circuit, it closes the relay faults from history after 200 hours. The HCM automatically
contacts and turns on the relay. The Battery Fan Relay clears a fault from history after that fault has been Inactive
powers the Battery Fan located in the Power Electronics for 200 hours.
Carrier (PEC), cooling the high-voltage batteries.
Possible Causes
The following preconditions must be met before the system • FMI 3, 4, 5
detects the fault:
- Vehicle Harness from HCM to Battery Fan Relay
• The HCM ignition voltage is greater than 7 volts
and less than 16 volts. - Battery Fan Relay
- HCM
• FMI 14
code Active: - Battery Fan Relay
• FMI 3 is set when the HCM detects a short to - Battery Fan
battery in the coil circuit of the Battery Fan Relay. - Plugged Air Filter
• FMI 4 is set when the HCM detects a short to - Battery Fan Relay Main Power Supply
ground in the coil circuit of the Battery Fan Relay.
• FMI 5 is set when the HCM detects an open in the Additional Tools
coil circuit of the Battery Fan Relay. • Basic hand tools
• FMI 14 is set when the following conditions are • Eaton® Test Adapter Kit
true for 10 minutes:
• Digital Volt/Ohm Meter
- High-voltage battery temperature is greater than
• ServiceRanger
131 °F (55 °C)
- Difference between the minimum and maximum
battery temperatures is less than 33 °F (1 °C)
- No battery temperature faults from the Battery
Control Module
Fallback

Fault Code 38 - Battery Fan Relay | Fault Isolation Procedures TRTS1000
Front Harness View

(HCM - Hybrid System Interface Connector) Harness Connector View
29 (PEC 19 - Way)
34
23 28
19 8 9
37 38
18 7 2 10
13 22 17 6 1 3 11
35 36 16 5 4 12
15 14 13
7 12
1 6
HCM
Battery Fan
Battery Fan 26 86 Relay
Battery Fan Return 4 85
87
30 Battery Fan Supply

Cooling Fan Plus 12
Cooling Fan Minus 14 Ground
PEC
12V Plus
30
86
12V Truck
Battery
85 87

Fault Code 38 - Battery Fan Relay

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of HCM Harness
A status. C circuits.

page 1.
3. Disconnect the HCM Harness 38-Way Connector.
4. Measure the resistance between the HCM Harness
dures to avoid shock, burn or death from improp- • If the resistance between Pin 26 and Pin 4 is
erly handled high-voltage. 40–120 ohms, replace Hybrid Control Module
(HCM) (Only if Fault Code is Active), then
3. Exchange Battery Fan Relay with another relay to go to Step V.
see if fault returns.
• If the resistance is outside the range, repair
• If fault does not return with new relay, replace the Vehicle Harness for an open circuit, then
the Battery Fan Relay, then go to Step V. go to Step V.
Pin 26 to Pin 4
Purpose: Verify FMI present.

B
1. Which 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 3 is listed, go to Step D.
• If FMI 14 is listed, go to Step F.

Purpose: Verify voltages of HCM Harness circuits. Purpose: Verify continuity of HCM Harness
D E circuits.

2. Measure voltage between HCM Harness 38-Way 2. Disconnect negative battery cable.
Connector Pin 26 and ground at key on:
• If voltage between Pin 26 and ground is
4. Measure the resistance between HCM System
0 volts, replace the Hybrid Control Module
Harness 38-Way Connector Pins 26 and ground:
(HCM) (only is fault code is Active), then
go to Step V. • If resistance between Pin 26 and ground is
10K ohms or greater, replace the Hybrid
Control Module (HCM) (only is fault code is
12 volts, repair the short to VBATT on the
Active), then go to Step V.
Harness, then go to Step V.
Vehicle Harness for a short to ground, then
Connection Measurement go to Step V.
Pin 26 to ground
Pin 26 to ground

Purpose: Verify condition of PEC Air Filter Element. Purpose: Verify voltages of PEC Harness circuits.
F H
2. Remove and inspect the Air Filter* on the PEC Inlet 2. Disconnect the 19-Way Connector at the PEC.
and the Exhaust Screen on the PEC Outlet.
• If the Air Filter and Exhaust Screen are clean Pin 12 to Pin 14:
and free from debris, go to Step G.
• If voltage between Pin 12 and Pin 14 is
• If the Air Filter is dirty or the Exhaust Screen is ±0.2 volts of battery voltage, replace the
plugged, replace the Air Filter and clean the Power Electronics Carrier (PEC), then
Exhaust Screen. Go to Step V. go to Step V.
• If voltage between Pin 12 and Pin 14 is outside
of range, repair wiring or relay problem.
• * See Air Filter. Refer to OEM.
Pin 12 to Pin 14
Purpose: Verify operation of PEC Battery Fan.

G
1. Key off.
Connector in the cab.
3. Key on.
4. Go to Product Tests and 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 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.


V
1. Key off.
battery cable.
3. Key on.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 39 - Heat Exchanger Relay
Fault Code 39 - Heat Exchanger Relay

J1939: SA 239 SPN 520247 FMI 3, 4, 5

The Heat Exchanger Fan Relay is an open relay connected to Only Inactive faults can be cleared from the TECU or HCM
the Hybrid Control Module (HCM) on the control side. history using ServiceRanger. The TECU automatically clears
When the HCM turns on the relay, it powers the control faults from history after 200 hours. The HCM automatically
circuit, closing the relay contacts. The Heat Exchange Fan clears a fault from history after that fault has been Inactive
Relay powers the Heat Exchanger Fan located on the hybrid for 200 hours.
liquid cooling system radiator. The fan provides additional
airflow in certain situations such as slow driving or ePTO Possible Causes
operation. This fault code can be caused by any of the following:
• FMI 3, 4, 5
Detection
The following preconditions must be met before the system - Vehicle Harness from HCM to Heat
detects the fault: Exchanger Relay
• The HCM ignition voltage is greater than 7 volts - Heat Exchanger Relay
and less than 16 volts. - HCM
- Heat Exchanger Relay fuse
code Active:
• FMI 3 is set when the HCM detects a short to
battery in the coil circuit of the Heat Exchanger • Eaton® Test Adapter Kit
Fan Relay. • Digital Volt/Ohm Meter
• FMI 4 is set when the HCM detects a short to • ServiceRanger
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.
Fallback

Fault Code 39 - Heat Exchanger Relay | Fault Isolation Procedures TRTS1000

(HCM - Hybrid System Interface Connector)
29 34
23 28
37 38
13 22
36
30
35
86
7 12
1 6
85 87
HCM Heat Exchanger
Heat Exchange Fan HSD 35 86 Fan Relay
Heat Exchange Fan LSD 37 85
87 HEF Plus
30 HEF Supply
HEF Plus A
B Ground Fuse
HEF Minus
Heat Exchanger
Fan
12V Plus
12V Truck
Battery

Fault Code 39 - Heat Exchanger Relay

Purpose: Check for Active or Inactive fault code Purpose: Verify FMIs present.
A status. C
1. Retrieve Active fault codes and FMIs with 1. Which FMIs were listed from Step A?
Note: The Heat Exchanger Fan Relay must be
Connector.
wired according to Eaton requirements
2. Exchange Heat Exchanger Fan Relay with another (shown on previous page) for this test to
relay and see if the fault returns: work properly. If wired differently consult
OEM for correct wiring schematic.
• If fault does not return with new relay,
replace the Heat Exchanger Fan Relay, then • If FMI 5 is listed, go to Step D.
go to Step V.
Purpose: Verify configuration of HCM.

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).

Fault Code 39 - Heat Exchanger Relay | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of HCM Harness Purpose: Verify voltages of HCM Harness circuits
D circuits. E to ground.

2. Disconnect negative battery cable. 2. Measure the voltage between HCM System
Harness 38-Way Connector Pin 35 and ground.
• If voltage between Pin 35 and ground is 0
4. Measure the resistance between HCM Harness
volts, replace the Hybrid Control Module
38-Way Connector Pin 35 and Pin 37.
(HCM) (only if fault code is Active), then
• If resistance between Pins 35 and 37 is go to Step V.
40–120 ohms, replace the Hybrid Control
Module (HCM) (only if fault code is Active),
volts, repair the short to VBATT on the
then go to Step V.
harness, then go to Step V.
Vehicle Harness for an open circuit or blown
fuse, then go to Step V. Connection Measurement
Pin 35 to ground
Pin 35 to Pin 37

Purpose: Verify continuity of HCM Harness circuits Purpose: Verify repair.

F to ground. V
2. Disconnect negative battery cable. 2. Reconnect all connectors and negative
battery cable.
3. Key on.
4. Measure the resistance between HCM System
Harness 38-Way Connector Pin 35 and ground. 4. Clear codes, see “Clear Inactive Faults” on page 13.
• If resistance between Pin 35 and ground is 5. Drive the vehicle and attempt to reset the code.
Control Module (HCM) (only if fault code is
Vehicle Harness for a short to ground, then • If Fault Code 39 appears, go to Step A. Find
go to Step V. error in testing.
Pin 35 to ground

Fault Code 40 - Cooling Pump Relay | Fault Isolation Procedures TRTS1000
Fault Code 40 - Cooling Pump Relay

J1939: SA 239 SPN 520248 FMI 3, 4, 5, 14

The Cooling Pump Relay is an open relay connected to the Only Inactive faults can be cleared from the TECU or HCM
Hybrid Control Module (HCM) on the control side. When history using ServiceRanger. The TECU automatically clears
the HCM powers the control circuit, it closes the relay faults from history after 200 hours. The HCM automatically
contacts and turns on the relay. The Cooling Pump Relay clears a fault from history after that fault has been Inactive
powers the Cooling Pump that circulates the coolant on the for 200 hours.
hybrid liquid system.
Possible Causes
The following preconditions must be met before the system • FMI 3, 4, 5
detects the fault:
- Vehicle Harness from HCM to Cooling
• The HCM ignition voltage is greater than 7 volts Pump Relay
and less than 16 volts.
- Cooling Pump Relay
Conditions to Set Fault Code Active - HCM
• FMI 14
code Active:
- Cooling Pump Relay
battery in the coil circuit of the Cooling - Cooling Pump
Pump Relay. - Cooling Pump Relay main power supply
• FMI 4 is set when the HCM detects a short to - Low coolant, Low coolant flow, plugged radiator,
ground in the coil circuit of the Cooling fan operation
Pump Relay.
• FMI 5 is set when the HCM detects an open in the Additional Tools
coil circuit of the Cooling Pump Relay. • Basic hand tools
• FMI 14 is set when the following occur for 10 • Eaton® Test Adapter Kit
minutes or longer:
- Inverter temperature is greater than 122 °F
• ServiceRanger
(50 °C)
- The difference between the maximum battery
temperature and the Inverter temperature is
greater than 68 °F (20 °C)
- No battery temperature or motor temperature
faults
Note: When troubleshooting an Inactive code refer
to the “Product Diagnostic Mode (PDM)” on page 19.
Fallback
When Fault Code is set the following conditions occur:

TRTS1000 Fault Isolation Procedures | Fault Code 40 - Cooling Pump Relay

29 34
23 28
37 38
13 22
36
30
35
86
7 12
1 6
85 87
HCM Coolant Pump
Coolant Pump 32 86 Relay
Coolant Pump Return 4 85
87
30 Coolant Pump Supply
Coolant Pump Plus A
Coolant Pump Minus B Ground
Coolant Pump
12V Plus
12V Truck
Battery

Fault Code 40 - Cooling Pump Relay

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of HCM Harness
A status. C circuits.

page 1.
dures to avoid shock, burn or death from improp- • If resistance between Pin 32 and Pin 4 is
erly handled high-voltage. 40–120 ohms, replace Hybrid Control Module
3. Exchange Cooling Pump Relay with another relay go to Step V.
and see if fault returns:
• If fault does not return with new relay, replace Vehicle Harness for an open circuit, then
the Cooling Pump Relay, then go to Step V. go to Step V.
Pin 32 to Pin 4
Purpose: Verify FMI present.

B
Note: The Cooling Pump 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 3 is listed, go to Step D.

Purpose: Verify voltages of HCM Harness circuits Purpose: Verify continuity of HCM Harness circuits
D to ground. E to ground.

2. Measure voltage between HCM Harness 38-Way 2. Disconnect negative battery cable.
Connector Pin 32 and ground at key on.
3. Disconnect the HCM System Harness
• If voltage between Pin 32 and ground is 0 38-Way Connector.
volts, replace the Hybrid Control Module
4. Measure the resistance between the HCM System
Harness 38-Way Connector Pins 32 and ground:
go to Step V.
• If resistance between Pin 32 and ground is
volts, repair the short to VBATT on the
Control Module (HCM) (only if fault code is
harness, then go to Step V.
Connection Measurement Vehicle Harness for a short to ground, then
go to Step V.
Pin 32 to ground
Pin 32 to ground
Purpose: Verify level of Hybrid System coolant.

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.

Purpose: Verify operation of Hybrid System Purpose: Verify voltages at Hybrid System Coolant
G Coolant Pump. H Pump.

2. Connect ServiceRanger to the 9-Way Diagnostic 2. Disconnect the 2-Way Connector at the
Connector in the cab. Coolant Pump.
3. Key on. 3. Measure voltage at the 2-Way Connector from
Pin A to Pin B.
4. Go to “Product Tests” and select “Coolant
Pump Relay.” • If voltage between Pin A and Pin B is ±0.2 volts
of battery voltage, refer to OEM for Coolant
5. Listen for the Coolant Pump to turn on and watch
Pump problem.
coolant flow in the reservoir.
• If voltage between Pin A and Pin B is outside
• If the Coolant Pump runs with coolant moving
of range, repair wiring or relay problem.
through the reservoir, and the Fault Code is
Refer to OEM.
Active, contact Eaton® at 1-800-826-4357.
• If the Coolant Pump does not run,
go to Step H. Connection Measurement
• If the Coolant Pump runs and coolant does not
flow, check for kinks or sharp bends in the Pin A to Pin B
coolant lines. If okay, contact OEM for
concerns with Coolant Pump.


V
1. Key off.
battery cable.
3. Key on.
error in testing.

Fault Code 47 - J1939 ABS Message (HCM) | Fault Isolation Procedures TRTS1000
Fault Code 47 - J1939 ABS Message (HCM)

J1939: SA 239 SPN 563 FMI 2, 9, 14

120 ohm resistor at each end of the link. The HCM is history using ServiceRanger. The TECU automatically clears
connected to the J1939 data link at the 38-Way Connector. faults from history after 200 hours. The HCM automatically
This link is used to transmit information to the HCM and clears a fault from history after that fault has been Inactive
communicate with the other modules on the network such for 200 hours.
as the Anti-lock Braking System (ABS) module.
Possible Causes
detects the fault:
- J1939 Data Link
less than 16 volts. - ABS Module
• J1939 data link communication fault is Inactive. • FMI 14

- ABS module configured to communicate on
Conditions to Set Fault Code Active J1708 or analog instead of J1939.
The following conditions must be met to set the fault - ABS Module
code Active:
• FMI 9 is set when the HCM fails to receive ABS Additional Tools
message “Anti-Lock Braking Active” for 30 • Basic hand tools
consecutive messages or greater, while it continues
communicating with other modules on J1939. • Eaton® Test Adapter Kit
• FMI 14 is set when the HCM detects messages • Digital Volt/Ohm Meter
coming from the ABS module; however, the • ServiceRanger
“Anti-Locking Braking Active” message is received
as an error or not available.
Fallback
• If the fault occurs while moving, the operation goes
into AutoShift Only mode.
remain powered.
Note: If the vehicle experiences an ABS event, the
hybrid regenerative braking is stopped until ABS
communication continues, but the vehicle will
still have motor assist.

TRTS1000 Fault Isolation Procedures | Fault Code 47 - J1939 ABS Message (HCM)
Front Harness View

29 34
23 28
37 38
13 22
35 36
7 12
1 6
J1939 Low 2 J1939 Low
ABS
HCM
J1939 High 3 J1939 High

Fault Code 47 - J1939 ABS Message (HCM) | Fault Isolation Procedures TRTS1000
Fault Code 47 - J1939 ABS Message (HCM)

Purpose: Verify Active and Inactive fault code
A status and present FMIs.
1. Retrieve the Active fault codes and FMIs with

Connector.
• If Fault Code 47 FMI 9 is listed, concern
is either with the ABS Module or the J1939
Data Link from ABS Module to J1939 Data
Link Backbone. Refer to OEM for
repair procedures.
• If Fault Code 47 FMI 14 is listed, concern
is with the ABS Module being configured for
J1708 instead of J1939 communication, or
with the ABS Module. Refer to OEM for
repair procedures.

TRTS1000 Fault Isolation Procedures | Fault Code 48 - J1939 Transmission Message (HCM)
Fault Code 48 - J1939 Transmission Message (HCM)

J1939: SA 239 SPN 523 FMI 2, 9

120 ohm resistor at each end of the link. The Hybrid Control history using ServiceRanger. The TECU automatically clears
Module (HCM) is connected to the J1939 data link at the faults from history after 200 hours. The HCM automatically
38-Way Connector. This link transmits information to the clears a fault from history after that fault has been Inactive
HCM and communicates with other modules on the for 200 hours.
network such as the Transmission Electronic Control Unit
(TECU). Possible Causes
Detection • FMI 9
detects the fault: - J1939 Data Link
• HCM ignition voltage is greater than 7 volts and - TECU

less than 16 volts.
Additional Tools
• J1939 data link communication fault is Inactive.
Conditions to Set Fault Code Active • Eaton® Test Adapter Kit
The following conditions must be met to set the fault • Digital Volt/Ohm Meter
code Active:
• ServiceRanger
• FMI 9 is set when the HCM fails to receive TECU
data for 30 consecutive messages or greater, while
it continues communicating with other modules on
J1939.
Fallback
• Red “Service” light may illuminate and a “F” may
flash in the gear display due to an Active Fault
Code 24.
• Operation mode changes to “AutoShift
Only” mode.
remain powered.
not crank.
• If the fault sets while driving, the vehicle will shift;
however, when the vehicle stops the clutch opens
and remains in the open position.

Fault Code 48 - J1939 Transmission Message (HCM) | Fault Isolation Procedures TRTS1000
1 29
6 34
7 23
12 28
36 35 37 38
22 13
13 22
38 37 35 36
28 23 7 12
34 29 1 6
J1939 Low 2 2 J1939 Low
TECU
HCM
J1939 High 3 3 J1939 High

TRTS1000 Fault Isolation Procedures | Fault Code 48 - J1939 Transmission Message (HCM)
Fault Code 48 - J1939 Transmission Message (HCM)

Purpose: Verify Active and Inactive fault code Purpose: Verify continuity of TECU Harness
A status and perform Electrical Pretest. B circuits.

Connector.
3. Disconnect TECU Harness 38-Way Connector.
Pretest” on page 25): 4. Measure the resistance between the TECU Harness
go to Step B. Note: Make sure the Volt/Ohm Meter is on the
Pretest, go to Step V. • If resistance between Pin 2 and Pin 3 is
between 50–70 ohms, replace the
Transmission Electronic Control Unit (TECU),
then go to Step V.
Data Link Harness, then go to Step V.
Pin 2 to Pin 3

Fault Code 48 - J1939 Transmission Message (HCM) | Fault Isolation Procedures TRTS1000

V
1. Key off.
battery cable.
3. Key on.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 49 - J1939 Engine Message (HCM)
Fault Code 49 - J1939 Engine Message (HCM)

J1939: SA 239 SPN 190 FMI 2, 9

38-Way Connector. This link transmits information to the clears a fault from history after that fault has been Inactive
HCM and communicate with other modules on the network for 200 hours.
such as the Electronic Control Unit (ECU).
Possible Causes
detects the fault:
- J1939 Data Link from Engine ECU
less than 16 volts. - ECU
• J1939 data link communication fault is Inactive. Additional Tools

The following conditions must be met to set the fault • Eaton® Test Adapter Kit
• FMI 9 is set when the HCM fails to receive Engine • ServiceRanger
ECU data (like engine torque) for 30 consecutive
messages or greater, while still communicating
with other modules on J1939.
Fallback
• Operation mode changes to “AutoShift Only” mode.
powered.

Fault Code 49 - J1939 Engine Message (HCM) | Fault Isolation Procedures TRTS1000
Harness Front View

29 34
23 28
37 38
13 22
35 36
7 12
1 6
J1939 Low 2 J1939 Low
ECM HCM

TRTS1000 Fault Isolation Procedures | Fault Code 49 - J1939 Engine Message (HCM)
Fault Code 49 - J1939 Engine Message (HCM)

A status.

Connector:
• If Fault Code 49 is Active, concern is either
with the Engine ECU or the Data Link from
Engine ECU to J1939 Data Link Backbone.
Refer to OEM for repair procedure.

Fault Code 50 - J1939 Body Controller Message (HCM) | Fault Isolation Procedures TRTS1000
Fault Code 50 - J1939 Body Controller Message (HCM)

J1939: SA 239 SPN 701 FMI 2, 9

J1939 is a high-speed twisted pair 250K data link with one Only Inactive faults can be cleared from the Transmission
120 ohm resistor at each end of the link. The Hybrid Control Electronic Control Unit (TECU) or HCM history using
Module (HCM) connects to the J1939 data link at the ServiceRanger. The TECU automatically clears faults from
38-Way Connector. This link transmits information to the history after 200 hours. The HCM automatically clears a
HCM and communicates with the other modules on the fault from history after that fault has been Inactive for 200
network such as the Body Controller. hours.

detects the fault: • FMI 9
• HCM ignition voltage is greater than 7 volts and - J1939 Data Link
less than 16 volts.
- Body Controller
• J1939 data link communication fault is not active.
Additional Tools
code Active: • Eaton® Test Adapter Kit
• FMI 9 is set when the HCM fails to receive Body • Digital Volt/Ohm Meter
Controller data for 5 seconds or greater, while it is • ServiceRanger
still communicating with other modules on J1939.
Fallback
• Amber and red lights do not illuminate since the
Body Controller activates the lights.
• HCM disables ePTO operation, since parameters
like hydraulic demand are unavailable.

TRTS1000 Fault Isolation Procedures | Fault Code 50 - J1939 Body Controller Message (HCM)
Harness Front View

29 34
23 28
37 38
13 22
35 36
7 12
1 6
J1939 Low 2 J1939 Low
Body Controller HCM

Fault Code 50 - J1939 Body Controller Message (HCM) | Fault Isolation Procedures TRTS1000
Fault Code 50 - J1939 Body Controller Message (HCM)

Purpose: Verify Active or Inactive fault code status.
A
Connector:
• If Fault Code 50 is Active, concern is either
with the Body Controller or the Data Link from
Body Controller to J1939 Data Link Backbone.
Refer to OEM for repair procedure.

TRTS1000 Fault Isolation Procedures | Fault Code 51 - Rail Position Sensor
Fault Code 51 - Rail Position Sensor

J1587: MID 130 PID 60 FMI 2, 3, 4, 10
J1939: SA 3 SPN 60 FMI 2, 3, 4, 10

The Rail Position Sensor is a Hall Effect position sensor that Only Inactive faults can be cleared from the TECU or HCM
provides feedback on the position of the shift finger. The history using ServiceRanger. The TECU automatically clears
Transmission Electronic Control Unit (TECU) delivers a faults from history after 200 hours. The HCM automatically
constant 5-volt reference to 1 terminal of the Rail Position clears a fault from history after that fault has been Inactive
Sensor. The signal output from sensor provides a regulated for 200 hours.
voltage signal from 0.5–4.5 volts. The last terminal
provides a ground for the Rail Position Sensor to the TECU. Possible Causes
Detection • FMI 2, 10
detects the fault: - Transmission Harness
• TECU ignition voltage is greater than 7 volts and - Rail Position Sensor
• FMIs 3 and 4 do not set if the TECU System Battery • FMI 3, 4
Voltage Low fault is Active. FMI 2 do not set if FMI
3, 4 is Active. - TECU

code 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. • ServiceRanger
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 the
expected supply voltage for 1 second or longer.
• FMI 10 (refer to troubleshooting guide TRTS0930)
Fallback
the gear display.
• If this fault occurs while moving, the transmission
remains in the current gear and the clutch opens
when the vehicle stops.
• The operation mode changes to “AutoShift
Fallback” mode.

Fault Code 51 - Rail Position Sensor | Fault Isolation Procedures TRTS1000
Harness Front View Rail Position Sensor Pins

(TECU - System Interface Connector) 1
6
7
12
36 35 C
22 13 B
38 37 A
28 23
34 29
TECU
Rail Position Minus 20 C
Rail Position Signal 19 B B Hall Effect C
Rail Position Plus 18 A

Fault Code 51 - Rail Position Sensor

Purpose: Verify Active and Inactive fault code Purpose: Verify continuity of Transmission
A status and FMIs. B Harness circuits.

Connector.
2. Key off.
38-Way Connector.
4. Measure resistance between the Transmission
• If FMI 3 or 4 is listed, replace the Harness 38-Way Connector Pins:
Transmission Electronic Control Unit (TECU), - 18 and 19
then go to Step V. - 18 and 20
• If FMI 2, 10 is listed, go to Step B. Note: An auto-ranging digital Volt/Ohm Meter
must be used.
• If Pin 18 and Pin 19 resistance is 100–200
ohms and if Pin 18 and 20 resistance is 5K to
7K ohms, go to Step C.
go to Step D.
Pin 18 to Pin 19
Pin 18 to Pin 20

Fault Code 51 - Rail Position Sensor | Fault Isolation Procedures TRTS1000

C Harness circuits to ground. D Harness Rail Position Sensor circuit.
1. Measure resistance between Transmission Harness 1. Disconnect Transmission Harness from Rail
38-Way Connector Pin 18 to ground. Select Sensor.
• If resistance is 10K ohms or greater, replace 2. Measure resistance between Rail Select
the Transmission Electronic Control Unit Sensor Pins:
(TECU) (Only if Fault Code is Active), then - A and C
go to Step V. - A and B
• If resistance is less than 10K ohms, Note: An auto-ranging digital Volt/Ohm Meter
go to Step D. must be used.
• If Pin A and Pin C resistance is 5K–7K and if
Connection Measurement Pin A and Pin B resistance is 100–200 ohms,
replace the Transmission Harness, then go to
Pin 18 to ground Step V.
• If any to the above conditions are not met,
replace Electric Shifter, then go to Step V.
Pin A to Pin C
Pin A to Pin B


V
1. Key off.
battery cable.
3. Key on.
error in testing.

Fault Code 52 - Gear Position Sensor | Fault Isolation Procedures TRTS1000
Fault Code 52 - Gear Position Sensor

J1587: MID 130 PID 59 FMI 2, 3, 4
J1939: SA 3 SPN 59 FMI 2, 3, 4

The Rail Position Sensor is a Hall Effect position sensor that Only Inactive faults can be cleared from the Transmission
provides feedback on the position of the shift finger. The Electronic Control Unit (TECU) or HCM history using
Transmission Electronic Control Unit (TECU) delivers a ServiceRanger. The TECU automatically clears faults from
constant 5-volt reference to 1 terminal of the Rail Position history after 200 hours. The HCM automatically clears a
Sensor. The signal output from sensor provides a regulated fault from history after that fault has been Inactive for 200
voltage signal from 0.5–4.5 volts. The last terminal hours.
provides a ground for the Rail Position Sensor to the TECU.
Possible Causes
detects the fault:
- Transmission Harness
less than 16 volts. - Rail Position Sensor
• FMI 3, 4 does not set if the TECU System Battery - TECU

Voltage Low fault is Active. FMI 2 does not set if • FMI 3, 4
FMI 3, 4 is Active.
- TECU
Additional Tools
• FMI 2 sets when the transmission controller • Eaton® Test Adapter Kit
detects the Rail Sensor voltage is above 4.5 volts or • Digital Volt/Ohm Meter
below 0.5 volts for 1 second of longer.
• ServiceRanger
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 the
expected supply voltage for 1 second or longer.
“Product Diagnostic Mode (PDM)” on page 19
Fallback
the gear display.
• Operation mode changes to “AutoShift Fallback”
mode.

TRTS1000 Fault Isolation Procedures | Fault Code 52 - Gear Position Sensor
Harness Front View Gear Position Sensor Pins

6
7
12
36 35 C
22 13 B
38 37 A
28 23
34 29
TECU
Gear Position Minus 12 C
Gear Position Signal 11 B B Hall Effect C
Gear Position Plus 10 A

Fault Code 52 - Gear Position Sensor

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of Transmission
A status. B Harness sensor circuits.

Connector.
2. Key off.
38-Way Connector.
• If FMI 3 or 4 is listed, replace the Harness 38-Way Connector Pins:
Transmission Electronic Control Unit (TECU), - 18 and 19
then go to Step V. - 18 and 20
• If FMI 2 is listed, go to Step B. Note: An auto-ranging digital Volt/Ohm Meter
must be used.
• If Pin 18 and Pin 19 resistance is 100–200
ohms and if Pin 18 and Pin 20 resistance is
5K–7K ohms, go to Step C.
go to Step D.
Pin 18 to Pin 19
Pin 18 to Pin 20

TRTS1000 Fault Isolation Procedures | Fault Code 52 - Gear Position Sensor

C Harness sensor circuits to ground. D Harness Gear Position Sensor circuit.
1. Measure resistance between Transmission Harness 1. Disconnect Transmission Harness from Rail
38-Way Connector Pin 18 to ground. Select Sensor.
• If resistance is 10K ohms or greater, replace 2. Measure resistance between the following Rail
the Transmission Electronic Control Unit Select Sensor Pins:
(TECU) (Only if Fault Code is Active), then - A and C
go to Step V. - A and B
• If resistance is less than 10K ohms, Note: An auto-ranging digital Volt/Ohm Meter must
go to Step D. be used.
• If Pin A and Pin C resistance is 5K–7K and if
Connection Measurement Pin A and Pin B resistance is 100–200 ohms,
replace the Transmission Harness, then
Pin 18 to ground go to Step V.
• If any to the above conditions are not met,
replace Electric Shifter, then go to Step V.
Pin A to Pin C
Pin A to Pin B


V
1. Key off.
battery cable.
3. Key on.
go to Step A.

TRTS1000 Fault Isolation Procedures | Fault Code 53 - DC/DC Converter
Fault Code 53 - DC/DC Converter

J1939: SA 239 SPN 520244 FMI 12, 14

The DC/DC Converter is connected to the high-voltage Only Inactive faults can be cleared from the Transmission
Power Electronics Carrier (PEC), which provides 340 volts Electronic Control Unit (TECU) or HCM history using
DC. The voltage is stepped down to 12-volts DC and used to ServiceRanger. The TECU automatically clears faults from
maintain the 12-volt system during engine off PTO history after 200 hours. The HCM automatically clears a
operation. The DC/DC maintains a steady 12.6 volts output fault from history after that fault has been Inactive for 200
and increases the amperage with vehicle demand up to hours.
1.5 kw or 120 amps.
Possible Causes
detects the fault:
- DC/DC Converter
less than 16 volts. • FMI 14
- Vehicle load is above the maximum 1.5 kw
Conditions to Set Fault Code Active output of the Converter
code Active: Additional Tools
• FMI 12 sets if vehicle voltage drop is greater than • Basic hand tools
0.7 volts from the start of ePTO mode, or if the
vehicle battery is equal to or less than 11.3 volts. If
there is no DC/DC to battery cable fault, this fault
will set if the power drop across the DC/DC is less • Lockout bracket J48506
than 900W. • Lockout tags
• FMI 14 sets if vehicle voltage drop is greater than • ServiceRanger
0.7 volts from the start of ePTO mode, or if the
vehicle battery is equal to or less than 11.3 volts. If
there is no DC/DC to battery cable fault, this fault
will set if the power drop across the DC/DC is
greater than 1500W.
Fallback
• HCM requires the engine to power the PTO and
maintain the 12-volt system.

Fault Code 53 - DC/DC Converter | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 53 - DC/DC Converter
Fault Code 53 - DC/DC Converter

Purpose: Verify Active and Inactive fault code Purpose: Verify repair.
A status. V
page 1.
2. Key on.
3. Key off.
battery cable.
dures to avoid shock, burn or death from improp- 6. Check for codes, see “View Active and Inactive
erly handled high-voltage. Faults” on page 13.
4. Which FMIs are present? • If no codes, test is complete.
• If FMI 12 is listed, replace the DC/DC • If Fault Code 53 appears,go to Step A. Find
Converter, then go to Step V. error in testing.
• If FMI 14 is listed, the vehicle 12-volt demand • If a code other than 53 appears, go to “Fault
exceeds the capacity of the DC/DC Converter. Code Isolation Procedure Index” on page 14.
Loads must be removed from the 12-volt
system to maintain a maximum of 1.5 kw
total usage.

Fault Code 54 - DC/DC Converter Output Voltage | Fault Isolation Procedures TRTS1000
Fault Code 54 - DC/DC Converter Output Voltage

J1939: SA 239 SPN 520245 FMI 2, 4

The DC/DC Converter is connected to the Power Electronics Only Inactive faults can be cleared from the Transmission
Carrier (PEC), which provides 340 volts DC. The voltage is Electronic Control Unit (TECU) or HCM history using
reduced to 12-volts DC and maintains the 12-volt system ServiceRanger. The TECU automatically clears faults from
during engine off PTO operation. The DC/DC maintains a history after 200 hours. The HCM automatically clears a
steady 14.2 (±0.2) volts output and increases the amperage fault from history after that fault has been Inactive for 200
with vehicle demand up to 1.5 kw or 120 amps. hours.
The DC/DC Converter also produces a feedback voltage Possible Causes

from the 4-Way Connector. The voltage output is a 0–5 volt This fault code can be caused by any of the following:
signal, which shows 5 volts when the Converter is at 14.2
(±0.2) volts on the output. If the Converter output drops, • FMI 2
the feedback signal drops accordingly. - Voltage Feedback wire from DC/DC Converter
to HCM
Detection
• FMI 4
detects the fault: - 12-volt power cables from the 12-volt battery to
the DC/DC Converter
• Hybrid Control Module (HCM) ignition voltage is
greater than 7 volts and less than 16 volts. - Power supply to HCM

code Active:
• FMI 2 is set whenever DC/DC voltage feedback with leather protectors J48603
signal reads greater than 15 volts or less than 10
volts and ePTO mode is engaged. • Lockout bracket J48506
• Lockout tags
• FMI 4 is set if the voltage feedback is less than 15
volts and greater than 10 volts and the difference • Eaton® Test Adapter Kit J43318
between the voltage feedback and the vehicle • Digital Volt/Ohm Meter J46708
battery voltage is greater than 0.5 volts for 1
second or more. • ServiceRanger
Fallback
• Depending on the voltage of the vehicle battery, the
engine may operate to maintain the 12-volt system
in ePTO mode.

TRTS1000 Fault Isolation Procedures | Fault Code 54 - DC/DC Converter Output Voltage
Harness Front View

(HCM - Hybrid System Interface Connector) Deutsch 4-Way OEM Connector
29 34
23 28
4 3
37 38
13 22 1 2
35 36
7 12
1 6
DC/DC
HCM Converter
Feedback 19 1
2 340V EPTO Plus
340V EPTO Minus
12V Plus
Thermocouple 11 3 12V Minus
4 Ground

Fault Code 54 - DC/DC Converter Output Voltage

Purpose: Verify Active or Inactive fault code status Purpose: Verify voltage from DC/DC Converter
A and FMIs present. B to HCM.
1. Review and follow the “Warnings & Cautions” on 1. Key on.

page 1.
2. Select ePTO Mode on the Pushbutton.
3. Measure voltage at the DC/DC Converter 12-Volt
Output Terminals:
3. Key off.
• If voltage is greater than 10 volts, repair the
! Warning: See “High-Voltage Service Shutdown and open or shorted harness from Pin 1 of the
Power-Up Procedure” on page 4. Follow the proce- DC/DC Converter to Pin 19 of the HCM, then
dures to avoid shock, burn or death from improp- go to Step V.
• If voltage is less than 10 volts, replace the
4. Which FMIs are present? DC/DC Converter, then go to Step V.
• If FMI 2 is listed, go to Step B.

• If FMI 4 is listed, go to Step C. Connection Measurement
DC/DC Converter
Output Terminals

TRTS1000 Fault Isolation Procedures | Fault Code 54 - DC/DC Converter Output Voltage
Purpose: Verify DC/DC Converter output voltage. Purpose: Verify voltage of DC/DC Converter.
C D
2. Connect ServiceRanger to the 9-Way Diagnostic 2. View the following Data Monitor parameters:
Connector in cab. - PID 121 “DC/DC Converter Output Voltage.”
3. View the following Data Monitor parameters - PID 165 “Battery Potential Voltage.”
in neutral: • If PID 165 is 0.5 volts less than PID 121, repair
- PID 121 “DC/DC Converter Output Voltage.” or replace the DC/DC Converter Power Supply
- PID 165 “Battery Potential Voltage.” Harness that powers the 12-Volt Battery
System, then go to Step V.
• If voltage at the DC/DC Converter is
12–14 volts, go to Step D. • If PID 121 is 0.5 volts less than PID 165, repair
the voltage feedback wire that goes from Pin 1
• If voltage is outside of range, repair the open
of the DC/DC Converter to Pin 19 of the HCM.
harness or fuse in the Main Power Supply
Go to Step V.
from the DC/DC Converter to the 12-Volt
Battery. Go to Step V.
DC/DC Converter
Output Voltage
DC/DC Converter
Output Voltage
Battery Potential
Voltage
Battery Potential
Voltage


V
1. Key off.
2. Key on.
battery cable.
go to Step A.

TRTS1000 Fault Isolation Procedures | Fault Code 56 - Input Shaft Speed Sensor
Fault Code 56 - Input Shaft Speed Sensor

J1587: MID 130 PID 161 FMI 2, 3, 4, 5, 10
J1939: SA 3 SPN 161 FMI 2, 3, 4, 5, 10
Overview Fallback
The Input Shaft Speed Sensor is located on the 6-bolt When Fault Code 56 is set the following conditions occur:
PTO Cover, which is standard on the right side of the • Red “Service” light illuminates and an “F” flashes in
transmission. The sensor is a magnetic pickup that the gear display.
produces an AC voltage as the countershaft gear teeth
moves past the end of the sensor. At idle the speed sensor • Fault is stored in TECU memory.
output is low and increases as the speed of the • The operation mode changes to “AutoShift
countershaft increases. Fallback” mode.
Detection remains in current gear and the clutch opens when
The following preconditions must be met before the system the vehicle stops.
detects the fault:
• If this fault occurs at power up, the vehicle cranks
• Transmission Electronic Control Unit (TECU) but the transmission does not engage a gear.
ignition voltage is greater than 7 volts and less than
16 volts. Conditions to Set Fault Code Inactive
• FMI 10 requires the transmission to be in neutral Only Inactive faults can be cleared from the Transmission
and the vehicle speed must be within range. Electronic Control Unit (TECU) or HCM history using
• FMI 2 does not set if there is already an Active FMI ServiceRanger. The TECU automatically clears faults from
5 for the Input or Output Shaft Speed Sensors. history after 200 hours. The HCM automatically clears a
fault from history after that fault has been Inactive for 200
Conditions to Set Fault Code Active hours.
code Active: Possible Causes
• FMI 2 is set when the TECU input shaft speed is
compared to the output shaft speed and it • FMI 2, 10
produces an inconsistent reading for 1 second - Input Shaft Speed Sensor
or greater. - TECU
• FMI 3 and 4 are set when the TECU detects a short - Transmission Harness
to ground, short to battery, and the input shaft
speed is 0 for 1 second or greater. - Damaged transmission gearing
• FMI 5 is set when the TECU detects an open circuit - Contamination on the Input Shaft Speed Sensor
and the Input Shaft Speed Sensor is 0 for 1 second
• FMI 3, 4, 5
or greater.
- Input Shaft Speed Sensor
• FMI 10 is set when the TECU detects a 200 RPM
or greater speed difference between the input shaft - TECU
speed and the raw input shaft speed for 10 ms - Transmission Harness
or greater.
Additional Tools
• ServiceRanger

Fault Code 56 - Input Shaft Speed Sensor | Fault Isolation Procedures TRTS1000
Harness Front View

6 Input Shaft Speed Sensor
7
12 (Connect View)
36 35
22 13 A B
38 37
28 23
34 29
TECU Input Shaft

Speed Sensor
Input Shaft Speed

Sensor High 7 A
Input Shaft Speed

Sensor Low 8 B

TRTS1000 Fault Isolation Procedures | Fault Code 56 - Input Shaft Speed Sensor
Fault Code 56 - Input Shaft Speed Sensor

Purpose: Verify continuity of Transmission Purpose: Verify voltages of Transmission Harness
A Harness sensor circuits. B sensor circuits and ground.
1. Retrieve Active fault codes and FMIs with 1. Key on.

2. Measure the voltage from between the
Connector.
Transmission Harness 38-Way Connector Pin 7
2. Key off. and ground.
3. Disconnect negative battery cable. • If voltage is 0 volts, go to Step C.
4. Disconnect the Transmission Harness • If voltage is 11–13 volts, repair the short
38-Way Connector. to battery in the Vehicle Harness, then
go to Step V.
5. Measure the resistance between the Transmission
Harness 38-Way Connector Pin 7 and Pin 8 and
Pin 7 and ground.
• If resistance is 2K–4.5K ohms and Pin 7 to
ground is 10K ohms or greater, go to Step B. Pin 7 to ground
• If resistance is outside of the range,
go to Step D.
Pin 7 to Pin 8
Purpose: Verify integrity of Input Shaft Speed
Pin 7 to ground C Sensor.
1. Inspect Input Shaft Speed Sensor for

contamination or damage:
• If no problem found, replace Transmission
Electronic Control Unit (TECU) (Only if Fault
• If problem is found or were sent here from
Step D or Step E, replace Input Shaft Speed
Sensor and inspect the Countershaft Gear for
damage. Go to Step V.

Fault Code 56 - Input Shaft Speed Sensor | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of Input Shaft Speed Purpose: Verify repair.

D Sensor. V
1. Disconnect the Transmission Harness from Input 1. Key off.
Shaft Speed Sensor.
2. Measure resistance between Input Shaft Speed battery cable.
Sensor Pin A and Pin B:
3. Verify proper installation of speed sensor.
• If resistance is 2K–4.5K ohms, go to Step E.
4. Key on.
• If resistance is outside of range, go to Step C.
Connection Measurement 7. Check for codes, see “View Active and Inactive
Pin A to Pin B
error in testing.
Purpose: Verify continuity of Input Shaft Speed

E Sensor to ground.
1. Measure resistance between Input Shaft Speed

Sensor Pin A and ground:
• If resistance is 10K ohms or greater, replace
the Transmission Harness, then go to Step V.
• If resistance is less than 10K ohms,
go to Step C.
Pin A to ground

TRTS1000 Fault Isolation Procedures | Fault Code 58 - Output Shaft Speed Sensor
Fault Code 58 - Output Shaft Speed Sensor

J1587: MID 130 PID 191 FMI 2, 3, 4, 5
J1939: SA 3 SPN 191 FMI 2, 3, 4, 5

The Output Shaft Speed Sensor is located on the rear Only Inactive faults can be cleared from the TECU or HCM
bearing cover at the 12 o’clock position. The sensor is a history using ServiceRanger. The TECU automatically clears
magnetic pickup that produces an AC voltage as the tone faults from history after 200 hours. The HCM automatically
wheel teeth moves past the end of the sensor. At idle, the clears a fault from history after that fault has been Inactive
Speed Sensor output is low and it increases as the speed of for 200 hours.
the output shaft increases.
Possible Causes
detects the fault:
- Output Shaft Speed Sensor
• Transmission Electronic Control Unit (TECU)
ignition voltage is greater than 7 volts and less than - TECU
16 volts. - Transmission Harness
• FMI 2 does not set if there is already an Active FMI - Damaged Transmission Gearing
5 for the Input or Output Shaft Speed Sensors. - Contamination on the Output Shaft
Speed Sensor
The following conditions must be met to set the fault • FMI 3, 4, 5
code Active: - Output Shaft Speed Sensor
• FMI 2 is set when the TECU output shaft speed is - TECU
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 Additional Tools
ground, short to battery, or the output shaft speed
is 0 for 1 second or greater. • Basic hand tools
• FMI 5 is set when the TECU detects an open and • Eaton® Test Adapter Kit
the Output Shaft Speed Sensor is 0 for 1 second • Digital Volt/Ohm Meter
or greater. • ServiceRanger
Fallback
the gear display.
mode.

Fault Code 58 - Output Shaft Speed Sensor | Fault Isolation Procedures TRTS1000
Harness Front View

6 Output Shaft Speed Sensor
7
12 (Connect View)
36 35
22 13 A B
38 37
28 23
34 29
TECU Output Shaft

Speed Sensor
Output Shaft Speed

Sensor High 23 A
Output Shaft Speed

Sensor Low 24 B

TRTS1000 Fault Isolation Procedures | Fault Code 58 - Output Shaft Speed Sensor
Fault Code 58 - Output Shaft Speed Sensor

Purpose: Verify continuity of Transmission Purpose: Verify voltage of Transmission Harness
A Harness sensor circuits. B sensor circuits to ground.
1. Retrieve Active fault codes and FMIs with 1. Key on.

2. Measure voltage between the Transmission
Connector.
Harness 38-Way Connector Pin 23 and ground.
2. Key off.
• If voltage is 0 volts, go to Step C.
• If voltage is 11–13 volts, repair the short to
4. Disconnect the Transmission Harness battery in the Vehicle Harness, then
38-Way Connector. go to Step V.
Harness 38-Way Connector Pin 23 and Pin 24 and
Pin 23 and ground: Connection Measurement
• If resistance is 2K–4.5K ohms and Pin 23 to Pin 23 to ground

ground is 10K ohms or greater, go to Step B.
• If resistance is outside of the range,
go to Step D.
Pin 23 to Pin 24
Purpose: Verify integrity of Output Shaft Speed
Pin 23 to ground
C Sensor.
1. Inspect Output Shaft Speed Sensor for

contamination or damage.
• If no problem found, replace Transmission
Electronic Control Unit (TECU) (only if fault
code is Active), then go to Step V.
• If problem is found or were sent here from
Step D or E, replace Output Shaft Speed
Sensor and inspect the Tone Wheel for
damage, looseness or corrosion. Go to Step V.

Fault Code 58 - Output Shaft Speed Sensor | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of Output Shaft Speed Purpose: Verify repair.

D Sensor. V
1. Disconnect the Transmission Harness from the 1. Key off.
Output Shaft Speed Sensor.
2. Measure resistance between Output Shaft Speed battery cable.
Sensor Pin A and Pin B:
3. Verify proper installation of Speed Sensor.*
• If resistance is 2K–4.5K ohms, go to Step E.
4. Key on.
Connection Measurement 7. Check for codes, see “View Active and Inactive
Pin A to Pin B
error in testing.
Purpose: Verify continuity of Output Shaft Speed • * See Output Shaft Speed Sensor.
E Sensor and ground.
1. Measure resistance between Output Shaft Speed

Sensor Pin A and ground:
the Transmission Harness, then go to Step V.
go to Step C.
Pin A to ground

TRTS1000 Fault Isolation Procedures | Fault Code 59 - J1939 Communication Link (HCM)
Fault Code 59 - J1939 Communication Link (HCM)

J1939: SA 239 SPN 639 FMI 2, 9

38-Way Connector. This link is used to transmit or receive clears a fault from history after that fault has been Inactive
operation information from other modules on the network for 200 hours.
like the Transmission Electronic Control Unit (TECU) or
Electronic Control Unit (ECU). Possible Causes
Detection • FMI 2
detects the fault: - J1939 Data Link
• HCM ignition voltage is greater than 7 volts and - HCM

less than 16 volts.
Additional Tools
code Active:
• FMI 9 is set when the HCM loses communication
with all modules on the J1939 data link for 30 • ServiceRanger
consecutive messages or greater.
Fallback
• Amber “Check Hybrid” and red “Stop Hybrid” lights
do not display, since the lights are driven over the
J1939 Data Link.
not crank.
• If the fault sets while driving, the vehicle will shift,
however; when the vehicle stops the clutch opens
and remains open.
remain powered.
• Red “Service” light and an “F” flashing in the gear
display may appear due to the Active fault code 24,
35, or 36.

Fault Code 59 - J1939 Communication Link (HCM) | Fault Isolation Procedures TRTS1000
Front Harness View

29 34 9 Pin Diagnostic Connector
23 28
E D
37 38 C
F A B
13 22
G J
35 36
H
7 12
1 6
J1939 Low 2 D J1939 Low
9 Pin Diagnostic
HCM Connector
J1939 High 3 C J1939 High

Fault Code 59 - J1939 Communication Link (HCM)

Purpose: Check for Active or Inactive fault code Purpose: Verify continuity of Vehicle Harness
A status. B circuits.

Connector.
3. Disconnect HCM Harness 38-way connector.
2. Key on.
4. Measure resistance between HCM Harness 38-Way
3. Select the “Vehicle Components” screen and view
Connector Pin 2 and Pin 3:
the various modules that are reporting on the
J1939 link: Note: Make sure the Volt/Ohm Meter is on the
• If the HCM is not reporting on J1939 but the
TECU is listed, go to Step B. • If resistance between Pin 2 and Pin 3 is
• If the HCM and TECU are not reporting on between 50–70 ohms, replace the Hybrid
J1939, go to Step C. Control Module (HCM), then go to Step V.
Data link Harness, then go to Step V.
Pin 2 to Pin 3

Fault Code 59 - J1939 Communication Link (HCM) | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of Diagnostic Connector Purpose: Verify continuity of Diagnostic Connector
C J1939 circuits. D J1939 circuits.

2. Measure the resistance between Pin C and Pin D on 2. Measure resistance between Pin C and ground on
the 9-Way Diagnostic Connector: the 9-Way Diagnostic Connector:
• If resistance between Pin C and Pin D is • If resistance between Pin C and ground is
50–70 ohms, go to Step D. 10K ohms or greater, attempt to communicate
with another vehicle and ensure ServiceRanger
• If resistance is 70 ohms or greater, one or
is working. If ServiceRanger fails to
more of the terminating resistors on the J1939
communicate with another vehicle, call
Data Link Harness is missing, out of range, or
1-800-826-HELP (4357).
there is an open in the link. Repair the OEM
J1939 Data Link Harness, then go to Step V. • If resistance is outside of range, repair J1939
Data link Harness for a short to ground, then
• If resistance is 50 ohms or less, there is an
go to Step V.
additional terminating resistor present. Repair
the OEM J1939 Data Link Harness, then
go to Step V.
Connection Measurement Pin C to ground
Pin C to Pin D


V
1. Key off.
2. Key on.
battery cable.
error in testing.
• If code other than 59 appears, go to “Fault

Fault Code 60 - CAN Communication Link (HCM) | Fault Isolation Procedures TRTS1000
Fault Code 60 - CAN Communication Link (HCM)

J1939: SA 239 SPN 625 FMI 2, 9

The Controller Area Network (CAN) is a high-speed twisted Only Inactive faults can be cleared from the TECU or HCM
pair 500K proprietary data link that connects the HCM to history using ServiceRanger. The TECU automatically clears
the Electric Clutch Actuator (ECA), Battery Control Module faults from history after 200 hours. The HCM automatically
and Inverter. The link contains one 120 ohm resistor at each clears a fault from history after that fault has been Inactive
end. The link is used to transmit information specific to for 200 hours.
clutch position or power electronics operations.
Possible Causes
detects the fault:
- CAN Data Link
• HCM is powered and ignition voltage is greater
than 7 volts and less than 16 volts. - HCM

• FMI 9 is set when the HCM loses communication • Digital Volt/Ohm Meter
with all modules on the CAN data link for 30
consecutive messages or greater. • ServiceRanger

Fallback
not crank.
powered.
• If the fault sets while driving, the clutch will
either close or open and remain in this
position permanently.

TRTS1000 Fault Isolation Procedures | Fault Code 60 - CAN Communication Link (HCM)
Harness Front View

29 34 9 Pin Diagnostic Connector
23 28
E D
37 38 C
F A B
13 22
G J
35 36
H
7 12
1 6
9 Pin Diagnostic
CAN High 28 Connector
HCM H CAN High
(Terminating
Resistor in HCM) J CAN Low
CAN Low 27

Fault Code 60 - CAN Communication Link (HCM) | Fault Isolation Procedures TRTS1000
Fault Code 60 - CAN Communication Link (HCM)

Purpose: Verify continuity of Diagnostic Connector Purpose: Verify continuity of Vehicle Harness
A circuits. B J1939 circuits.

Connector.
3. Disconnect HCM Harness 38-Way Connector.
2. Key off.
3. Measure the resistance between one of
the following:
- Pin H and Pin J on the 9-Way Connector. Note: Make sure the Volt/Ohm Meter is on the
- Pin A and Pin B on the 3-Way Connector. proper scale (around 200 ohm scale).
- Pin 1 and Pin 2 on the 2-Way Connector. • If resistance between Pin 27 and Pin 28 is
Note: The 3-Way and 2-Way Data Link Connectors
are located next to the 9-Way Diagnostic Control Module (HCM), then go to Step V.
Connector. • If resistance is outside of range, repair the
CAN Data Link Harness, then go to Step V.
• If resistance between Pin H and Pin J, Pin A Connection Measurement
and Pin B, or Pin 1 and Pin 2 is between 50 to
70 ohms, go to Step B. Pin 27 to Pin 28
• If resistance is more than 70 ohms, one or
more of the terminating 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, then
go to Step V.
• If resistance is less than 50 ohms, there is
an additional terminating resistor present.
Repair the OEM CAN Data Link Harness,
then go to Step V.
Pin H to Pin J on
9-Way Connector
Pin A to Pin B on
3-Way Connector
Pin 1 to Pin 2 on
2-Way Connector

TRTS1000 Fault Isolation Procedures | Fault Code 60 - CAN Communication Link (HCM)

V
1. Key off.
2. Key on.
battery cable.
error in testing.

Fault Code 61 - Rail Select Motor | Fault Isolation Procedures TRTS1000
Fault Code 61 - Rail Select Motor

J1587: MID 130 SID 39 FMI 5, 6
J1939: SA 3 SPN 772 FMI 5, 6

The Electric Shifter contains two electric motors—the Rail Only Inactive faults can be cleared from the TECU or HCM
motor and Gear motor. These motors move a shift finger history using ServiceRanger. The TECU automatically clears
between the various rails which engage the shift rails. faults from history after 200 hours. The HCM automatically
Power is supplied from the Transmission Electronic Control clears a fault from history after that fault has been Inactive
Unit (TECU). for 200 hours.

detects the fault: • FMI 5, 6
• TECU ignition voltage is greater than 7 volts and - Electric Shifter
less than 16 volts.
- TECU
• TECU System Battery Voltage Weak Fault
is Inactive. Additional Tools
• Electric Shifter is not energized and the shift finger • Basic hand tools
is not moving.
code Active:
• 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.
Fallback
the gear display.
• The operation mode changes to “AutoShift
Fallback” mode.

TRTS1000 Fault Isolation Procedures | Fault Code 61 - Rail Select Motor
Harness Front View

(TECU - System Interface Connector) Harness Front View
1
6 (Rail Select Motor)
7
12
36 35
22 13
B A
38 37
28 23
34 29
TECU
Rail Select Motor
Rail Motor Plus 35
Rail Motor Minus 37

Fault Code 61 - Rail Select Motor | Fault Isolation Procedures TRTS1000
Fault Code 61 - Rail Select Motor

Purpose: Verify continuity of Transmission Purpose: Verify continuity of Rail Select Motor
A Harness circuits. C Harness circuit.
1. Retrieve Active fault codes and FMIs with 1. Disconnect 2-Way Rail Select Motor Connector
ServiceRanger using the 9-Way Diagnostic from the Transmission Harness.
Connector.
2. Measure resistance between Rail Select Motor
2. Key off. Harness 2-Way Connector Pin A and Pin B and
Pin A to ground:
• If resistance between Pin A and Pin B is
4. Disconnect the Transmission Harness 38-Way 0.3–150 ohms and Pin A to ground is 10K
Connector from the TECU. ohms or greater, replace Transmission
5. Measure resistance between the Transmission Harness, then go to Step V.
Harness 38-Way Connector Pin 35 and Pin 37: • If resistance is outside of range, replace
• If resistance is 0.3–150 ohms, go to Step B. Electric Shifter, then go to Step V.

Pin 35 to Pin 37
Pin 35 to Pin 37
Pin B and ground

V
Purpose: Verify continuity of Transmission
B Harness circuits to ground.
1. Key off.
battery cable.
Harness 38-Way Connector Pin 35 and ground: 3. Key on.
• If resistance is 10K ohms or greater, replace 4. Clear codes, see “Clear Inactive Faults” on page 13.
(Only if Fault Code is Active), then
go to Step V. 6. Check for codes, see “View Active and Inactive
go to Step C. • If no codes, test is complete.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 63 - Gear Select Motor
Fault Code 63 - Gear Select Motor

J1587: MID 130 SID 40 FMI 5, 6
J1939: SA 3 SPN 773 FMI 5, 6

The Electric Shifter contains two electric motors called the Only Inactive faults can be cleared from the TECU or HCM
Rail and Gear motors. These motors move a shift finger history using ServiceRanger. The TECU automatically clears
between the various rails which engage the shift rails. faults from history after 200 hours. The HCM automatically
Power is supplied from the Transmission Electronic Control clears the faults from history after the fault has been
Unit (TECU). Inactive for 200 hours.

detects the fault: • FMI 5, 6
• TECU ignition voltage is greater than 7 volts and - Electric Shifter
less than 16 volts.
- TECU
is Inactive. Additional Tools
• Electric Shifter is not energized and the shift finger • Basic hand tools
is not moving.
code Active:
• 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.
Fallback
the gear display.
mode. If this fault occurs while moving,
transmission remains in the current gear position
and the clutch opens when the vehicle stops.

Fault Code 63 - Gear Select Motor | Fault Isolation Procedures TRTS1000
Harness Front View

(TECU - System Interface Connector) 1 Harness Front View
6 (Gear Select Motor)
7
12
36 35
22 13
38 37 B A
28 23
34 29
TECU
Gear Select Motor
Gear Motor Plus 36
Gear Motor Minus 38

TRTS1000 Fault Isolation Procedures | Fault Code 63 - Gear Select Motor
Fault Code 63 - Gear Select Motor

A Harness circuits B Harness circuits and ground.
1. Retrieve Active fault codes and FMIs with 1. Measure resistance between the Transmission
ServiceRanger using the 9-Way Diagnostic Harness 38-Way Connector Pin 36 and ground.
Connector.
2. Key off. Transmission Electronic Control Unit (TECU)
(Only if Fault Code is Active), then
go to Step V.
4. Disconnect the Transmission Harness 38-Way
Connector from the TECU.
go to Step C.
Harness 38-Way Connector Pin 36 and Pin 38:
• If resistance is 0.3–150 ohms, go to Step B. Connection Measurement
• If resistance is outside of range, go to Step C. Pin 36 to ground
Pin 36 to Pin 38

Fault Code 63 - Gear Select Motor | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of Gear Select Motor Purpose: Verify repair.

C Harness circuit. V
1. Disconnect 2-Way Gear Select Motor Connector 1. Key off.
from the Transmission Harness.
2. Measure resistance between Gear Select Motor battery cable.
Harness 2-Way Connector Pin A and Pin B and
3. Key on.
Pin A to ground.
• If resistance between Pin A and Pin B is
0.3–150 ohms and Pin A to ground is 10K 5. Drive the vehicle and attempt to reset the code.
ohms or greater, replace Transmission
• If resistance is outside of range, replace
Electric Shifter, then go to Step V.
error in testing.
Connection Measurement • If a code other than 63 appears, go to “Fault
Pin A to Pin B
Pin A to ground

TRTS1000 Fault Isolation Procedures | Fault Code 64 - ECA Fault
Fault Code 64 - ECA Fault

J1939: SA 239 SPN 788 FMI 12, 21–28

The Electric Clutch Actuator (ECA) controls the position of Only Inactive faults can be cleared from the TECU or HCM
the clutch assembly. The ECA has a main power 3-Way history using ServiceRanger. The TECU automatically clears
Connector connected to the 12-volt battery and an 8-Way faults from history after 200 hours. The HCM automatically
Connector connected to inputs such as the Hybrid Control clears a fault from history after that fault has been Inactive
Module (HCM) and the Engine Speed Sensor. The ECA for 200 hours.
communicates with the HCM over the proprietary Controller
Area Network (CAN) data link to change position, show Possible Causes
faults or include other operation information. This fault code can be caused by any of the following:
• FMI 12
Detection
The following preconditions must be met before the system - ECA
detects the fault:
• FMI 21–28
• ECA ignition voltage is greater than 8.5 volts. - Excessive debris buildup on or around the ECA.
• ECA Battery Voltage is greater than 7.8 when - Damaged exhaust heat shielding near ECA.
ignition voltage is greater than 8.5 volts.
- Binding Cross-Shafts.
• FMI 12 is set for various internal ECA failures. • Eaton® Test Adapter Kit
• FMI 22–28 can be set for excessive motor current, • Digital Volt/Ohm Meter
excessive motor temperature, or incorrect
• Service Ranger
motor position.
Fallback
• Red Stop Hybrid light illuminate.
• If the fault occurs while driving, the ECA either
maintains current clutch position or moves to the
last position commanded by the HCM.
• If the fault occurs at power up, the vehicle will
not crank.

Fault Code 64 - ECA Fault | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 64 - ECA Fault
Fault Code 64 - ECA Fault

Purpose: Verify FMIs present. Purpose: Verify no binding on Cross-Shafts.
A C
1. Retrieve Active fault codes and FMIs with 1. Disconnect the ECA 8-Way and 3-Way Connectors.
2. Remove the ECA*.
Connector.
Note: For additional information on ECA removal,
2. Key off.
see the Hybrid Service Manual (TRSM1000).
3. Rotate the Cross-Shafts by grabbing the exposed
4. Which FMIs are present? Lower Cross-Shaft and rotating it:
• If FMI 12 is listed, replace the Electric Clutch • If the Cross-Shafts rotate without any binding,
Actuator (ECA), then go to Step V. replace the Electric Clutch Actuator (ECA),
• If FMI 21–28 are listed, go to Step B. then go to Step V.
• If the Cross-Shafts bind when rotated,
replace the Cross-Shafts and Bushings, then
go to Step V.
• * See Electric Clutch Actuator (ECA).
Purpose: Verify integrity of ECA Motor.

B
1. Check the ECA for any debris build-up, damaged
exhaust, or missing Exhaust Heat Shields near
the ECA:
V
• ECA has no debris build-up or damaged 1. Key off.
exhaust by the unit, go to Step C.
2. Key on.
• ECA has debris build-up or exhaust damage
next to the unit, remove the debris build-up, or 3. Clear codes, see “Clear Inactive Faults” on page 13.
repair the exhaust damage, then go to Step V. 4. Reconnect all connectors and the negative
battery cable.
error in testing.

Fault Code 65 - ECA Speed Sensor | Fault Isolation Procedures TRTS1000
Fault Code 65 - ECA Speed Sensor

J1939: SA 239 SPN 520203 FMI 2, 5

the clutch assembly. The ECA has a main power 3-Way history using ServiceRanger. The TECU automatically clear
Connector that is directly connected to the 12-Volt Battery the faults from history after 200 hours. The HCM
and an 8-Way Connector that is connected to inputs like the automatically clears a fault from history after that fault has
Hybrid Control Module (HCM) and the Engine Speed been Inactive for 200 hours.
Sensor. The ECA communicates with the HCM over the
proprietary Controller Area Network (CAN) data link to Possible Causes
change position, show faults, or include other This fault code can be caused by any of the following:
operation information. • FMI 2, 5
Detection - ECA Speed Sensor
The following preconditions must be met before the system - ECA Speed Sensor Harness
detects the fault: - ECA
• ECA ignition voltage is greater than 8.5 volts.
• Fault Code 18 or 87 are Active. Additional Tools
• FMI 2 is set when the HCM detects engine speed at • ServiceRanger

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.
Fallback

TRTS1000 Fault Isolation Procedures | Fault Code 65 - ECA Speed Sensor
ECA 3-Way Connector ECA Speed Sensor ECA 8-Way Connector

(Connect View)
C B A A B C D
A B
H G F E
Speed Sensor
A
ECA
2G Eng Speed Sensor (-)
2F Eng Speed Sensor (+)

Fault Code 65 - ECA Speed Sensor | Fault Isolation Procedures TRTS1000
Fault Code 65 - ECA Speed Sensor

Purpose: Verify FMIs present. Purpose: Verify continuity of ECA Harness and
A C ground.

2. Check resistance between ECA 8-Way Connector
Connector.
Pin F and ground:
2. Which FMIs are listed?
• If resistance is 10K or greater, go to Step D.
• If resistance is out of range, repair the short to
• If FMI 2 is listed, go to Step C. ground in the Sensor or the harness from the
ECA to the Sensor, then go to Step V.
Pin F to ground
Purpose: Verify continuity of ECA Harness.

B
1. Check resistance between ECA 8-Way Connector
Pin F and Pin G:
• If resistance between ECA 8-Way Connector
Pin F and Pin 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, then go to Step V.
Pin F to Pin G

TRTS1000 Fault Isolation Procedures | Fault Code 65 - ECA Speed Sensor
Purpose: Verify voltage of ECA Harness and Purpose: Verify integrity of engine Flywheel.
D ground. F
1. Key on. 1. Inspect the engine Flywheel to ensure there are no
missing or damaged teeth:
2. Measure voltage from the ECA 8-Way Connector
Pin G and ground: • If flywheel teeth are all intact and in good
condition, reinstall Flywheel Sensor until it
• If voltage is 0 volts at key on and FMI 5 is
touches the Flywheel then rotate
Active, replace the Electric Clutch Actuator
counterclockwise 1/2 to 1 full turn. Tighten
(ECA) (only if Fault Code is Active), then
Jam Nut and drive vehicle. If fault returns,
go to Step V.
replace the Sensor, then go to Step V.
• If voltage is 0 volts at key on and FMI 2 is
• If flywheel teeth are damaged or missing,
Active, go to Step E.
concern is with the Flywheel. Contact OEM for
• If voltage is greater than 0 volts at key on, repair procedures.
repair the short to power on the ECA Speed
Sensor Harness, then go to Step V.
Pin G to ground
V
1. Key off.
2. Key on.
Purpose: Verify integrity of ECA Speed Sensor. 4. Reconnect all connectors and the negative
E battery cable.
1. Key off.
2. Remove the ECA Speed Sensor and examine the Faults” on page 13.
sensor end for signs of damage or debris buildup:
• If the Sensor shows no cracks or signs of
metallic debris buildup on the end,
error in testing.
go to Step F.
• If a code other than 34 appears, go to“Fault
• If the Sensor is damaged or has debris
buildup, replace or clean the ECA Sensor, then
go to Step V.

Fault Code 66 - ECA Battery Voltage | Fault Isolation Procedures TRTS1000
Fault Code 66 - ECA Battery Voltage

J1939: SA 239 SPN 520271 FMI 3, 4, 14

the clutch assembly. The ECA has a main power 3-Way history using ServiceRanger. The TECU automatically clears
Connector that is directly connected to the 12-volt battery the faults from history after 200 hours. The HCM
positive and negative terminals. automatically clears a fault from history after it has been
Inactive for 200 hours.
Detection
less than 16 volts. - Charging System
• ECA ignition voltage is greater than 8.5 volts. - ECA
Conditions to Set Fault Code Active • FMI 4
The following conditions must be met to set the fault - ECA Power Supply Harness, connections and
code Active: fuse holder
• FMI 3 is set when the ECA battery voltage is above - Low batteries or bad main power connection
17 volts for 10 MS or greater.
- Charging system
• FMI 4 is set when the ECA battery voltage is below
- ECA
8.5 volts for 10 MS or greater.
• FMI 14 is set when the ECA battery voltage is below • FMI 14
8.5 volts for 10 MS or greater, but the HCM reports - ECA Power Supply Harness, connections and
the battery voltage is within range. fuse holder
Fallback Additional Tools

• Fault is stored in HCM memory. If the fault occurs
while driving, the ECA either maintains current
clutch position or moves to the last position • ServiceRanger
commanded by the HCM. Then the ECA holding
device engages. If the fault occurs at power up, the
vehicle will not crank.

TRTS1000 Fault Isolation Procedures | Fault Code 66 - ECA Battery Voltage
ECA 3-Way Connector
C B A
ECA
Ground 1B ECA Ground
1C ECA Power
Plus (+)
Battery

Fault Code 66 - ECA Battery Voltage | Fault Isolation Procedures TRTS1000
Fault Code 66 - ECA Battery Voltage

Purpose: Verify FMI present and perform Electrical Purpose: Verify repair.
A Pretest. V
2. Key on.
Connector.
Pretest” on page 25). 4. Reconnect all connectors and the negative
battery cable.
• If FMI 3 or 4 is Active after performing the
Electrical Pretest, replace the Electric Clutch 5. Drive the vehicle and attempt to reset the code.
Actuator (ECA), then go to Step V.
• If FMI 14 is Active after performing the Faults” on page 13.
Electrical Pretest, replace the ECA Power
Supply Harness, then go to Step V.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 67 - ECA Ignition Voltage
Fault Code 67 - ECA Ignition Voltage

J1939: SA 239 SPN 520274 FMI 3, 4, 5

the clutch assembly. The ECA has a 8-Way Connector that history using ServiceRanger. The TECU automatically clears
supplies ignition power to the ECA from the Hybrid Control faults from history after 200 hours. The HCM automatically
Module (HCM). clears a fault from history after that fault has been Inactive
for 200 hours.
Detection
• HCM ignition voltage is greater than 7 volts and • FMI 3, 4, 5
less than 16 volts. - ECA Ignition Supply Harness from HCM
Conditions to Set Fault Code Active - HCM
The following conditions must be met to set the fault - ECA
code Active:
• FMI 3 is set when the ECA ignition voltage is Additional Tools
shorted to the 12-volt system which is detected • Basic hand tools
through the HCM prior to powering the ignition • Eaton® Test Adapter Kit
supply for the ECA.
• FMI 4 is set when the ECA ignition voltage is
shorted to ground during key on operation which is • ServiceRanger
detected by the HCM.
• FMI 5 is set when the ECA ignition voltage is open
circuit after the key is on.
Fallback
• Fault is stored in HCM memory. If the fault occurs
while driving, the ECA either maintains current
clutch position or moves to 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.

Fault Code 67 - ECA Ignition Voltage | Fault Isolation Procedures TRTS1000
Note: No schematic for this code.

TRTS1000 Fault Isolation Procedures | Fault Code 67 - ECA Ignition Voltage
Fault Code 67 - ECA Ignition Voltage

Purpose: Verify FMIs present. Purpose: Verify voltage of ECA Harness and
A C ground.

2. Disconnect the ECA 8-Way Connector.
Connector.
3. Key on.
2. Key off.
4. Measure voltage from the ECA 8-Way Connector
from Pin H to ground:
• If voltage from H to ground is 11–13 volts,
• If FMI 4 is listed, go to Step C. replace the Hybrid Control Module (HCM),
then go to Step V.
• If voltage is outside of range, go to Step D.
Pin H to ground
Purpose: Verify voltage of ECA Harness and

B ground.
1. Key off. Purpose: Verify continuity of HCM System Harness

2. Disconnect the ECA 8-Way Connector. D and ground.
3. Measure voltage on the ECA 8-Way Connector from

Pin H to ground: 1. Key off.
• If voltage is less than 0 volts, replace the 2. Disconnect the HCM 38-Way System
Hybrid Control Module (HCM), then Harness Connector.
go to Step V. 3. Measure the resistance between the HCM System
• If voltage is 11–13 volts, repair the short to Harness 38-Way Connector Pin 13 and ground.
battery in the Vehicle Harness, then • If resistance from Pin 13 to ground is 10K
go to Step V. ohms or greater, replace the Hybrid Control
Module (HCM), then go to Step V.
Vehicle Harness from the ECA to the HCM,
then go to Step V.
Pin H to ground
Pin 13 to ground

Fault Code 67 - ECA Ignition Voltage | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of HCM Harness and Purpose: Verify repair.

E ECA Harness. V
2. Disconnect the HCM 38-Way System 2. Key on.
Harness Connector.
38-Way Connector and the ECA 8-Way Connector
battery cable.
on the following pins:
- HCM Pin 13 to ECA Pin H 5. Drive the vehicle and attempt to reset the code.
• If the resistance between Pin 13 and Pin H is 6. Check for codes, see “View Active and Inactive
0–0.3 ohms, replace the Electric Clutch Faults” on page 13.
Actuator (ECA) (only if Fault Code is Active), • If no codes, test is complete.
then go to Step V.
• If resistance is outside of range, repair the error in testing.
open in the harness between the ECA and
HCM, then go to Step V. • If a code other than 67 appears, go to “Fault
HCM Connector Pin 13

to ECA Connector Pin H

TRTS1000 Fault Isolation Procedures | Fault Code 70 - Engine Failed to Respond (HCM)
Fault Code 70 - Engine Failed to Respond (HCM)

J1939: SA 239 SPN 93, 188, 539, 544 FMI 0, 1, 2, 7

The Hybrid Control Module (HCM) communicates with the Only Inactive faults can be cleared from the TECU or HCM
Engine Electronic Control Unit (ECU) over the J1939 data history using ServiceRanger. The TECU automatically clears
link during normal operation to control the engine torque faults from history after 200 hours. The HCM automatically
and speed for transmission shifting. clears faults from history after that fault has been Inactive
for 200 hours.
Detection
less than 16 volts. - Engine
• J1939 Communication Link Fault (HCM) is Inactive. - Fuel system
• J1939 Engine Message Fault (HCM) is Inactive. - Exhaust back pressure
Conditions to Set Fault Code Active - Turbo charger
The following conditions must be met to set the fault - Air Intake/filter restriction
code Active: - Unreported engine loads
• FMI 7 is set when the HCM commanded engine - Incorrect engine configuration settings for
torque is less than 80% Max Engine Torque, HCM transmission assembly
commanded engine torque is greater than 100 ft.
lbs, and the difference between commanded engine Additional Tools
torque and engine torque feedback is greater than
80 lb-ft for more than 1 second. Or, if the engine • Basic hand tools
speed or torque maps are received with an error. • Eaton® Test Adapter Kit
Fallback

• If the fault is set while driving, the vehicle may
experience shifting concerns.

Fault Code 70 - Engine Failed to Respond (HCM) | Fault Isolation Procedures TRTS1000
Note: For component location refer to OEM service literature.

TRTS1000 Fault Isolation Procedures | Fault Code 70 - Engine Failed to Respond (HCM)
Fault Code 70 - Engine Failed to Respond (HCM)

A status.

Connector.
2. Key on.
3. Retrieve codes, see “View Active and Inactive
• If Fault 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.

Fault Code 71 - Failed to Disengage a Gear | Fault Isolation Procedures TRTS1000
Fault Code 71 - Failed to Disengage a Gear

J1587: MID 130 SID 60 FMI 7
J1939: SA 3 SPN 520275 FMI 7

The Transmission Electronic Control Unit controls the Only Inactive faults can be cleared from the TECU or HCM
Electric Shifter, which engages the different rails and gear history using ServiceRanger. The TECU automatically clears
positions. The Electric Shifter is comprised of two electric faults from history after 200 hours. The HCM automatically
motors; one changes the rail position and the other clears a fault from history after that fault has been Inactive
changes the gear position. for 200 hours.

• TECU ignition voltage is greater than 7 volts and - Dragging Clutch
less than 16 volts.
- ECA
- Shift Bar Housing
is Inactive. - Electric Shifter
• TECU J1939 Communication Link Fault is Inactive. - Gear Select Sensor
• J1939 engine torque is zero ± 5% and J1939 - Yoke, Sliding Clutch, Mainshaft
engine speed is within 50 RPM of synchronous. - TECU
- Torque locked in gear
code Active:
• FMI 7 is set when the Electric Shifter fails three
consecutive attempts to disengage a gear. • Eaton® Test Adapter Kit
Fallback • ServiceRanger
• Fault is stored in TECU memory
• If the fault sets while driving, the vehicle maintains
the current gear and clutch opens when the vehicle
stops.

TRTS1000 Fault Isolation Procedures | Fault Code 71 - Failed to Disengage a Gear
Note: The picture above shows the Shift Forks in the neutral position.

Fault Code 71 - Failed to Disengage a Gear | Fault Isolation Procedures TRTS1000
Fault Code 71 - Failed to Disengage a Gear

Purpose: Verify gear display in neutral gear Purpose: Perform manual Shift Bar Housing
A position. C inspection.

2. Remove Electric Shifter* from Shift Bar Housing to
Connector.
see what gear position is currently engaged.
2. Key on.
3. Attempt to move the engaged rail back to neutral:
3. Press N on the Push Button Shift Control.
• If rails move from the engaged position to
4. Observe Gear Display: neutral, go to Step D.
• If gear display shows: “N”, go to Step V. • If rails do not move from the engaged position,
attempt to take the torque off the driveline. If
• If gear display shows: “71”, go to Step B.
concern is still present, inspect the Main Case
for a damaged Mainshaft, sliding Clutch, or
Parameter Reading Fork. Go to Step V.
Gear Display • * See Electric Shifter in TRSM1000 Manual.
Purpose: Verify integrity of Shift Bar Housing

B Purpose: Perform Electrical Pretest.
D components.
1. Perform the Electrical Pretest (see “Electrical 1. Key off.

Pretest” on page 25): 2. Inspect the following:
• If no issues found during the Electrical Pretest, - Shift blocks are fastened to Shift Rails securely
go to Step C. - Electric Shifter is free from any excessive lube
contamination buildup
Pretest, go to Step A. - Two gear positions can not be engaged at the
same time
• If no problem found, replace the Electric
Shifter, then go to Step V.
• If problem is found, repair as required, then
go to Step V.

TRTS1000 Fault Isolation Procedures | Fault Code 71 - Failed to Disengage a Gear

V
1. Key off.
battery cable.
3. Key on.
error in testing.

Fault Code 72 - Failed to Select Rail | Fault Isolation Procedures TRTS1000
Fault Code 72 - Failed to Select Rail

J1587: MID 130 SID 59 FMI 7
J1939: SA 3 SPN 520277 FMI 7

positions. The Electric Shifter is comprised of two electric the faults from history after 200 hours. The HCM
motors; one changes the rail position and the other automatically clears a fault from history after it has been
changes the gear position. Inactive for 200 hours.

• TECU ignition voltage is greater than 7 volts and - Shift Bar Housing
less than 16 volts.
- Electric Shifter
- Rail Select Sensor
is Inactive. - TECU
• This fault may occur at power up after 15 seconds. Additional Tools

• FMI 7 is set when the Electric Shifter fails five • ServiceRanger
consecutive attempts to engage a particular
rail position.
Fallback
• If the fault sets while driving, the vehicle continues
to select the proper rail position.

TRTS1000 Fault Isolation Procedures | Fault Code 72 - Failed to Select Rail

Fault Code 72 - Failed to Select Rail | Fault Isolation Procedures TRTS1000
Fault Code 72 - Failed to Select Rail

Purpose: Verify gear display in neutral gear Purpose: Verify integrity of Shift Bar Housing
A position. C components.

2. Remove Electric Shifter* from Shift Bar Housing.
Connector.
3. Inspect the following:
2. Key on.
- Shift Blocks are fastened to Shift Rails securely
3. Place Shift Device in neutral. - Shift Rails move into each gear position
4. Press Service Brake. - Electric Shifter is free from any excessive lube
5. Select Drive.
- Two gear positions can not be engaged at the
6. Observe gear display: same time
• If there is an Active Fault Code 72, • If no problem found, replace the Electric
go to Step B. Shifter, then go to Step V.
• If Gear Display shows solid gear, go to Step V. • If problem is found, repair as required, then
go to Step V.
Parameter Reading
Gear Display • * See Electric Shifter.

V
Purpose: Perform Electrical Pretest.
B 1. Key off.
battery cable.
Pretest” on page 25). 3. Key on.
• If no issues found during the Electrical Pretest, 4. Clear codes, see “Clear Inactive Faults” on page 13.
go to Step C. 5. Drive the vehicle and attempt to reset the code.
• If issue was repaired during the Electrical 6. Check for codes, see “View Active and Inactive
Pretest, go to Step A. Faults” on page 13.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 73 - Failed to Engage a Gear
Fault Code 73 - Failed to Engage a Gear

J1587: MID 130 SID 58 FMI 7
J1939: SA 3 SPN 520278 FMI 7

positions. The Electric Shifter is comprised of two electric faults from history after 200 hours. The HCM automatically
motors—the Rail motor and Gear motor. The Rail motor clears a fault from history after that fault has been Inactive
changes the rail position and the Gear motor changes the for 200 hours.
gear position.
Possible Causes
detects the fault:
- Dragging Clutch
less than 16 volts. - ECA
• TECU System Battery Voltage Low Fault is Inactive. - Shift Bar Housing
• TECU System Battery Voltage Weak Fault - Electric Shifter

is Inactive. - Gear Select Sensor
- Yoke, Sliding Clutch, Mainshaft
The following conditions must be met to set the fault - TECU
code Active:
Additional Tools
• FMI 7 is set when the Electric Shifter fails 5
consecutive attempts to engage a particular • Basic hand tools
gear position. • Eaton® Test Adapter Kit
Fallback

• If the fault sets while driving, the vehicle maintains
the current position.

Fault Code 73 - Failed to Engage a Gear | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 73 - Failed to Engage a Gear
Fault Code 73 - Failed to Engage a Gear

Purpose: Verify gear display in neutral gear Purpose: Verify integrity of Shift Bar Housing
A position. C components.

Connector.
2. Key on.
3. Place Shift Device in neutral. - Electric Shifter is free from any excessive lube
4. Press Service Brake. contamination buildup
5. Select Drive.
same time
6. Observe Gear Display:
• If no problem is found, replace the Electric
• If there is an Active Fault Code 73, Shifter, then go to Step V.
go to Step B.
• If gear display shows solid gear, go to Step V. go to Step V.
Parameter Reading
• * See Electric Shifter.
Gear Display

V
Purpose: Perform Electrical Pretest. 1. Key off.
B 2. Reconnect all connectors and the negative
battery cable.
3. Key on.
go to Step C. 5. Drive the vehicle and attempt to reset the code.
• If issue was repaired during the Electrical 6. Check for codes, see “View Active and Inactive
Pretest, go to Step A. Faults” on page 13.
error in testing.

Fault Code 74 - Engine Failed to Respond (TECU) | Fault Isolation Procedures TRTS1000
Fault Code 74 - Engine Failed to Respond (TECU)

J1587: MID 130 PID 93, 190 FMI 7
J1939: SA 3 SPN 93, 190 FMI 7

The Transmission Electronic Control Unit (TECU) Only Inactive faults can be cleared from the TECU or HCM
communicates with the Electronic Control Unit (ECU) over history using ServiceRanger. The TECU automatically clears
the J1939 data link during normal operation; however, faults from history after 200 hours. The HCM automatically
engine control is accomplished by the ECU during hybrid clears a fault from history after that fault has been Inactive
mode. The TECU changes mode to AutoShift Only or for 200 hours.
AutoShift Fallback mode. Then the TECU requests changes
in engine speed and torque instead of the Hybrid Control Possible Causes
Module (HCM). This fault code can be caused by any of the following:
• FMI 7
Detection
The following preconditions must be met before the system - Engine
detects the fault: - Fuel system
• TECU ignition voltage is greater than 7 volts and - Exhaust back pressure
less than 16 volts. - Turbo charger
• J1939 Communication Link Fault (TECU) Inactive. - Air Intake/filter restriction
• J1939 Engine Message Fault (TECU) Inactive. - Unreported engine loads
• J1939 engine speed is greater than 300 RPM if the - Incorrect engine configuration settings for
TECU is in speed control mode, or greater than transmission assembly
1000 RPM if the TECU is in torque control mode.
• Desired engine speed is less than J1939 engine Additional Tools
configuration map speed. • Basic hand tools
code Active: • ServiceRanger
• 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.
Fallback
the current gear position. Once the vehicle stops,
start and reverse gears can be engaged.
• TECU changes to “AutoShift Fallback” mode.

TRTS1000 Fault Isolation Procedures | Fault Code 74 - Engine Failed to Respond (TECU)

Fault Code 74 - Engine Failed to Respond (TECU) | Fault Isolation Procedures TRTS1000
Fault Code 74 - Engine Failed to Respond (TECU)

A status.

Connector.
2. Key on.
3. Retrieve codes, see “View Active and Inactive
• If Fault Code 74 is Active, contact the OEM
because the engine is failing to respond to the
transmission commands during a shift.

TRTS1000 Fault Isolation Procedures | Fault Code 75 - Power Down in Gear
Fault Code 75 - Power Down in Gear

J1587: MID 130 SID 60 FMI 14
J1939: SA 3 SPN 520276 FMI 14

The Push Button Shift Control (PBSC) is connected to the Only Inactive faults can be cleared from the TECU or HCM
Transmission Electronic Control Unit (TECU) over the High history using ServiceRanger. The TECU automatically clears
Integrity Link (HIL) to communicate driver mode selection faults from history after 200 hours. The HCM automatically
and fault status. At power down the PBSC should be placed clears a fault from history after that fault has been Inactive
in “N” to perform the proper calibration sequence and to for 200 hours.
prevent a torque locked transmission.
Possible Causes
The following preconditions must be met before the system • FMI 14: Driver powered down in non-neutral mode
detects the fault:
• TECU ignition voltage is greater than 7 volts and Additional Tools
less than 16 volts. • Basic hand tools
• PBSC ignition voltage is greater than 7 volts and • Eaton® Test Adapter Kit
less than 16 volts.
Conditions to Set Fault Code Active • ServiceRanger
code Active:
• FMI 14 is set when the TECU goes into the
power-down sequence and a drive mode selection
other than “N” is confirmed.
Fallback
• Fault is stored in TECU memory only as an
Inactive fault, since it only sets during the
power-down sequence.

Fault Code 75 - Power Down in Gear | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 75 - Power Down in Gear
Fault Code 75 - Power Down in Gear

A status.

Connector.
2. Key on.
3. Retrieve Codes, see “View Active and Inactive
• If Fault Code 75 is Inactive, no action
necessary. This code indicates the driver
powered down the system prior to selecting
neutral.
• 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.

Fault Code 76 - High Voltage Battery 1 Potential Voltage | Fault Isolation Procedures TRTS1000
Fault Code 76 - High Voltage Battery 1 Potential Voltage

J1939: SA 239 SPN 520250 FMI 3, 4, 16, 18

The high-voltage batteries are 172 volts each. They are Only Inactive faults can be cleared from the TECU or HCM
connected in a series to produce 340 volts DC. The Battery history using ServiceRanger. The TECU automatically clears
Control Unit, located in the Relay Box, communicates with a fault from history after 200 hours. The HCM automatically
each battery to determine temperature, State Of Charge clears a fault from history after that fault has been Inactive
(SOC) and voltage. This information is then sent to the for 200 hours.
Inverter.
Possible Causes
The following preconditions must be met before the system • FMI 3, 4
detects the fault:
- PEC
• Inverter ignition voltage is greater than 7 volts and
less than 16 volts. - DC cable
• Battery Control Unit ignition voltage is greater than - DC Interlock Loop

7 volts and less than 16 volts. - Inverter
- Service Switch
The following conditions must be met to set the fault - Inertia Switch
code Active:
Additional Tools
• FMI 3 is set when the BCU detects the high-voltage
battery is greater than 417 volts for 240 MS. • Basic hand tools
• FMI 16 is set when the BCU detects the • ASTM Class 0 electrical insulating rubber gloves
high-voltage battery is greater than 408 volts for with leather protectors J48603
240 MS. • Lockout bracket J48506
• FMI 4 is set when the BCU detects the high-voltage • Lockout tags
battery is less than 211 volts for 240 ms. • Eaton® Test Adapter Kit J43318
• FMI 18 is set when the BCU detects the • Digital Volt/Ohm Meter J46708
high-voltage battery is less than 240 volts for
240 ms. • ServiceRanger

Fallback
• Amber “Check Hybrid” light blinks for FMI 4 and
displays solid for FMI 3.
• Inverter shuts high-voltage system off.
diesel-only mode.

TRTS1000 Fault Isolation Procedures | Fault Code 76 - High Voltage Battery 1 Potential Voltage
Note: 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 key off. After 2 minutes turn the key
on.


A status. V
page 1.
2. Key on.
2. Key off.
3. Key on.
4. Retrieve Active fault codes and FMIs with battery cable.
Connector.
5. Key off.
dures to avoid shock, burn or death from improp- • If Fault Code 76 appears, go to Step A. Find
erly handled high-voltage. error in testing.
6. Which FMIs are present? • If a code other than 76 appears, go to “Fault

• If Fault Code 76 is listed with an Active Fault
Code 101 FMI 27, 28, go to “Fault Code 101 -
High Voltage Battery 1” on page 303.
Code 101 FMI 29, go to “Fault Code 101 - High
Voltage Battery 1” on page 303.
• 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).
• If Fault Code 76 FMI 3 or 4 are listed with other
Active hybrid fault codes, go to “View Active
and Inactive Faults” on page 13 to look up
Active hybrid fault code(s).
• If Fault Code 76 FMI 16 or 18 are listed, test is
complete. FMIs 16 and 18 require no action
or replacement.


J1939: SA 239 SPN 520262 FMI 3, 4, 16, 18

The high-voltage batteries are 172 volts each connected in Only Inactive faults can be cleared from the TECU or HCM
series to produce 340 volts DC. The Battery Control Unit, history using ServiceRanger. The TECU automatically clears
located in the Relay Box, communicates with each battery faults from history after 200 hours. The HCM automatically
to determine temperature, State Of Charge (SOC) and clears a fault from history after that fault has been Inactive
voltage. This information is then sent to the Inverter. for 200 hours.

detect the fault: • FMI 3, 4
• Inverter ignition voltage is greater than 7 volts and - PEC
less than 16 volts.
- DC cable
• Battery Control Unit ignition voltage is greater than
7 volts and less than 16 volts. - DC Interlock Loop
- Inverter
Conditions to Set Fault Code Active - Service Switch
code Active: - Inertia Switch
• FMI 3 is set when the BCU detects the high-voltage Additional Tools
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 • ASTM Class 0 electrical insulating rubber gloves
240 MS. with leather protectors J48603
• FMI 4 is set when the BCU detects the high-voltage • Lockout bracket J48506
battery is less than 211 volts for 240 MS. • Lockout tags
• FMI 18 is set when the BCU detects the • Eaton® Test Adapter Kit J43318
high-voltage battery is less than 240 volts for • Digital Volt/Ohm Meter J46708
240 MS.
• ServiceRanger
Fallback
• Amber “Check Hybrid” light blinks for FMI 4 and
displays solid for FMI 3
• Fault is stored in HCM memory
diesel-only mode
• Transmission defaults start gear to 1st

Note: No Schematic for this Code.
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 key off. After 2 minutes, turn the key on.


A status. V
page 1.
2. Key on.
2. Key off.
3. Key on.
4. Retrieve Active fault codes and FMIs with battery cable.
Connector.
5. Key off.
dures to avoid shock, burn or death from improp- • If Fault Code 77 appears, go to Step A. Find
erly handled high-voltage. error in testing.
6. Which FMIs are present? • If a code other than 77 appears, go to “Fault

Code 102 FMI 27 or 28, go to “Fault Code 102
- High Voltage Battery 2” on page 307.
Code 102 FMI 29, go to go to “Fault Code 102
- High Voltage Battery 2” on page 307.
• If Fault Code 77, FMI 3 or 4 are listed with no
other Active hybrid fault codes, contact Eaton
at 1-800-826-HELP (4357).
• If Fault Code 77, FMI 3 or 4 are listed with
other Active hybrid fault codes, go to “View
Active and Inactive Faults” on page 13 to look
up Active hybrid fault code(s).
• If Fault Code 77, FMI 16 or 18 are listed, test
is complete. FMIs 16 and 18 require no action
or replacement.

Fault Code 78 - High Voltage Battery 1 Current | Fault Isolation Procedures TRTS1000
Fault Code 78 - High Voltage Battery 1 Current

J1939: SA 239 SPN 520232 FMI 6

series to produce 340 volts DC. The Battery Control Unit history using ServiceRanger. The TECU automatically clears
(BCU), located in the Relay Box, communicates with each faults from history after 200 hours. The HCM automatically
battery to determine temperature, State Of Charge and clears a fault from history after that fault has been Inactive
voltage. This information is then sent to the Inverter. for 200 hours.

detects the fault: • FMI 6 PEC
• Battery Control Unit ignition voltage is greater than • Basic hand tools
7 volts and less than 16 volts. • ASTM Class 0 electrical insulating rubber gloves
The following conditions must be met to set the fault • Lockout bracket J48506
code Active: • Lockout tags
• FMI 6 is set when the BCU detects high-voltage • Eaton® Test Adapter Kit J43318
battery current is greater than 200 amps for • Digital Volt/Ohm Meter J46708
1 second.
• ServiceRanger
Fallback
(HCM) memory.
• Inverter shuts high-voltage system off, HCM
continues to control the hybrid vehicle in a
diesel-only mode.

TRTS1000 Fault Isolation Procedures | Fault Code 78 - High Voltage Battery 1 Current


A status. V
page 1.
2. Key on.
3. Key off.
battery cable.
4. Which faults are present? • If no codes, test is complete.
• If Fault Code 78 is listed with an Active Fault • If Fault Code 78 appears, go to Step A. Find
Code 113, go to “Fault Code 113 - Inverter error in testing.
Current” on page 355, FMI 6. • If a code other than 78 appears, go to “Fault
• If Fault Code 78 is listed with no Fault Code Code Isolation Procedure Index” on page 14.
113, replace the Power Electronics Carrier
(PEC), then go to Step V.


J1939: SA 239 SPN 520263 FMI 6

The high-voltage batteries are 172 volts each and are Only Inactive faults can be cleared from the TECU or HCM
connected in series to produce 340 volts DC. The Battery history using ServiceRanger. The TECU automatically clears
Control Unit (BCU), located in the Relay Box, communicates faults from history after 200 hours. The HCM automatically
with each battery to determine temperature, State Of clears the faults from history after that fault has been
Charge (SOC) and voltage. This information is then sent to Inactive for 200 hours.
the Inverter.
Possible Causes
The following preconditions must be met before the system • FMI 6: PEC
detects the fault:
• Inverter ignition voltage is greater than 7 volts and Additional Tools
• Battery Control Unit ignition voltage is greater than • ASTM Class 0 electrical insulating rubber gloves
7 volts and less than 16 volts. with leather protectors J48603
Conditions to Set Fault Code Active • Lockout bracket J48506
The following conditions must be met to set the fault • Lockout tags
• FMI 6 is set when the BCU detects high-voltage • Digital Volt/Ohm Meter J46708
battery current is greater than 200 amps for
1 second. • ServiceRanger
Fallback
(HCM) memory.
diesel-only mode.



A status. V
page 1.
2. Key on.
3. Key off.
battery cable.
4. Which faults are present? • If no codes, test is complete.
• If Fault Code 79 is listed with an Active Fault • If Fault Code 79 appears, go to Step A. Find
Code 113, go to “Fault Code 113 - Inverter error in testing.
Current” on page 355, FMI 6. • If a code other than 79 appears, go to “Fault
• If Fault Code 79 is listed with no Active Fault Code Isolation Procedure Index” on page 14.
Code 113, replace the Power Electronics
Carrier (PEC), then go to Step V.

Fault Code 82 - High Voltage Battery 1 Temperature | Fault Isolation Procedures TRTS1000
Fault Code 82 - High Voltage Battery 1 Temperature

J1939: SA 239 SPN 1800 FMI 0, 16

Control Unit, located in the Relay Box, communicates with faults from history after 200 hours. The HCM automatically
each battery to determine temperature, State Of Charge, clears a fault from history after that fault has been Inactive
and voltage. This information is then sent to the Inverter. for 200 hours.

less than 16 volts.
- Battery Fan
7 volts. - Battery Fan Air Filter
- Battery Fan Relay Power Supply Harness
Conditions to Set Fault Code Active - Battery Fan Relay
code Active: - Battery Fan Exhaust Screen
• FMI 0 is set when the BCU detects high-voltage Additional Tools

battery temperature is greater than 158 °F (70 °C)
for 6.4 seconds. • Basic hand tools
• FMI 16 is set when the BCU detects high-voltage • ASTM Class 0 electrical insulating rubber gloves
battery temperature is greater than 140 °F (60 °C) with leather protectors J48603
for 6.4 seconds. • Lockout bracket J48506
• Lockout tags
Fallback
When Fault Code 82 is set the following conditions occur: • Eaton® Test Adapter Kit J43318
• Amber “Check Hybrid” light illuminates. • Digital Volt/Ohm Meter J46708
• Fault is stored in HCM memory. • ServiceRanger

diesel-only mode.
Note: The conditions above are only present for FMI 0.

TRTS1000 Fault Isolation Procedures | Fault Code 82 - High Voltage Battery 1 Temperature
19 - Way Mating Connector View

Harness Front View
(PEC - Low Voltage Connector)
29 34
23 28
19 8 9
18 7 2 10
37 38
17 6 1 3 11
13 22 16 5 4 12
35 36
15 14 13
7 12
1 6
HCM
Battery Fan
87

Cooling Fan Plus 12
PEC
12V Plus
30
86
12V Truck
Battery
85 87


Purpose: Check for Active or Inactive fault code Purpose: Verify operation of PEC fan.
A status. C
page 1.
2. Retrieve Active fault codes and FMIs with Ser- Connector in the cab.
3. Key on.
3. Key off.
4. Go to “Product Tests” and select “Battery Fan
! Warning: See “High-Voltage Service Shutdown and Relay.”
in the PEC:
• If airflow can be felt from the PEC Air Inlet and
4. Which faults are present? exhaust, go to Step E.
• If Fault Code 82 FMI 0 is listed, go to Step B. • If airflow can not be felt from the PEC Air Inlet
• If Fault Code 82 FMI 16 is listed, test is and exhaust, go to Step D.
complete. FMI 16 requires no action
or replacement.
Purpose: Verify integrity of PEC Air Filter Element.

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 Exhaust 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, then go to Step V.
• * See Air Filter.

Purpose: Verify voltage at PEC connector. Purpose: Verify repair.

D V
2. Disconnect the 19-Way Connector at the PEC. 2. Reconnect all connectors and negative
battery cable.
3. Measure voltage at the 19-Way Connector from Pin
12 to Pin 14: 3. Key on.
• If voltage between Pin 12 and Pin 14 is ±0.2 4. Clear codes, see “Clear Inactive Faults” on page 13.
volts of battery voltage, replace the Power
Electronics Carrier (PEC), then go to Step V.
of range, repair Battery Fan Relay circuit.
Refer to OEM. • If no codes, test is complete.
error in testing.
Pin 12 to Pin 14 Code Isolation Procedure Index” on page 14.
Purpose: Verify fault code present.

E
1. Is Fault Code 105 FMI 29 listed Active?
• Fault Code 105 FMI 29 is Active, replace
the Power Electronics Carrier (PEC), then
go to Step V.
• Fault Code 105 FMI 29 is Inactive. 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).


J1587: MID 130 SID 18 FMI 12, 13
J1939: SA 3 SPN 751 FMI 12, 13

connected to the shift device, which sends driver mode history using ServiceRanger. The TECU automatically clears
selection data. The only compatible shift devices are the faults from history after 200 hours. The HCM automatically
Eaton® Push Button Shift Control (PBSC) and OEM clears a fault from history after the fault has been Inactive
supplied shift lever (if equipped with park). The TECU for 200 hours.
Detection • FMI 12, 13
detects the fault: - Faulty Sensors
• TECU ignition voltage is greater than 7 volts and - Harness

Additional Tools
• TECU is being powered up for the first time and no
shift device has been configured. • Basic hand tools
• Eaton Test Adapter Kit
• Fault Code 83 is set when redundant sensor

voltages do not agree.
Fallback
• “F” appears in the gear display.
• TECU changes to “AutoShift” control.

Harness Front View

(TECU - Vehicle Interface Connector) 1 4-Pin Park Pawl Actuator
6 Connector
7 3
12
2
36 35
22 13
38 37
1
4
28 23
34 29
Park Pawl
TECU
Actuator


Purpose: Verify supply voltage to Shift Lever. Purpose: Verify voltage to Shift Lever in neutral
A B gear position.
1. Review and follow the “Warnings & Cautions” on 1. With the actuator/shift lever in the Neutral position
page 1. check voltage on pins:
2. Disconnect the 4-Way Connector to the - 3 to ground
Park Pawl Actuator. - 4 to ground
3. Key on. • If measurement is between 2.25–2.75 volts,

go to Step C.
4. Check for 12-volt supply at 4-Way Connector at
Pin 1 and Pin 2: • If voltage is outside the range, replace the Park
Pawl Mechanism Sensor, then go to Step V.
• If voltage between Pin 1 and Pin 2 is ±0.2
volts of battery voltage, go to Step B.
• If voltage is outside the range, go to Step D. Connection Measurement
Pin 3 to ground
Pin 4 to ground
Pin 1 to Pin 2

Purpose: Verify continuity of Shift Lever circuits in Purpose: Verify continuity of Shift Lever circuits in
C Vehicle Harness. D Vehicle Harness.
1. Disconnect the TECU Harness 38-Way Connector. 1. Disconnect the TECU Vehicle Harness
38-way connector.
2. Check continuity between:
- 38-Way Connector Pin 15 and 4-Way Connector 2. Check continuity between:
Pin 4 - 38-Way Connector Pin 17 and 4-Way Connector
- 38-Way Connector Pin 16 and 4-Way Connector Pin 1
Pin 3 - 38-Way Connector Pin 31 and 4-Way Connector
Pin 2
• If continuity is okay, replace the Transmission
Electronic Control Unit (TECU), then • If continuity is okay, replace the Transmission
go to Step V. Electronic Control Unit (TECU), then
go to Step V.
• If an open is found, repair or replace the
Harness, then go to Step V. • If an open is found, repair or replace the
38-Way Pin 15
to 4-Way Pin 4 38-Way Pin 17
to 4-Way Pin 1
38-Way Pin 16
to 4-Way Pin 3 38-Way Pin 31
to 4-Way Pin 2


V
1. Key off.
3. Key on.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 84 - Shift Control Device Not Configured
Fault Code 84 - Shift Control Device Not Configured

J1587: MID 130 SID 18 FMI 13, 14
J1939: SA 3 SPN 751 FMI 13, 14

selection data. The only compatible shift device is the faults from history after 200 hours. HCM automatically
Eaton® Push Button Shift Control (PBSC) and OEM clears a fault from history after that fault has been Inactive
supplied shift lever (if equipped with park). The TECU for 200 hours.
Note: This fault code will only be set Active.
• FMI 13
Detection - OEM Wiring Harness between TECU and
The following preconditions must be met before the system shift control device is disconnected
detects the fault: - PBSC
• TECU ignition voltage is greater than 7 volts and • FMI 14
less than 16 volts.
- OEM Wiring Harness between TECU and
• TECU System Battery Voltage Low Fault is Inactive. shift control device is disconnected
• TECU is being powered up for the first time and no - Shift Lever
shift device has been configured.
Additional Tools
• FMI 13 is set when the TECU powers-up the first • Digital Volt/Ohm Meter
time and fails to recognize any valid shift device • ServiceRanger
connected to the vehicle within five seconds.
Fallback
• Red “Service” light may or may not come on
depending on the failure.
• The engine does not crank.

Fault Code 84 - Shift Control Device Not Configured | Fault Isolation Procedures TRTS1000
4-Pin Park Pawl Actuator
3 Connector

(TECU - Vehicle Interface Connector) 1 (Push Button Shift Control 30-Way Connector)
6
7
12
K J H G F E D C B A
36 35
1 K1 A1
22 13
2
38 37
3 K3 A3
28 23
34 29
TECU PBSC
HIL High 28 F1 HIL High
HIL Low 27 F2 HIL Low
Shift Power (Plus) 31 C1 Shift Power (Plus)
Shift Return (Minus) 25 J3 Shift Return (Minus)
B3
VDash Dimmer
Shift Lever
TECU
Controller

Fault Code 84 - Shift Control Device Not Configured

Purpose: Verify status of Transmission Service Purpose: Verify voltage to PBSC.
A light. C
2. Disconnect the PBSC 30-Way Connector.
Connector.
3. Key on.
2. Key on and observe the Push Button Service Light.
4. Measure the voltage between Pin J3 and Pin C1 on
• If red “Service” light comes on, go to Step B.
the 30-Way Connector:
• If red “Service” light does not turn on,
• If voltage is within 0.6 volts of battery voltage,
go to Step C.
replace the PBSC (see Shift Control), then
• If FMI 14 is present, Call 1-800-826-HELP go to Step V.
(4357). Go to Step V.
• If voltage is out of range, go to Step D.
Pin J3 to Pin C1
Purpose: Verify operation of PBSC Mode Lights.

B
1. Key off and on while observing the green “Mode”
lights on the PBSC:
• If green Mode lights turn on, go to Step F.
• If green Mode lights do not turn on, replace
PBSC (see Shift Control), then go to Step V.

Purpose: Verify continuity of Shift Lever circuits in Purpose: Verify continuity of Shift Lever circuits in
D Vehicle Harness. E Vehicle Harness.

2. Disconnect negative battery cable. 2. Disconnect negative battery cable.
3. Disconnect Vehicle Harness 38-Way Connector. 3. Disconnect Vehicle Harness 38-Way Connector.
4. Measure the resistance between Pin J3 on the Shift 4. Measure the resistance between the following:
Control 30-Way Connector and the Pin 25 on the - Pin C1 on the Shift Control 30-Way Connector
Vehicle Harness 38-Way Connector. and Pin 31 on the Vehicle Harness 38-Way
• If resistance between Pins J3 and Pin 25 is Connector
0–0.3 ohms, go to Step E. - Pin C1 on the Shift Control and ground
• If resistance is out of range, repair the Vehicle • If resistance between Pin C1 and Pin 31 is
Harness between the PBSC and the TECU, then 0–0.3 ohms and resistance between Pin C1
go to Step V. and ground is 10K ohms or greater, replace the
(only if fault code is Active). Go to Step V.
Connection Measurement • If resistance is out of range, repair the Vehicle
Harness between the PBSC and the TECU, then
30-Way Pin J3 to go to Step V.
38-Way Pin 25
30-Way Pin C1 to
38-Way Pin 31
30-Way Pin C1 to
ground

Purpose: Verify AC voltage at PBSC. Purpose: Verify continuity between PBSC Harness
F G and Vehicle Harness.

2. Disconnect the Shift Control 30-Way Connector. 2. Disconnect negative battery cable.
3. Key on. 3. Disconnect Vehicle Harness 38-Way Connector.
4. Measure the AC voltage between Pin F1 and Pin F2: 4. Measure the resistance between the following:
- Pin F1 on the Shift Control 30-Way Connector
Note: Make sure the meter is on the AC auto
and Pin 28 on the Vehicle Harness 38-Way
feature or set to the AC 10 volts scale.
Connector
• If voltage is 0.10 volts AC or greater, replace - Pin F1 on the Shift Control 30-Way Connector
the Push Button Shift Control (PBSC) (see and ground
Shift Control), then go to Step V.
• If resistance between Pin F1 and Pin 28 is
• If voltage is 0.10 volts AC or less, 0–0.3 ohms and resistance between Pin F1
go to Step G. and ground is 10K ohms or greater,
go to Step H.
• If resistance is out of range, repair the Vehicle
go to Step V.
Pin F1 to Pin F2
30-Way Pin F1 to
38-Way Pin 28
30-Way Pin F1 to
ground

Purpose: Verify continuity between PBSC Harness Purpose: Verify repair.

H and Vehicle Harness. V
battery cable.
3. Disconnect Vehicle Harness 38-Way Connector.
3. Key on.
4. Measure the resistance between the following:
- Pin F2 on the Shift Control 30-Way Connector 4. Clear codes, see “Clear Inactive Faults” on page 13.
and Pin 27 on the Vehicle Harness 38-Way 5. Drive the vehicle and attempt to reset the code.
Connector
- Pin F2 on the Shift Control 30-Way Connector 6. Check for codes, see “View Active and Inactive
and ground Faults” on page 13.
• If resistance between Pin F2 and Pin 27 is • If no codes, test is complete.

0–0.3 ohms and resistance between Pin F2 • If Fault Code 84 appears, go to Step A. Find
and ground is 10K ohms or greater, replace the error in testing.
Transmission Electronic Control Unit (TECU).
Go to Step V. • If a code other than 84 appears, go to “Fault
• If resistance is out of range, repair the Vehicle
go to Step V.
30-Way Pin F2 to
38-Way Pin 27
30-Way Pin F2 to
ground

TRTS1000 Fault Isolation Procedures | Fault Code 85 - Shift Control Device Incompatible
Fault Code 85 - Shift Control Device Incompatible

J1587: MID 130 SID 18 FMI 12
J1939: SA 3 SPN 639 FMI 12

selection data. The TECU checks the vehicle for the type of faults from history after 200 hours. The HCM automatically
Push Button Shift Control (PBSC) device during the first clears a fault from history after that fault has been Inactive
power up to determine if a compatible model is being used. for 200 hours.

detects the fault:
• FMI 12: Shift Control Device
• TECU System Battery Voltage Low Fault is Inactive. • Basic hand tools
• HIL Link Fault is Inactive. • Eaton® Test Adapter Kit
code 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 identification 10
seconds after power up.
Fallback

Fault Code 85 - Shift Control Device Incompatible | Fault Isolation Procedures TRTS1000
Note: No Schematic for this Code.

TRTS1000 Fault Isolation Procedures | Fault Code 85 - Shift Control Device Incompatible
Fault Code 85 - Shift Control Device Incompatible

Purpose: Verify PBSC configuration. Purpose: Verify HCM configuration.
A B
1. Retrieve Active fault codes and FMIs with 1. View the Hybrid Control Module (HCM) selection
ServiceRanger using the 9-Way Diagnostic under the Roadranger Configurations option in
Connector. ServiceRanger.
2. Select the “Roadranger Configurations” menu and 2. View the System Configuration field for one of the
view the “Transmission” selection. following options:
3. View the “Pushbutton Type” field for one of the - UPG = Used in EH-8E306A-UPG transmission
following options: - UP = Used in EH-8E306A-UP transmissions
- EARNDM = Used with EH-8E306A-UPG - CD or U = Used in EH-8E306A-CD and
transmissions (shown on transmission tag) EH-8E306A-U transmissions
- ERNDM = Used with EH-8E306A-UP 3. Compare the HCM System Configurations selection
transmissions (shown on transmission tag) to the TECU Pushbutton Type selection:
- RNDML = Used with EH-8E306A-CD and
• If HCM System Configuration and TECU
EH-8E306A-U transmissions (shown on
Pushbutton Type are the same, contact Eaton
transmission tag)
at 1-800-826-HELP (4357).
• If the “Pushbutton Type” field matches the
• If HCM System Configuration and TECU
Pushbutton installed in the vehicle,
Pushbutton Type are different, install a Hybrid
go to Step B.
Control Module (HCM) with the correct
• If the “Pushbutton Type” field does not match configuration to match the transmission tag,
the Pushbutton installed in the vehicle, change then go to Step V.
the “Pushbutton Type Field” or Pushbutton to
match the transmission model number shown
on the transmission tag. Use this step (Step
A.3.) to determine correct pushbutton for
each model.

Fault Code 85 - Shift Control Device Incompatible | Fault Isolation Procedures TRTS1000

V
1. Key off.
battery cable.
3. Key on.
error in testing.


J1939: SA 239 SPN 1801 FMI 0, 16

Control Unit, located in the Relay Box, communicates with faults from history after 200 hours. The HCM automatically
each battery to determine temperature, State Of Charge clears a fault from history after that fault has been Inactive
(SOC) and voltage. This information is then sent to the for 200 hours.
Inverter.
Possible Causes
detects the fault:
- PEC
less than 16 volts. - Battery Fan
• Battery Control Unit ignition voltage is greater than - Battery Fan Air Filter
7 volts. - Battery Fan Relay Power Supply Harness
- Battery Fan Relay
The following conditions must be met to set the fault - Battery Fan Exhaust Screen
code Active:
Additional Tools
• FMI 0 is set when the BCU detects high-voltage
battery temperature is greater than 70 °C for 6.4 • Basic hand tools
seconds. FMI 16 is set when the BCU detects • ASTM Class 0 electrical insulating rubber gloves
high-voltage battery temperature is greater than with leather protectors J48603
60 °C for 6.4 seconds. • Lockout bracket J48506
Fallback • Lockout tags
diesel-only mode.
Note: The conditions above are only present for FMI 0.

Front Harness View

29 34
23 28
19 8 9
37 38 18 7 2 10
13 22 17 6 1 3 11
35 36 16 5 4 12
15 14 13
7 12
1 6
HCM
Battery Fan
87

Cooling Fan Plus 12
PEC
12V Plus
30
12V Truck 86
Battery
85 87


Purpose: Verify FMIs present. Purpose: Verify that PEC Fan operates.
A C
page 1.
2. Retrieve Active fault codes and FMIs with Ser- Connector in the cab.
3. Key on.
3. Key off.
4. Go to “Product Tests” and select “Battery Fan
! Warning: See “High-Voltage Service Shutdown and Relay.”
in the PEC:
• If airflow can be felt from the PEC Air Inlet and
4. Which faults are present? exhaust, go to Step E.
• If Fault Code 86 FMI 0 is listed, go to Step B. • If airflow can not be felt from the PEC Air Inlet
• If Fault Code 86 FMI 16 is listed, test is and exhaust, go to Step D.
complete. FMI 16 requires no action
or replacement.
Purpose: Inspect PEC Air Filter.

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 Exhaust 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, then go to Step V.
• * See Air Filter.

Purpose: Verify voltage for fan circuit on PEC Purpose: Verify repair.
D 19-Way Connector. V
2. Disconnect the 19-Way Connector at the PEC. 2. Reconnect all connectors and negative
battery cable.
Pin 12 to Pin 14: 3. Key on.
• If voltage between Pin 12 and Pin 14 is ±0.2 4. Clear codes, see “Clear Inactive Faults” on page 13.
volts of battery voltage, replace the Power
of range, repair Battery Fan Relay circuit. Refer
to OEM. • If no codes, test is complete.
error in testing.
Pin 12 to Pin 14 Code Isolation Procedure Index” on page 14.
Purpose: Verify if code 106 FMI 29 is Active too.

E
1. Is Fault Code 106 FMI 29 listed Active?
• If Fault Code 106 FMI 29 is Active, replace
go to Step V.
• If Fault Code 106 FMI 29 is Inactive, using
ServiceRanger, go to the “Advanced Product
Functions” menu and select the “HCM” option.
Download the Snapshot file and contact Eaton
at 1-800-826-HELP (4357).

TRTS1000 Fault Isolation Procedures | Fault Code 87 - CAN ECA Message (HCM)
Fault Code 87 - CAN ECA Message (HCM)

J1939: SA 239 SPN 520273 FMI 2, 9

Controller Area Network (CAN) is a high-speed twisted pair Only Inactive faults can be cleared from the TECU or HCM
500K proprietary data link with one 120 ohm resistor at history using ServiceRanger. The TECU automatically clears
each end of the link. The Hybrid Control Module (HCM) is faults from history after 200 hours. The HCM automatically
connected to the CAN data link at the 38-Way Connector. clears a fault from history after that fault has been Inactive
This link is used to transmit information to the HCM as well for 200 hours.
as communicate or receive data from the other modules on
the network like the Electric Clutch Actuator (ECA). Possible Causes
Detection • FMI 9
detects the fault: - CAN Data Link
• HCM ignition voltage is greater than 7 volts and - ECA

less than 16 volts.
Additional Tools
• HCM CAN Communication Link Fault is Inactive.
code Active:
• ServiceRanger
• 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.
Fallback
not crank.
remain powered.
• If the fault occurs while driving, the ECA either
maintains current clutch position or moves to the
last position commanded by the HCM.

Fault Code 87 - CAN ECA Message (HCM) | Fault Isolation Procedures TRTS1000
Harness Front View

29 34
23 28 ECA 8-Way Connector
37 38
A B C D
13 22
35 36 H G F E
7 12
1 6
HCM
ECA
CAN - Low (Vehicle) 27 2B CAN - Low
CAN - High (Vehicle) 28 2A CAN - High

TRTS1000 Fault Isolation Procedures | Fault Code 87 - CAN ECA Message (HCM)
Fault Code 87 - CAN ECA Message (HCM)

Purpose: Verify Active and Inactive fault code Purpose: Verify resistance on ECA 8-Way CAN
A status. B Harness.

Connector.
3. Disconnect ECA 8-Way Connector.
Pretest” on page 25). 4. Measure resistance between ECA 8-Way Connector
Pin A and Pin B:
go to Step B. Note: Make sure the Volt/Ohm Meter is on the
Pretest, go to Step V. • If resistance between Pin A and Pin B is
between 50–70 ohms, replace Electric Clutch
Actuator (ECA), then go to Step V.
• If resistance is outside of range, repair CAN
Data Link Harness, then go to Step V.
Pin A to Pin B

Fault Code 87 - CAN ECA Message (HCM) | Fault Isolation Procedures TRTS1000

V
1. Key off.
battery cable.
3. Key on.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 88 - CAN Inverter Message (HCM)
Fault Code 88 - CAN Inverter Message (HCM)

J1939: SA 239 SPN 520223 FMI 2, 9

The Inverter communicates with the Battery Control Unit Only Inactive faults can be cleared from the TECU or HCM
(BCU) located in the Power Electronics Carrier (PEC) and history using ServiceRanger. The TECU automatically clears
the Hybrid Control Module (HCM) on the Controller Area faults from history after 200 hours. The HCM automatically
Network (CAN) high-speed proprietary data link. The data clears a fault from history after the fault has been Inactive
link is a two wire twisted pair with two 120 ohm resistors for 200 hours.
located in the link.
Possible Causes
detects the fault:
- Inverter
less than 16 volts. - CAN Data Link
• HCM CAN data link fault is Inactive. Additional Tools

• FMI 9 is set when the HCM has not received • ServiceRanger
a Inverter message for 30 consecutive
message cycles.
Fallback
remain powered.
diesel-only mode.

Fault Code 88 - CAN Inverter Message (HCM) | Fault Isolation Procedures TRTS1000
Harness Front View

29 Inverter 56-Way Mating Connector View 1
34
23 28
14
28
37 38 15
13 22
35 36
42 29
7 12 56
1 6
43
HCM Inverter
CAN - Low (Vehicle) 27 27 CAN - Low
CAN - High (Vehicle) 28 13 CAN - High

TRTS1000 Fault Isolation Procedures | Code 88 - CAN Inverter Message (HCM)
Code 88 - CAN Inverter Message (HCM)

Purpose: Check for Active or Inactive code status Purpose: Verify continuity of Inverter circuits.
A and perform Electrical Pretest. B
Connector. ! Warning: See “High-Voltage Service Shutdown and
2. Perform the Electrical Pretest (see “Electrical dures to avoid shock, burn or death from improp-
Pretest” on page 25) and Hybrid Electrical Pretest erly handled high-voltage.
(see “Hybrid Electrical Pretest” on page 29):
2. Disconnect Inverter 56-Way Connector.
• If no issues are found during the Hybrid
Electrical Pretest, go to Step B. 3. Measure resistance between Inverter 56-Way
• If issue was repaired during the Hybrid
Electrical Pretest, go to Step V. Note: Make sure the Volt/Ohm Meter is on the
Note: Gently flex the Inverter 56-Way Connector
Harness near the Connector while monitoring
the resistance values:
between 50–70 ohms, replace Inverter, then
go to Step V.
• If resistance is outside of range, repair
Pin 27 to Pin 13

Code 88 - CAN Inverter Message (HCM) | Fault Isolation Procedures TRTS1000

V
1. Key off.
battery cable.
3. Key on.
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 89 - CAN BCU 1 Message (HCM)
Fault Code 89 - CAN BCU 1 Message (HCM)

J1939: SA 239 SPN 1800 FMI 2, 9

The Hybrid Control Module (HCM) communicate with the Only Inactive faults can be cleared from the TECU or HCM
Inverter communicates with the Battery Control Unit (BCU) history using ServiceRanger. The TECU automatically clears
located in the Power Electronics Carrier (PEC) and the HCM faults from history after 200 hours. The HCM automatically
on the Controller Area Network (CAN) high-speed clears a fault from history after that fault has been Inactive
proprietary data link. The data link is a two wire twisted pair for 200 hours.
with two 120 ohm resistors located in the link.
Possible Causes
detects the fault:
- Inverter
less than 16 volts. - CAN Data Link from PEC to Inverter
• HCM CAN data link fault is Inactive. - PEC

• FMI 9 is set when the HCM has not received a BCU • Digital Volt/Ohm Meter
1 message for 30 consecutive message cycles.
• ServiceRanger
Fallback
remain powered.
• HCM continues to control the Hybrid vehicle in a
diesel-only mode.

Fault Code 89 - CAN BCU 1 Message (HCM) | Fault Isolation Procedures TRTS1000
Delphi 56-Way Mating Connector View

14
28
15
42 29
56
43
Harness Front View PEC Harness Connector View
(HCM - Vehicle Interface Connector) (Deutsch 19 - Way)
29 34
23 28
19 8 9
38
18 7 2 10
37
17 6 1 3 11
13 22
16 5 4 12
35 36
15 14 13
7 12
1 6
HCM Inverter PEC
CAN - Low (Vehicle) 27 27 CAN - Low 28 2 CAN - Low

CAN - High (Vehicle) 28 13 CAN - High 14 1 CAN - High


Purpose: Verify Active and Inactive fault code Purpose: Verify continuity of PEC circuits.
A status. B
2. Disconnect PEC 19-Way Connector.
Electrical Pretest, go to Step B. 3. Measure resistance between PEC 19-Way
proper scale (around 200 ohm scale)
Harness near the Connector while monitoring
the resistance values.
between 50–70 ohms, replace Power
Pin 1 to Pin 2

Purpose: Verify continuity between Inverter Purpose: Verify repair.

C circuits and PEC circuits. V
1. Disconnect Inverter 56-Way Connector. 1. Key off.
2. Measure resistance between: 2. Reconnect all connectors and the negative
- Inverter 56-Way Connector Pin 28 and PEC battery cable.
19-Way Connector Pin 2 3. Key on.
- Inverter 56-Way Connector Pin 14 and PEC
19-Way Connector 1 4. Clear codes, see “Clear Inactive Faults” on page 13.
proper scale (around 200 ohm scale). 6. Check for codes, see “View Active and Inactive
between 0–0.2 ohms, and resistance between • If no codes, test is complete.
Pin 14 and Pin 1 is between 0–0.2 ohms,
replace Inverter, then go to Step V.
error in testing.
Data Link Harness between Inverter and PEC,
then go to Step V.
56-Way Pin 28 to
19-Way Pin 2
56-Way Pin 14 to
19-Way Pin 1


J1939: SA 239 SPN 1801 FMI 2, 9

The Hybrid Control Module (HCM) communicate with the Only Inactive faults can be cleared from the TECU or HCM
Inverter communicates with the Battery Control Unit (BCU) history using ServiceRanger. The TECU automatically clears
located in the Power Electronics Carrier (PEC) and the HCM faults from history after 200 hours. The HCM automatically
on the Controller Area Network (CAN) high-speed clears a fault from history after that fault has been Inactive
proprietary data link. The data link is a two wire twisted pair for 200 hours.
with two 120 ohm resistors located in the link.
Possible Causes
detect the fault:
- Inverter
less than 16 volts. - PEC
• HCM CAN data link fault is Inactive. - CAN Data Link from PEC to Inverter

• FMI 9 is set when the HCM has not received • Digital Volt/Ohm Meter
an BCU 2 message for 30 consecutive
message cycles. • ServiceRanger
Fallback
powered.
diesel-only mode.

Delphi 56-Way Mating Connector View
14
28
15
42 29
56
Harness Front View PEC Connector View
43
(HCM - Vehicle Interface Connector) (Deutsch 19 - Way)
29 34
23 28
19 8 9
38
18 7 2 10
37
17 6 1 3 11
13 22
16 5 4 12
35 36
15 14 13
7 12
1 6
HCM Inverter PEC



Purpose: Verify Active and Inactive fault code Purpose: Verify CAN resistance on PEC 19-Way
A status. B Connector.

Electrical Pretest, go to Step B. 3. Measure the resistance between PEC 19-Way
between 50–70 ohms, replace Power
Pin 1 to Pin 2

Purpose: Verify continuity on PEC to Inverter CAN Purpose: Verify repair.

C Harness. V
1. Disconnect Inverter 56-Way Connector. 1. Key off.
2. Measure resistance between: 2. Reconnect all connectors and the negative
- Inverter 56-Way Connector Pin 28 and PEC battery cable.
19-Way Connector Pin 2. 3. Key on.
- Inverter 56-Way Connector Pin 14 and PEC
19-Way Connector Pin 1. 4. Clear codes, see “Clear Inactive Faults” on page 13.
proper scale (around 200 ohm scale). 6. Check for codes, see “View Active and Inactive
Note: Gently flex the Inverter 56-Way
Connector Harness near the Connector • If no codes, test is complete.
while monitoring the resistance values.
• If resistance between Pin 28 and Pin 2 is error in testing.
between 0–0.2 ohms, and resistance between
Pin 14 and Pin 1 is between 0–0.2 ohms,
replace Inverter, then go to Step V.
Data Link Harness between Inverter and PEC,
then go to Step V.
56-Way Pin 28 to
19-Way Pin 2
56-Way Pin 14 to
19-Way Pin 1

TRTS1000 Fault Isolation Procedures | Fault Code 91 - APG Unit 1 CAN
Fault Code 91 - APG Unit 1 CAN

J1939: SA 239 SPN 520283 FMI 9

The Auxiliary Power Generator (APG) is a 5kW/5kVA DC/AC Only Inactive faults can be cleared from the TECU or HCM
Inverter that is connected to the high voltage DC bus of the history using ServiceRanger. The TECU automatically clears
Eaton Hybrid electric vehicle system, and generates 60 Hz faults from history after 100 hours. The HCM automatically
single-phase 120V AC power for utility applications. The clears a fault from history after that fault has been Inactive
Controller Area Network (CAN) is a high-speed twisted pair for 200 hours.
500K proprietary data link that connects the HCM to the
Electric Clutch Actuator (ECA), Battery Control Module, Possible Causes
Inverter and APG. The link contains one 120 ohm resistor at This fault code can be caused by any of the following:
each end. The link is used to transmit information specific • FMI 9
to clutch position or power electronics operations.
- CAN Data Link near APG
Detection - APG
detects the fault: Additional Tools
• HCM is powered and ignition voltage is greater • Basic hand tools
than 7 volts and less than 16 volts. • ASTM Class 0 electrical insulating rubber gloves
• HCM data link fault (FC60) is Inactive. with leather protectors J48603
code Active: • Digital Volt/Ohm Meter J46708
• FMI 9 is set if communication from the APG unit is • ServiceRanger
not received for 7.5 seconds and it is expected to
be received based on the configuration settings:
Vehicle Type = UPG and Number of APGs.
Fallback
• Amber “Check Hybrid” light illuminate.
• If the fault sets at command on the APG
remains off.
• If the fault sets during operation the APG shuts off.

Fault Code 91 - APG Unit 1 CAN | Fault Isolation Procedures TRTS1000
E D
1 8
C
2 7 A B
F
3 6
4 5
G J
H
APG 8-way low-voltage

harness connector
9-way diagnostic connector

TRTS1000 Fault Isolation Procedures | Fault Code 91 - APG Unit 1 CAN
Fault Code 91 - APG Unit 1 CAN

Purpose: Verify Active and Inactive fault code Purpose: Verify resistance on APG CAN Harness.
A status and FMIs present. B
1. Review and follow the “Warnings & Cautions” on 1. Measure the resistance between the following:
page 1. - Diagnostic 9-Way Connector Pins H and J
2. Retrieve Active fault codes and FMIs with Ser- - 2-Way Data Link Connector Pins 1 and 2
viceRanger using the 9-Way Diagnostic Connector. - 3-Way Data Link Connector Pins A and B
3. Key off. Note: The 3-Way and 2-Way Data Link
Connectors are located next to the
9-Way Diagnostic Connector.
dures to avoid shock, burn or death from improp- Note: Make sure the Volt/Ohm meter is on the
erly handled high-voltage. proper scale (around 200 ohm scale).
4. Which FMIs are present? • If the resistance between Pin H and Pin J, Pin
A and Pin B, or Pin 1 and Pin 2 is between
• If FMI 9 is Active, go to Step B.
50–70 ohms, go to Step C.
• If the resistance is more than 70 ohms, one or
more of the terminating resistors on the CAN
Data Link Harness is either missing or out of
range, or there is an open in the link. Repair
the OEM CAN Data Link Harness, then
go to Step V.
• If the resistance is less than 50 ohms, there is
an additional terminating resistor present.
Repair the OEM CAN Data Link Harness, then
go to Step V.
Pin H to Pin J on
9-Way Connector
Pin 1 to Pin 2 on
2-Way Connector
Pin A to Pin B on
3-Way Connector

Fault Code 91 - APG Unit 1 CAN | Fault Isolation Procedures TRTS1000
Purpose: Verify resistance on APG CAN Harness. Purpose: Verify repair.

C V
2. Disconnect the negative battery cable. 2. Reconnect all connectors.
3. Disconnect the APG 8-Way Connector at the APG. ! Warning: See “High-Voltage Service Shutdown and
4. Measure the resistance between APG 8-Way
Connector Pin 4 and Pin 5: dures to avoid shock, burn or death from improp-
3. Key on.
4. Operate the APG and attempt to reset the code.
• If the resistance between Pin 4 and Pin 5 is
between 110–130 ohms, replace the 5. Check for codes, see “View Active and Inactive
Auxiliary Power Generator (APG) Inverter, Faults” on page 13.
then go to Step V.
• If the resistance is outside the range, repair the
error in testing.
Connection Measurement Code Isolation Procedure Index” on page 14.
Pin 4 to Pin 5

TRTS1000 Fault Isolation Procedures | Fault Code 95 - 12-Volt Cranking Relay
Fault Code 95 - 12-Volt Cranking Relay

J1939: SA 239 SPN 520249 FMI 3, 4

The 12-volt Cranking Relay is wired into the Hybrid Control Only Inactive faults can be cleared from the TECU or HCM
Module (HCM) on the coil side of the relay. At key on, the history using ServiceRanger. The TECU automatically clears
HCM determines which starting method to use either faults from history after 200 hours. The HCM automatically
High-Voltage Motor/Generator, or Engine Starter. clears a fault from history after the fault has been Inactive
for 200 hours.
If the HCM uses the Motor/Generator to start the engine,
the clutch is closed, the 12-Volt Cranking Relay is Possible Causes
de-energized, which disconnects the main battery power This fault code can be caused by any of the following:
supply to the Start Enable Relay. If the HCM uses the
standard engine starter, the 12-Volt Cranking Relay is • FMI 3, 4
energized supplying battery power to the Start Enable Relay - Vehicle Harness from HCM to 12-volt
main feed, which then powers the Starter Solenoid. Cranking Relay
- 12-volt Cranking Relay
Detection
The following preconditions must be met before the system - HCM
detects the fault:
Additional Tools
• The HCM ignition voltage is greater than 7 volts
and less than 16 volts. • Basic hand tools
• Engine speed is 0 RPM or unknown. • Eaton® Test Adapter Kit

Conditions to Set Fault Code Active • ServiceRanger
code Active:
• FMI 3 if the HCM detects am open or short to
VBATT in the control circuit of the 12-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 12-Volt Cranking Relay for
1 second or greater.
Fallback
• 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.

Fault Code 95 - 12-Volt Cranking Relay | Fault Isolation Procedures TRTS1000

29 34
23 28
37 38
13 22
35 36 30
86
7 12
1 6
85 87
HCM
12-Volt
Crank Enable Plus 32 86 Cranking Relay
Crank Enable Minus 4 85
Crank Enable Latch 26 87
AutoShift Start Enable Relay (30)

12V Plus
12V Truck
Battery

TRTS1000 Fault Isolation Procedures | Fault Code 95 - 12-Volt Cranking Relay
Fault Code 95 - 12-Volt Cranking Relay

Purpose: Verify operation of Cranking Relay. Purpose: Verify continuity of Vehicle Harness
A C circuits.

ServiceRanger using 9-Way Diagnostic Connector.
2. Exchange the 12-Volt Cranking Relay with another
relay and see if the fault returns:
4. Measure the resistance between HCM Vehicle
• If the fault does not return with new relay,
Harness 38-Way Connector Pin 32 and Pin 4:
replace 12-Volt Cranking Relay, then
go to Step V. • If resistance between Pin 32 and Pin 4 is
40–120 ohms, go to Step D.
• If the fault returns with new relay,
go to Step B. • If resistance is outside of range, repair the
Vehicle Harness for an open circuit, then
go to Step V.
Purpose: Verify FMIs present.

B
Purpose: Verify voltage between Vehicle Harness
D circuits and ground.
Note: The 12-Volt Cranking Relay must be wired

1. Key on.
according to Eaton® Hybrid requirements
(shown on previous page) for this test to 2. Measure voltage between HCM Harness 38-Way
work properly. If wired differently, consult Connector Pin 32 and ground at key on:
OEM for correct wiring schematic.
• If FMI 3 is listed, go to Step C. 5 volts, replace the Hybrid Control Module
• If FMI 4 is listed, go to Step E. go to Step V.
12 volts, repair the short to VBATT on the
Pin 32 to ground

Fault Code 95 - 12-Volt Cranking Relay | Fault Isolation Procedures TRTS1000
Purpose: Verify voltage between Vehicle Harness Purpose: Verify repair.

E circuits and ground. V
battery cable.
3. Key on.
4. Measure voltage between HCM Harness 38-Way
Connector Pin 32 and ground: 4. Clear codes, see “Clear Inactive Faults” on page 13.
• If voltage between Pin 32 and ground is 10K 5. Drive the vehicle and attempt to reset the code.
ohms or greater, replace the Hybrid Control
Module (HCM) (only if fault code is Active),
then go to Step V.
Vehicle Harness for a short to ground, then • If Fault Code 95 appears, go to Step A. Find
go to Step V. error in testing.
Pin 32 to ground

TRTS1000 Fault Isolation Procedures | Fault Code 96 - Accelerator Pedal Offset
Fault Code 96 - Accelerator Pedal Offset

J1939: SA 239 SPN 91 FMI 2

The Hybrid Control Module (HCM) uses the vehicle Only Inactive faults can be cleared from the TECU or HCM
Accelerator Pedal position as input for the Hybrid Electric history using ServiceRanger. The TECU automatically clears
Motor/Generator torque demand. faults from history after 200 hours. The HCM automatically
clears a fault from history after the fault has been Inactive
Detection for 200 hours.
detects the fault: Possible Causes
• HCM ignition voltage is greater than 7-volts and This fault code can be caused by any of the following:
less than 16-volts. • FMI 2: This fault indicates the Accelerator Pedal
• There is no Active Fault Code 48. position is not returning to the “Non-Applied’ state.

code Active:
• If the accelerator pedal is detected to be depressed
to a position between 0.01 and 0.1 and held to a
near constant position and the vehicle is stopped
for 30 seconds and there are no Engine message
faults Active, the fault shall be latched Active.
Fallback

Fault Code 96 - Accelerator Pedal Offset | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 96 - Accelerator Pedal Offset
Fault Code 96 - Accelerator Pedal Offset

Purpose: Verify Active and Inactive fault code
A status.
1. Key on.
2. Retrieve Codes, see “View Active and Inactive
• If Fault Code 96 is Active, concern is with the
Accelerator Pedal reading a value above 0%
when there is no driver demand. This value
can be seen by selecting the “Engine and Brake
Data Monitor” list from ServiceRanger and
viewing the Accelerator Pedal Position SPN
91. Refer to OEM.

Fault Code 97 - PTO Engagement | Fault Isolation Procedures TRTS1000
Fault Code 97 - PTO Engagement

J1939: SA 239 SPN 976 FMI 7, 14
Overview Conditions to Set Fault Code Active

The PTO is an optional installation on the transmission. The The following conditions must be met to set the fault
PTO is an electric-over-air unit. The PTO is controlled either code Active:
by the Hybrid Control Module (HCM) or the Body Controller. • FMI 3 is set when the HCM detects a short to the
Note: This fault is only set if the HCM is directly wired to the VBATT in the PTO control circuit.
PTO. This can be determined by checking the HCM • FMI 4 is set when the HCM detects a short to
configuration. The “PTO Feedback” will read analog. ground in the PTO control circuit.
HCM-Controlled PTO: • FMI 5 is set when the HCM detects an open in the
PTO control circuit.
The HCM controlled PTO energizes the electric solenoid
and air pressure engages the PTO. The PTO feedback signal • FMI 7 is set when the HCM detects the
is a 12-volt signal. Less than 1 volt indicates the PTO transmission is in neutral and, if after 8 seconds
is engaged, and greater than 3 volts indicates the PTO from requesting PTO mode the PTO engaged signal
is disengaged. reads “Disengaged.”
• FMI 14 is set when the ePTO option on the Push
Body Controller Operated PTO:
Button Shift Control is selected and the HCM
The Body Controller operated PTO energizes the electric
detects the transmission is not in neutral based on
solenoid and air pressure engages the PTO. When the user
output shaft speed.
selects the ePTO option the Hybrid Control Module (HCM)
sends a request to the Body Controller to activate the PTO. Fallback
When the PTO is engaged, the Body Controller sends back a
confirmation message.
Note: When determining which module is controlling the
• If the PTO is engaged and the fault occurs, the
PTO, connect ServiceRanger and view the
PTO remains engaged until the ePTO request
“Configurations” screen. Under the “Hybrid Control
changes, or the air pressure drops below a
Module” is a listing for PTO Feedback, which is either
set limit.
Analog Controlled (HCM), or J1939 Controlled (Body
Controller). The “PTO Engaged” parameter provides • If the PTO is not engaged the ePTO light flashes on
the input from the HCM or the Body Controller on the the Push Button Shift Console.
current state of the PTO. This parameter is available
in ServiceRanger under the Data Monitor “Hybrid Conditions to Set Fault Code Inactive
ePTO” list. Only Inactive faults can be cleared from the TECU or HCM
Detection faults from history after 200 hours. The HCM automatically
The following preconditions must be met before the system clears a fault from history after that fault has been Inactive
detects the fault: for 200 hours.
less than 16 volts.

TRTS1000 Fault Isolation Procedures | Fault Code 97 - PTO Engagement
Possible Causes
• FMI 7:
- PTO Air Solenoid
- Low air pressure
- PTO control circuit wires
- PTO
- PTO feedback circuit
- HCM (only on HCM controlled PTOs)
- PTO Ball Switch
Note: These FMIs only set if the HCM is directly wired to the
PTO. This can be determined by selecting the
Roadranger Configuration option and then view the
HCM option. The PTO Feedback will read Analog.
Additional Tools
• ServiceRanger


Fault Code 97 - PTO Engagement

Purpose: Verify FMIs present. Purpose: Verify voltage output at HCM 38-Way.
A B
2. Disconnect the negative battery cable.
Connector.
2. Key off.
4. Key on.
5. Measure the voltage from Pin 34 to ground on the
• If Fault Code 97 FMI 3 is listed, go to Step B.
HCM Harness 38-Way Connector:
• If Fault Code 97 FMI 4 or 5 are listed,
• If voltage from Pin 34 to ground is 0 volts,
go to Step C.
replace the Hybrid Control Module (HCM)
• If Fault Code 97 FMI 7 is listed, go to Step F. (only if fault code is Active), then go to Step V.
• If Fault Code 97 FMI 14 is listed, contact Eaton • If voltage from Pin 34 to ground is 11–13
at 1-800-826-HELP (4357). volts, repair the Hybrid System Harness for a
short to battery, then go to Step V.
Pin 34 to ground

Purpose: Verity continuity of PTO solenoid circuit. Purpose: Verity continuity of PTO solenoid circuit.
C D
2. Disconnect the negative battery cable. 2. Disconnect the PTO 2-Way Connector at the PTO.
3. Disconnect the HCM Harness 38-way connector. 3. Measure the resistance between the PTO 2-Way
Connector at the following pins:
38-Way Connector and the following pins: - Pin A to Pin B
- Pin 34 to Pin 6 - Pin A to ground
- Pin 34 to ground • If resistance between Pin A and Pin B is 0–0.3
ohms and resistance between Pin A and
• If resistance between Pin 34 and Pin 6 is 0–0.3
ground is 10K ohms or greater, repair the
ohms and resistance between Pin 34 and
Hybrid System Harness for an open or short to
ground is 10K ohms or greater, replace the
ground, then go to Step V.
Hybrid Control Module (HCM) (only if fault
code is Active). Go to Step V. • If resistance is outside of range, replace the
PTO Switch, then go to Step V.
• If resistance is out of range, go to Step D.
Pin A to Pin B
Pin 34 to Pin 6
Pin A to ground
Pin 34 to ground
Purpose: Check for Active FMIs

E
1. If Fault Code 97 FMI 3, 4, or 5 are Active:
• Go to Step A.

Purpose: Verify voltage at PTO. Purpose: Verify continuity on PTO signal wire.
F G
1. Disconnect the PTO single signal wire at the PTO. 1. Key off.
2. Key on. 2. Disconnect the negative battery cable.
3. Measure the voltage from the PTO Signal Wire 3. Disconnect the HCM Harness 38-Way Connector.
Connector to ground.
4. Measure the resistance from the HCM Harness
• If the voltage is 12 volts at key on, concern 38-Way Connector Pin 18 to the opposite PTO end
is with the faulty PTO Engagement Signal of the Signal Wire.
Switch in the PTO. Contact OEM for repair
• If the resistance from Pin 18 to the PTO end
procedures.
of the signal wire is 0–0.3 ohms, replace
• If the voltage is less than 1 volt at key on, the Hybrid Control Module (HCM), then
go to Step G. go to Step V.
• If the resistance is outside of range, repair the
open in the PTO signal wire from the HCM to
Connection Measurement the PTO, then go to Step V.
Signal Wire to
ground Connection Measurement
HCM Harness to
Signal Wire


V
1. Key off.
2. Key on.
battery cable.
6. Check for codes, See “View Active and Inactive
error in testing.

TRTS1000 Fault Isolation Procedures | Fault Code 101 - High Voltage Battery 1
Fault Code 101 - High Voltage Battery 1

J1939: SA 239 SPN 520238 FMI 0, 22–31

The High-Voltage Batteries are 172 volts each connected in Only Inactive faults can be cleared from the TECU or HCM
located in the Relay Box communicates with each battery to faults from history after 200 hours. The HCM automatically
determine temperature, State Of Charge (SOC), and voltage. clears a fault from history after the fault has been Inactive
This information is then sent to the Inverter. for 200 hours.

detect the fault: • FMI 22–25, 27–29
less than 16 volts.
• FMI 0
7 volts and less than 16 volts. - PEC
- Software
code Active:
• FMI 0, 22–31 are set for various internal
High-Voltage Battery failures. • ASTM Class 0 electrical insulating rubber gloves
Fallback • Lockout bracket J48506
When Fault Code 101 is set the following conditions occur: • Lockout tags
• Red “Stop Hybrid” light illuminates for FMI 0. • Eaton® Test Adapter Kit J43318
• Amber “Check Hybrid” light illuminates for FMI • Digital Volt/Ohm Meter J46708
22–29.
• ServiceRanger
• Depending on the FMI the Inverter or HCM shuts
the high-voltage system off.
diesel-only mode.

Fault Code 101 - High Voltage Battery 1 | Fault Isolation Procedures TRTS1000


Purpose: Check for Active or Inactive fault code Purpose: Verify Battery State of Charge.
A status. B
1. Review and follow the “Warnings & Cautions” on 1. View the Data Monitor parameter PID 133
page 1. “Battery SOC”:
2. Retrieve Active fault codes and FMIs with Ser- • If PID 133 “Battery SOC” is less than 80
viceRanger using the 9-Way Diagnostic Connector. percent, replace the Power Electronics Carrier
3. Key off.
• If PID 133 “Battery SOC” is greater than
80% contact Eaton at
1-800-826-HELP (4357).
4. Which FMIs are present? Parameter Reading
• If Fault Code 101, FMI 27 or 28 are listed with
an Active Fault Code 101 FMI 26, replace the PID 133 “Battery SOC”
Power Electronics Carrier (PEC), then
go to 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,
replace the Power Electronics Carrier (PEC),
Purpose: Verify Battery State of Charge.
then go to Step V.
C
• If Fault Code 101 FMI 29 is listed,
go to Step C.
1. View the Data Monitor parameter PID 133
• If Fault Code 101 FMI 30 or 31 are listed, test “Battery SOC”:
• If PID 133 “Battery SOC” is greater than 10%
or replacement.
then go to Step V.
• If PID 133 “Battery SOC” is less than 10%,
contact Eaton at 1-800-826-HELP (4357).
Parameter Reading
PID 133 “Battery SOC”


V
1. Key off.
2. Key on.
battery cable.
go to Step A.


J1939: SA 239 SPN 520264 FMI 22–31

series to produce 340 volts DC. The Battery Control Unit history using ServiceRanger. The TECU automatically clear
located in the Relay Box communicates with each battery to faults from history after 200 hours. The HCM automatically
determine temperature, State Of Charge, and voltage. This clears a fault from history after that fault has been Inactive
information is then sent to the Inverter. for 200 hours.

detects the fault: • FMI 22–25, 27–29: PEC
• Battery Control Unit ignition voltage is greater than • Basic hand tools
7 volts and less than 16 volts. • ASTM Class 0 electrical insulating rubber gloves
The following conditions must be met to set the fault • Lockout bracket J48506
code Active: • Lockout tags
• FMI 22–31 are set for various internal High-Voltage • Eaton® Test Adapter Kit J43318
Battery failures. • Digital Volt/Ohm Meter J46708
• Depending on the FMI the Inverter or the HCM
shuts high-voltage system off.
diesel-only mode.



Purpose: Verify Active and Inactive fault code Purpose: Verify Battery State of Charge.
A status. B
1. Review and follow the “Warnings & Cautions” on 1. View the Data Monitor parameter PID 133
page 1. “Battery State Of Charge (SOC)”:
2. Retrieve Active fault codes and FMIs with Ser- • If PID 133 “Battery SOC” is less than 80
viceRanger using the 9-Way Diagnostic Connector. percent, replace the Power Electronics Carrier
3. Key off.
• If PID 133 “Battery SOC” is greater than
80 percent, contact Eaton at
1-800-826-HELP (4357).
4. Which FMIs are present? Parameter Reading
• If Fault Code 102 FMI 27 or 28 are listed
with an Active Fault Code 102 FMI 26, PID 133 “Battery SOC”
then go to Step V.
• If Fault Code 102 FMI 27 or 28 are not listed
with an Active Fault Code 102 FMI 26,
go to Step B.
• If Fault Code 102 FMI 22–25 are listed, replace
Purpose: Verify Battery State of Charge.
go to Step V.
C
go to Step C.
1. View the Data Monitor parameter PID 133
• If Fault Code 102 FMI 30 or 31 are listed, test “Battery SOC”:
• If PID 133 “Battery SOC” is greater than 10
or replacement.
percent, replace the Power Electronics Carrier
• If PID 133 “Battery SOC” is less than
10 percent, contact Eaton at
1-800-826-HELP (4357).
Parameter Reading


V
1. Key off.
2. Key on.
battery cable.
go to Step A.

TRTS1000 Fault Isolation Procedures | Fault Code 103 - High Voltage Battery 1 Control Unit Communication
Fault Code 103 - High Voltage Battery 1 Control Unit Communication

J1939: SA 239 SPN 520265 FMI 22–26

The high-voltage batteries each contain a cell controller that Only Inactive faults can be cleared from the TECU or HCM
communicates over a twisted pair data link to the Battery history using ServiceRanger. The TECU automatically clears
Control Unit (BCU). The Battery Control Unit located in the faults from history after 200 hours. The HCM automatically
Relay Box communicates with each battery to determine clears a fault from history after it has been Inactive for 200
temperature, State Of Charge, and voltage. This information hours.
is then sent to the Inverter.
Possible Causes
detects the fault:
- PEC
less than 16 volts. • FMI 22, 25
• Battery Control Unit ignition voltage is greater than - PEC

7 volts and less than 16 volts. - CAN Data Link between PEC and Inverter

The following conditions must be met to set the fault - PEC
code Active: - CAN Data Link between PEC and HCM
• FMI 22 is set when the BCU fails to communicate • FMI 24
over the CAN data link for 30 ms.
- PEC
• FMI 23 is set when the BCU fails to receive HCM
- Inverter
data over the CAN data link for 2.5 seconds or
greater after communication is established. - CAN Data Link between PEC and Inverter
• FMI 24 is set when the BCU fails to receive Inverter
Additional Tools
data over the CAN data link for 2.5 seconds or
greater after communication is established. • Basic hand tools
• FMI 25 is set when the BCU detects an error on • ASTM Class 0 electrical insulating rubber gloves
initial check. with leather protectors J48603
• FMI 26 is set when the BCU fails to transmit • Lockout bracket J48506
anything over the data link for 2 seconds. • Lockout tags
Fallback
When Fault Code 103 is set the following conditions occur: • Digital Volt/Ohm Meter J46708
• Amber “Check Hybrid” light illuminates. • ServiceRanger
diesel-only mode.

Fault Code 103 - High Voltage Battery 1 Control Unit Communication | Fault Isolation Procedures TRTS1000
Front Harness View

29 34
23 28
37 38
13 22
35 36 19 8 9
18 7 2 10
12 17 6 1 3 11
7
1 6 16 5 4 12
56-Way Mating Connector View 15 14 13
14
28
15
42 29
56
43
HCM Inverter PEC



Purpose: Verify Active or Inactive fault code status Purpose: Verify FMIs present.
page 1.
2. Key off. Power-Up Procedure” on page 4. Follow the proce-
3. Key on.
ServiceRanger using the 9-Way Diagnostic 2. Which faults are present?
Connector. • If Fault Code 103 FMI 26 is listed, replace
5. Perform the Electrical Pretest (see “Electrical Power Electronics Carrier (PEC), then
Pretest” on page 25) and Hybrid Electrical Pretest go to Step V.
(see “Hybrid Electrical Pretest” on page 29): • If Fault Code 103 FMI 22, 23, 24, or 25 are
• If no issues are found during either Electrical listed, go to procedure for Fault Code 89 (see
Test, go to Step B. “Fault Code 89 - CAN BCU 1 Message (HCM)”
on page 277.).
• If issue was repaired during either Electrical
Test, go to Step V.


V
1. Key off.
battery cable.
3. Key on.
go to Step A.


J1939: SA 239 SPN 520266 FMI 22–26

Relay Box communicates with each battery to determine clears a fault from history after that fault has been Inactive
temperature, State Of Charge (SOC), and voltage. This for 200.
information is then sent to the Inverter.
Possible Causes
The following preconditions must be met before the system • FMI 26: PEC
detects the fault:
• FMI 22, 25
• Battery Control Unit ignition voltage is greater than - CAN Data Link between PEC and Inverter
7 volts and less than 16 volts. • FMI 23
- PEC
The following conditions must be met to set the fault - CAN Data Link between PEC and HCM
code Active: • FMI 24
• FMI 22 is set when the BCU fails to communicate - PEC
over the CAN Data Link for 30 MS.
- Inverter
• FMI 23 is set when the BCU fails to receive HCM
- CAN Data Link between PEC and Inverter
data over the CAN Data Link for 2.5 seconds or
greater after communication is established.
Additional Tools
• 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. • ASTM Class 0 electrical insulating rubber gloves
• FMI 25 is set when the BCU detects an error on with leather protectors J48603
initial check. • Lockout bracket J48506
• FMI 26 is set when the BCU fails to transmit • Lockout tags
anything over the data link for 2 seconds. • Eaton® Test Adapter Kit J43318

diesel-only mode.

Harness Front View

29 34
23 28
37 38
13 22
35 36 19 8 9
18 7 2 10
12 17 6 1 3 11
7
1 6 16 5 4 12
56-Way Mating Connector View 15 14 13
14
28
15
42 29
56
43
HCM Inverter PEC



Purpose: Verify Active or Inactive fault code status Purpose: Verify faults and FMIs present.
page 1.
3. Key on.
ServiceRanger using the 9-Way Diagnostic 2. Which fault codes are present?
Connector. • If Fault Code 104 FMI 26 is listed, replace
5. Perform the Electrical Pretest (see “Electrical Power Electronics Carrier (PEC), then
Pretest” on page 25) and Hybrid Electrical Pretest go to Step V.
(see “Hybrid Electrical Pretest” on page 29). • If Fault Code 104 FMI 22, 23, 24, or 25 are
• If no issues are found during either Electrical listed with an Active Fault Code 111, go to
Test, go to Step B. procedures for Fault Code 111 and other
appropriate FMIs (see “Fault Code 111 -
• If issue was repaired during either Electrical Inverter Communication” on page 347.)
Test, go to Step V.
• If Fault Code 104 FMI 22, 23, 24, or 25
are listed with no Active Fault Code 111,
go to Step C.
• If Fault Code 88 is listed, see “Fault Code 88 -
CAN Inverter Message (HCM)” on page 273.
• If Fault Code 89 is listed, see “Fault Code 89 -
CAN BCU 1 Message (HCM)” on page 277.

Purpose: Verify resistance on PEC CAN Harness. Purpose: Verify repair.

C V
2. Disconnect the PEC 19-Way Connector. 2. Reconnect all connectors and the negative
battery cable.
3. Inspect the connector pins for damage, corrosion,
and loose wires. 3. Key on.
4. Measure the resistance between the PEC 19-Way 4. Clear codes, see “Clear Inactive Faults” on page 13.
Connector at the following pins:
- Pin 1 and 2
- Pin 1 and ground 6. Check for codes, see “View Active and Inactive
- Pin 2 and ground
50–70 ohms and resistance from Pin 1 and • If Fault Code 104 appears, find error in testing,
Pin 2 to ground are each 10K ohms or greater, go to Step A.
replace Power Electronics Carrier (PEC).
Go to Step V.
CAN data link between the PEC and Inverter,
then go to Step V.
Pin 1 to Pin 2
Pin 1 to ground
Pin 2 to ground

Fault Code 105 - High Voltage Battery 1 Control Unit | Fault Isolation Procedures TRTS1000
Fault Code 105 - High Voltage Battery 1 Control Unit

J1939: SA 239 SPN 520240 FMI 22–30

Relay Box communicates with each battery to determine clears a fault from history after that fault has been Inactive
temperature, Stat of Charge (SOC), and voltage. This for 200 hours.
information is then sent to the Inverter.
Possible Causes
The following preconditions must be met before the system • FMI 22–30: PEC
detects the fault:
• FMI 22–30 are set for various internal Battery • Digital Volt/Ohm Meter J46708
Control Unit failures.
• ServiceRanger
Fallback
diesel-only mode.


TRTS1000 Fault Isolation Procedures | Fault Code 105 - High Voltage Battery 1 Control Unit

Purpose: Verify Active and Inactive fault code Purpose: Verify continuity of AC High-Voltage
A status. B Cable.
1. Review and follow the “Warnings & Cautions” on 1. Disconnect the AC High-Voltage Connector at the
page 1. Motor/Generator.
2. Retrieve Active fault codes and FMIs with Ser- ! Warning: See “High-Voltage Service Shutdown and
viceRanger using the 9-Way Diagnostic Connector. Power-Up Procedure” on page 4. Follow the proce-
3. Key off.
2. With the AC Cable disconnected at both ends,
measure resistance to cable shielding at all
erly handled high-voltage. 3 terminals:
Note: Cable should be flexed while measuring.
• If Open or “OL” on meter, replace the Power
• If Fault Code 105, FMI 23–29 is listed,
Electronics Carrier (PEC).
then go to Step V. • If any resistance/continuity is found, replace
the AC High Voltage Cable, then go to Step V.
• If Fault Code 105, FMI 30 is listed,
go to Step B.
• If Fault Code 105, FMI 22 is listed, turn key off Cable Measurement
and back on. If fault is still present at key on,
replace the Power Electronics Carrier (PEC), AC High-Voltage Cable
then go to Step V.


V
1. Key off.
2. Key on.
battery cable.
go to Step A.


J1939: SA 239 SPN 520267 FMI 22–30

The High-Voltage Batteries each contain a cell controller Only Inactive faults can be cleared from the TECU or HCM
that communicates over a twisted pair data link to the history using ServiceRanger. The TECU automatically clears
Battery Control Unit (BCU). The Battery Control Unit located faults from history after 200 hours. The HCM automatically
in the Relay Box communicates with each battery to clears a fault from history after that fault has been Inactive
determine temperature, State Of Charge (SOC), and voltage. for 200 hours.
This information is then sent to the Inverter.
Possible Causes
The following preconditions must be met before the system • FMI 22–30: PEC
detects the fault:
• FMI 22–30 are set for various internal Battery • Digital Volt/Ohm Meter J46708
Control Unit failures.
• ServiceRanger
Fallback
diesel-only mode.


TRTS1000 Fault Isolation Procedures | Fault Code 106 - High Voltage Battery 2 Control Unit

A status. V
page 1.
2. Key on.
3. Key off.
battery cable.
• If Fault Code 106, FMI 23–30 or is listed, • If Fault Code 106 appears, find error in testing,
replace the Power Electronics Carrier (PEC), go to Step A.
then go to Step V. • If a code other than 106 appears, go to “Fault
• If Fault Code 106, FMI 22 is listed, Key off and Code Isolation Procedure Index” on page 14.
back on. If fault is still present at key on,
then go to Step V.

TRTS1000 Fault Isolation Procedures | Fault Code 107 - High Voltage Battery Leak Detection
Fault Code 107 - High Voltage Battery Leak Detection

J1939: SA 239 SPN 520242 FMI 1

The Battery Control Unit (BCU) continuously monitors Only Inactive faults can be cleared from the TECU or HCM
the vehicle to detect a high-voltage leak. The circuit is history using ServiceRanger. The TECU automatically clears
connected to 3 locations on the DC high-voltage line faults from history after 200 hours. The HCM automatically
with the opposite end connected to the chassis through clears a fault from history after that fault has been Inactive
a resistor. for 200 hours.

detect the fault: • FMI 1
• Inverter ignition voltage is greater than 7 volts and - High-voltage cable insulation damage
less than 16 volts.
- High-voltage component leaking
7 volts and less than 16 volts. Additional Tools
The following conditions must be met to set the fault • ASTM Class 0 electrical insulating rubber gloves
code Active: with leather protectors J48603
• FMI 1 is set when the BCU detects the resistance • Lockout bracket J48506
between the high-voltage line and the Inverter case • Lockout tags
is less than 82k ohms.
• Amber “Check Hybrid” light illuminates. • Megatest Meter AMB-45
diesel-only mode.


Fault Code 107 - High Voltage Battery Leak Detection | Fault Isolation Procedures TRTS1000
Fault Code 107 - High Voltage Battery Leak Detection

Purpose: Verify Active and Inactive fault code Purpose: Verify continuity of PEC DC Cable
A status. B connector terminals and shielding.

page 1.
2. Disconnect the Inverter DC Connector at the PEC.
2. Key on.
3. Retrieve Active fault codes and FMIs with Power-Up Procedure” on page 4. Follow the proce-
ServiceRanger using the 9-Way Diagnostic dures to avoid shock, burn or death from improp-
Connector. erly handled high-voltage.
• If Fault Code 107 is Active, go to Step B. 3. Measure the resistance to ground at the DC
• If Fault Code 107 is Inactive, test is complete. Cable Connector on both the positive and
Go to Step V. negative terminals.
• If Open or “OL” on meter, go to Step I.
• If any resistance/continuity is found,
go to Step C.
Cable Measurement
PEC DC Cable (+)

to ground
PEC DC Cable (-)

to ground

Purpose: Verify continuity of Inverter DC Cable Purpose: Verify continuity of Inverter DC

C connector terminals and shielding. D connector.
1. Disconnect the DC Connector at the Inverter. 1. Measure the resistance to ground at the
Inverter DC Connector on both positive and
! Warning: See “High-Voltage Service Shutdown and negative terminals:
dures to avoid shock, burn or death from improp- ! Warning: See “High-Voltage Service Shutdown and
erly handled high-voltage. Power-Up Procedure” on page 4. Follow the proce-
2. With the DC Cable disconnected at both ends
measure the resistance to cable shielding at both
the positive and negative terminals. • If Open or “OL” on meter, possible error with
testing. Go to Step V.
• If Open or “OL” on meter, go to Step D.
• If any resistance/continuity is found, replace
go to Step E.
DC High-Voltage Cable between the PEC and
Inverter, then go to Step V.
Cable Measurement
Inverter DC (+)
to ground
Inverter DC Cable (+)
to Cable shield
Inverter DC (-)
to ground
Inverter DC Cable (-)
to Cable shield

Purpose: Verify continuity of Inverter AC Cable. Purpose: Verify continuity of Inverter AC Cable to
E F ground.
1. Disconnect the AC Connector at the Inverter. 1. Measure the resistance to ground at all 3 terminals
at the Inverter AC Connector.
Power-Up Procedure” on page 4. Follow the proce- ! Warning: See “High-Voltage Service Shutdown and
dures to avoid shock, burn or death from improp- Power-Up Procedure” on page 4. Follow the proce-
erly handled high-voltage. dures to avoid shock, burn or death from improp-
2. Measure the resistance to ground on all three
terminals at the AC Cable. • If Open or “OL” on meter, possible error with
• If Open or “OL” on meter, go to Step F.
go to Step G.
Cable Measurement Pin A to Pin A
AC Cable Pin A to Pin B to Pin B

ground
Pin C to Pin C
AC Cable Pin B to
ground
AC Cable Pin C to
ground

Purpose: Verify continuity of AC High-Voltage Purpose: Verify continuity of Motor/Generator

G Cable terminals and shielding. H AC Connector to ground.
1. Disconnect the AC High-Voltage Connector at the 1. Measure the resistance to ground at the
Motor/Generator. Motor/Generator AC Connector.
! Warning: See “High-Voltage Service Shutdown and ! Warning: See “High-Voltage Service Shutdown and
Power-Up Procedure” on page 4. Follow the proce- Power-Up Procedure” on page 4. Follow the proce-
dures to avoid shock, burn or death from improp- dures to avoid shock, burn or death from improp-
erly handled high-voltage. erly handled high-voltage.
2. With the AC Cable disconnected at both ends, • If Open or “OL” on meter, possible error with
measure resistance to cable shielding at all testing. Go to Step V.
3 terminals.
• If Open or “OL” on meter, go to Step H. Motor/Generator, then go to Step V.
AC high-voltage cable, then go to Step V.
Motor/Generator AC
Pin A to AC Cable Shield Connector to ground
Pin B to AC Cable Shield
Pin C to AC Cable Shield
Purpose: Verify components present.

I
1. Is unit supplied with a DC/DC Converter or APG?
• Yes, go to Step J.
• No, replace Power Electronics Carrier (PEC),
then go to Step V.

Purpose: Verify continuity of DC cable from PEC to Purpose: Verify continuity of PEC High-Voltage
J DC/DC Converter. K DC Cable terminals to shielding.
1. Disconnect 12-volt positive and negative cables 1. Disconnect the high-voltage DC cable at the
from DC/DC Converter. DC/DC Converter.
! Warning: See “High-Voltage Service Shutdown and ! Warning: See “High-Voltage Service Shutdown and
Power-Up Procedure” on page 4. Follow the proce- Power-Up Procedure” on page 4. Follow the proce-
dures to avoid shock, burn or death from improp- dures to avoid shock, burn or death from improp-
erly handled high-voltage. erly handled high-voltage.
2. Disconnect the PEC to DC/DC Converter DC Cable 2. With the DC cable disconnected at both ends,
at the PEC. measure resistance to cable shielding at positive
and negative terminals.
3. Measure the resistance to ground at the DC
Cable connector on both the positive and • If Open or “OL” on meter, go to Step L.
negative terminals.
• If Open or “OL” on meter, possible error in the High-Voltage DC Cable, then go to Step V.
testing. If vehicle does not have an APG,
go to Step V.
• If vehicle is equipped with APG, go to Step M. Cable Measurement
• If any resistance/continuity is found, PEC DC Cable (+) to

go to Step K. Cable shield
PEC DC Cable (-) to

Connection Measurement Cable shield
DC Cable (+) to ground
DC Cable (-) to ground

Purpose: Verify continuity of DC/DC Converter DC Purpose: Verify continuity of APG DC high-voltage
L high-voltage cable terminals to ground. M cable terminals to ground.
1. Measure the resistance to ground at the DC/DC 1. Disconnect the APG DC High-Voltage Cable at
Converter High-Voltage DC Connector at both the PEC.
positive and negative terminals.
! Warning: See “High-Voltage Service Shutdown and Power-Up Procedure” on page 4. Follow the proce-
Power-Up Procedure” on page 4. Follow the procedures to avoid shock, burn or death from improp-
dures to avoid shock, burn or death from improperly handled high-voltage.
2. Measure the resistance to ground at the DC
• If Open or “OL” on meter, possible error with Cable Connector on both the positive and
testing. Go to Step V. negative terminals.
• If any resistance/continuity is found, replace • If Open or “OL” on meter, replace the Power
DC/DC Converter, then go to Step V. Electronics Carrier (PEC), then go to Step V.
go to Step N.
Cable Measurement
PEC DC Cable (+) to Connection Measurement

Cable shield
APG DC Cable Pin 1 (+)
PEC DC Cable (-) to to ground
Cable shield
APG DC Cable Pin 4 (-)
to ground

Purpose: Verify continuity of APG DC high-voltage Purpose: Verify continuity of APG high-voltage DC
N cable terminals to shielding. O cable pin to ground.
1. Disconnect the high-voltage DC cable at the APG. 1. Measure the resistance to ground at APG
High-Voltage DC connector Pin 1 (positive +) and
! Warning: See “High-Voltage Service Shutdown and Pin 4 (negative -).
dures to avoid shock, burn or death from improp- ! Warning: See “High-Voltage Service Shutdown and
erly handled high-voltage. Power-Up Procedure” on page 4. Follow the proce-
2. With the DC cable disconnected at both ends
measure the resistance from positive and negative
terminals to cable shielding at PEC Cable end. • If Open or “OL” on meter, possible error with
• If Open or “OL” on meter, go to Step O.
Auxiliary Power Generator (APG) Inverter,
DC high-voltage cable, then go to Step V.
then go to Step V.
DC Cable (+) to ground

APG DC Cable Pin 1 (+)
to ground
DC Cable (-) to ground
APG DC Cable Pin 4 (-)
to ground


V
1. Key off.

3. Key on.
go to Step A.

Fault Code 108 - High Voltage Battery 1 Control Unit Power Supply | Fault Isolation Procedures TRTS1000
Fault Code 108 - High Voltage Battery 1 Control Unit Power Supply
J1939: SA 239 SPN 520268 FMI 3, 4

located in the Relay Box receives 12-volts ignition power faults from history after 200 hours. The HCM automatically
and ground from the Inverter. clears a fault from history after the fault has been Inactive
for 200 hours.
Detection
The following conditions must be met to set the fault - PEC Low-voltage harness from Inverter to PEC
code Active: - HCM
• FMI 3 is set when the BCU detects the ignition - Low-voltage harness from HCM to Inverter
voltage is greater than 16 volts for 1 second.
- Inverter
• FMI 4 is set when the BCU detects the ignition
voltage is less than 7 volts for 1 second. Additional Tools
Fallback • Basic hand tools
When Fault Code 108 is set the following conditions occur: • ASTM Class 0 electrical insulating rubber gloves
• Amber “Check Hybrid” light illuminates. with leather protectors J48603
• Fault is stored in HCM memory. • Lockout bracket J48506
• Inverter shuts high-voltage system off. • Lockout tags
• HCM continues to control the hybrid vehicle in a • Eaton® Test Adapter Kit J43318
diesel-only mode. • Digital Volt/Ohm Meter J46708
• Transmission defaults start gear to 1st. • ServiceRanger

TRTS1000 Fault Isolation Procedures | Fault Code 108 - High Voltage Battery 1 Control Unit Power Supply
Harness Front View

29 34
23 28
37 38
13 22
35 36
7 12
1 6
14 19 8 9
28 18 7 2 10
15
17 6 1 3 11
16 5 4 12
42 29 15 14 13
56
43
HCM Inverter PEC
VB_B 16 6 VB_B
Ground BC 34 7 Ground BC
Inverter Enable 2 15 Inverter Enable

Purpose: Check for Active or Inactive fault code Purpose: Verify voltage at PEC connector.
A status. B
1. Review and follow the “Warnings & Cautions” on 1. Disconnect the PEC 19-Way Connector.
page 1.
2. Connect a multimeter to the PEC 19-Way
2. Retrieve Active fault codes and FMIs with Ser- Connector Pin 6 and Pin 7.
3. Place multimeter where it can be viewed, while
3. Key off. standing next to the truck.
! Warning: See “High-Voltage Service Shutdown and 4. Key on.

5. Observe multimeter voltage reading:
erly handled high-voltage. • If voltage between Pin 6 and Pin 7 is 11–13
volts, replace the Power Electronics Carrier
4. Which Faults are present? (PEC), then go to Step V.
• If Fault Code 108 FMI 3 or 4 are listed with an • If voltage between Pin 15 and Pin 1 is less than
Active Fault Code 114, go to “Fault Code 114 - 7 volts, go to Step C.
Inverter Power Supply” on page 360.
Active Fault Code 114, go to Step B. Connection Measurement
Pin 6 to Pin 7

Purpose: Verify continuity between PEC and Purpose: Verify repair.

C Inverter connectors. V
2. Disconnect the Inverter 56-Way Connector. 2. Reconnect all connectors and the negative
battery cable.
3. Measure resistance on the following:
- Inverter 56-Way Connector Pin 16 to PEC 19-Way 3. Key on.
Connector Pin 6. 4. Clear codes, see “Clear Inactive Faults” on page 13.
- Inverter 56-Way Connector Pin 34 to PEC 19-Way
Connector Pin 7. 5. Drive the vehicle and attempt to reset the code.
Connector Harness near the Connector Faults” on page 13.
while monitoring the voltage values. • If no codes, test is complete.
• If resistance from Pin 16 to Pin 6 is • If Fault Code 108 appears, find error in testing,
0–0.3 ohms and resistance from Pin 34 to Pin go to Step A.
7 is 0–0.3 ohms, replace the Inverter, then
go to Step V.
low-voltage harness from the PEC to the
Pins Measurement
56-Way Pin 16 to
19-Way Pin 6
56-Way Pin 34 to
19-Way Pin 7

J1939: SA 239 SPN 520269 FMI 3, 4

located in the Relay Box receives 12-volt ignition power and faults from history after 200 hours. The HCM automatically
ground from the Inverter. clears a fault from history after that fault has been Inactive
for 200 hours.
Detection
The following conditions must be met to set the fault - Charging system PEC Low-voltage harness from
code Active: Inverter to PEC
• FMI 3 is set when the BCU detects the ignition - HCM
voltage is greater than 16 volts for 1 second. - Low-voltage harness from the HCM to Inverter
• FMI 4 is set when the BCU detects the ignition - Inverter
voltage is less than 7 volts for 1 second.
Additional Tools
Fallback
When Fault Code 109 is set the following conditions occur: • Basic hand tools
• Amber “Check Hybrid” light illuminates. • ASTM Class 0 electrical insulating rubber gloves
• Lockout tags
diesel-only mode. • Eaton® Test Adapter Kit J43318
• Transmission defaults start gear to 1st. • Digital Volt/Ohm Meter J46708

• ServiceRanger

Harness Front View

29 34
23 28
37 38
13 22
35 36
7 12
1 6
14 19 8 9
28 18 7 2 10
15
17 6 1 3 11
16 5 4 12
42 29 15 14 13
56
43
HCM Inverter PEC
VB_B 16 6 VB_B
Ground BC 34 7 Ground BC

Purpose: Check for Active or Inactive fault code Purpose: Verify battery voltage at PEC 19-Way
A status. B Connector.
1. Review and follow the “Warnings & Cautions” on 1. Disconnect the PEC 19-Way Connector.
page 1.
2. Connect a multi meter to the PEC 19-Way
2. Retrieve Active fault codes and FMIs with Ser- Connector Pin 6 and Pin 7.
3. Place multimeter where it can be viewed, while
3. Key off. standing next to the truck.
! Warning: See “High-Voltage Service Shutdown and 4. Key on.

erly handled high-voltage. • If voltage between Pin 6 and Pin 7 is 11–13
volts, replace the Power Electronics Carrier
4. Which FMIs are present? (PEC), then go to Step V.
• If Fault Code 109 FMI 3 or 4 are listed with an • If voltage between Pin 6 and Pin 7 is less than
Active Fault Code 114, go to “Fault Code 114 - 7 volts, go to Step C.
Inverter Power Supply” on page 360.
Active Fault Code 114, go to Step B. Connection Measurement
Pin 6 to Pin 7

Purpose: Verify continuity on PEC 19-Way to Purpose: Verify repair.

C Inverter 56-Way Low Voltage Harness. V
2. Disconnect the Inverter 56-Way Connector. 2. Reconnect all connectors and the negative
battery cable.
3. Measure resistance on the following:
- Inverter 56-Way Connector Pin 16 to PEC 19-Way 3. Key on.
Connector Pin 6 4. Clear codes, see “Clear Inactive Faults” on page 13.
- Inverter 56-Way Connector Pin 34 to PEC 19-Way
Connector Pin 7 5. Drive the vehicle and attempt to reset the code.
Connector Harness near the connector Faults” on page 13.
while monitoring the voltage values. • If no codes, test is complete.
• If resistance from Pin 16 to Pin 6 is • If Fault Code 109 appears, find error in testing,
0–0.3 ohms and resistance from Pin 34 to go to Step A.
Pin 7 is 0–0.3 ohms, replace the Inverter,
then go to Step V.
Low-Voltage Harness from the PEC to the
56-Way Pin 16 to
19-Way Pin 6
56-Way Pin 34 to
19-Way Pin 7

Fault Code 110 - Inverter | Fault Isolation Procedures TRTS1000
Fault Code 110 - Inverter

J1939: SA 239 SPN 520220 FMI 22–29

The Inverter assembly is connected to the High-Voltage DC Only Inactive faults can be cleared from the TECU or HCM
Cable from the PEC along with the high-voltage AC cable history using ServiceRanger. The TECU automatically clears
from the Motor/Generator. It inverts the DC to AC voltage to faults from history after 200 hours. The HCM automatically
power the motor during electric assist and rectifies the AC clears faults from history after that fault has been Inactive
back to DC to charge the high-voltage batteries during for 200 hours.
coasting or regenerative braking. The Inverter is also the
main controller for the high-voltage system communicating Possible Causes
to the Battery Control Module in the PEC along with This fault code can be caused by any of the following:
communicating to the HCM for overall system operation. • FMI 22–29: Inverter
detects the fault: • Basic hand tools
• HCM is powered and ignition voltage is greater • ASTM Class 0 electrical insulating rubber gloves
than 7 volts and less than 16 volts. with leather protectors J48603
• Inverter ignition voltage is greater than 7 volts and • Lockout bracket J48506
less than 16 volts. • Lockout tags
The following conditions must be met to set the fault • Digital Volt/Ohm Meter J46708
• FMI 22–29 are set due to various internal failures of
the Inverter.
Fallback
• Depending on the internal failure the Inverter may
continue to operate with the fault logged, or
shutdown the high-voltage system.
diesel-only mode for most failures.

TRTS1000 Fault Isolation Procedures | Fault Code 110 - Inverter
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. ASTM Class 0 electrical insulating rubber gloves with leather protectors must be used when working on
any of these components. Failure to follow these instructions may result in severe personal injury or death.


Fault Code 110 - Inverter | Fault Isolation Procedures TRTS1000
Fault Code 110 - Inverter

A status. V
page 1.
2. Key on.
3. Key off.
battery cable.
• If Fault Code 110 is Active, replace the • If Fault Code 110 appears, find error in testing,
Inverter, then go to Step V. go to Step A.
• If Fault Code 110 is Inactive, test is complete. • If a code other than 110 appears, go to “Fault

TRTS1000 Fault Isolation Procedures | Fault Code 111 - Inverter Communication
Fault Code 111 - Inverter Communication

J1939: SA 239 SPN 520260 FMI 22–26

The Inverter communicates with the Battery Control Unit Only Inactive faults can be cleared from the TECU or HCM
(BCU) located in the PEC and the Hybrid Control Module history using ServiceRanger. The TECU automatically clears
(HCM) on the CAN high-speed proprietary data link. The faults from history after 200 hours. The HCM automatically
data link is a two wire twisted pair with two 120 ohm clears a fault from history after that fault has been Inactive
resistors located in the link. for 200 hours.

• HCM is powered and ignition voltage is greater - Inverter
than 7 volts and less than 16 volts.The Inverter
ignition voltage is greater than 7 volts and less than • FMI 23, 24, or 25
16 volts. - CAN Data Link
- Inverter
Conditions to Set Fault Code Active - PEC
code Active: • FMI 26
• FMI 22 is set when Inverter detects an internal CAN - HCM
communication failure at power up.
• FMI 23, 24, or 25 are set when the Inverter fails to Additional Tools
transmit, receive or obtain any messages on the • Basic hand tools
CAN data link.
• FMI 26 is set when a specific message sent from with leather protectors J48603
the HCM is invalid.
powered.
diesel-only mode.

Fault Code 111 - Inverter Communication | Fault Isolation Procedures TRTS1000
Harness Front View

29 34
23 28
37 38
(PEC - Low-Voltage Connector)
13 22
35 36 19 8 9
18 7 2 10
12 17 6 1 3 11
7
1 6 16 5 4 12
Delphi 56-Way Mating Connector View 15 14 13
(Inverter - Low-Voltage Connector) 1
14
28
15
42 29
56
43
HCM Inverter PEC


TRTS1000 Fault Isolation Procedures | Fault Code 111 - Inverter Communication
Fault Code 111 - Inverter Communication

Purpose: Check for Active or Inactive fault code Purpose: Verify FMIs present.
A status and perform Electrical Pretest. B
page 1.
3. Key on.
ServiceRanger using the 9-Way Diagnostic 2. Which faults are present?
Connector. • If Fault Code 111 FMI 22 is listed, replace the
5. Perform the Electrical Pretest (see “Electrical Inverter, then go to Step V.
Pretest” on page 25) and Hybrid Electrical Pretest • If Fault Code 111 FMI 26 is listed, contact
(see “Hybrid Electrical Pretest” on page 29): Eaton® at 1-800-826-HELP (4357).
• If no issues are found during either Electrical • If Fault Code 111 FMI 23, 24 are listed, go to
Test, go to Step B. “Fault Code 88 - CAN Inverter Message
• If issue was repaired during either Electrical (HCM)” on page 273.
Test, go to Step V. • If Fault Code 111 FMI 25 is listed with an
Active code 88, go to “Fault Code 88 - CAN
Inverter Message (HCM)” on page 273.
• If Fault Code 111 FMI 25 is listed with an
Active code 89, go to “Fault Code 89 - CAN
BCU 1 Message (HCM)” on page 277.

Fault Code 111 - Inverter Communication | Fault Isolation Procedures TRTS1000

V
1. Key off.
battery cable.
3. Key on.
go to Step A.

TRTS1000 Fault Isolation Procedures | Fault Code 112 - Inverter Voltage
Fault Code 112 - Inverter Voltage

J1939: SA 239 SPN 520221 FMI 3, 4

The Inverter is connected to the Power Electronics Carrier Only Inactive faults can be cleared from the TECU or HCM
(PEC) through a high-voltage DC cable, which supplies 340 history using ServiceRanger. The TECU automatically clears
volts from the batteries. During operation, the Inverter faults from history after 200 hours. The HCM automatically
monitors the input voltage to determine an over or under clears a fault from history after that fault has been Inactive
voltage concern. for 200 hours.

detect the fault: • FMI 3, 4
less than 16 volts.
- PEC
Conditions to Set Fault Code Active - DC high-voltage cable
code Active: Additional Tools
• FMI 4 is set when the Inverter input voltage • Basic hand tools
measured at the capacitor is less than 200 volts for • ASTM Class 0 electrical insulating rubber gloves
1 second, while the main relays in the Relay Box with leather protectors J48603
are on.
• FMI 3 is set when the Inverter input voltage
measured at the capacitor is greater than 435 volts • Lockout tags
for 0.05 MS. • Eaton® Test Adapter Kit J43318
Fallback

diesel-only mode.

Fault Code 112 - Inverter Voltage | Fault Isolation Procedures TRTS1000
1 High Voltage DC Connector View 2
(Yazaki Connector)
High-Voltage DC Connector to PEC
DC(+) DC(-)
DC(+) DC(-)
Inverter PEC
340-Volt Neg (High Voltage) DC (-) DC (-) 340-Volt Neg (High Voltage)
340-Volt Pos (High Voltage) DC (+) DC (+) 340-Volt Pos (High Voltage)

TRTS1000 Fault Isolation Procedures | Fault Code 112 - Inverter Voltage
Fault Code 112 - Inverter Voltage

Purpose: Check for Active or Inactive fault code Purpose: Verify capacitance of Inverter DC
A status and perform Electrical Pretest. B High-Voltage Connector.

page 1.
2. Disconnect the DC High-Voltage Connector at
2. Key off. the Inverter.
3. Key on. 3. Place the multimeter on uF option.
4. Retrieve Active fault codes and FMIs with ! Warning: See “High-Voltage Service Shutdown and
ServiceRanger using the 9-Way Diagnostic Power-Up Procedure” on page 4. Follow the proce-
Connector. dures to avoid shock, burn or death from improp-
Power-Up Procedure” on page 4. Follow the proce- 4. Place the leads into the 2 Inverter DC High-Voltage
dures to avoid shock, burn or death from improp- Sockets making sure the probes touch the
erly handled high-voltage. terminals.
5. Which faults are present? 5. Record the measurement after 2 minutes:
• If Fault Code 112 FMI 3 is listed, contact Eaton • If the uF reading is 1104 uF–1656 uF at 68 °F
at 1-800-826-HELP (4357). (20 °C), go to Step C.
• If Fault Code 112 FMI 3 is listed with other • If the uF reading is outside 1104 uF–1656 uF
Active Hybrid Fault Codes beside 112, go to at 68 °F (20 °C), replace the Inverter, then
“View Active and Inactive Faults” on page 13. go to Step V.
Inverter DC High-Voltage
Sockets

Fault Code 112 - Inverter Voltage | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of circuits on the DC Purpose: Verify repair.

C Cable between PEC and Inverter. V
2. Disconnect the DC High-Voltage Connector from 2. Reconnect all connectors and the negative
the PEC. battery cable.
3. Measure the resistance of each circuit on the 3. Key on.
DC Cable from the PEC Connector to the
Inverter Connector:
• If the resistance for each circuit is 1 ohm or
less, replace the Inverter, then go to Step V. 6. Check for codes, see “View Active and Inactive
• If resistance is out of range, replace the DC
high-voltage cable, then go to Step V. • If no codes, test is complete.
go to Step A.
Each circuit on the

DC Cable from the
PEC Connector to the
Inverter Connector

TRTS1000 Fault Isolation Procedures | Fault Code 113 - Inverter Current
Fault Code 113 - Inverter Current

J1939: SA 239 SPN 520222 FMI 6

The Inverter is connected to the Power Electronics Carrier Only Inactive faults can be cleared from the TECU or HCM
(PEC) through a high-voltage DC cable which supplies history using ServiceRanger. The TECU automatically clears
340 volts from the batteries. During operation, the Inverter a fault from history after 200 hours. The HCM automatically
monitors the output current to the Motor/Generator. clears a fault from history after the fault has been Inactive
for 200 hours.
Detection
detect the fault: This fault code can be caused by any of the following:
• Inverter ignition voltage is greater than 7 volts and • FMI 6
less than 16 volts. - Inverter
Conditions to Set Fault Code Active - Motor/generator
The following conditions must be met to set the fault - AC high-voltage cables
code Active:
• FMI 6 is set when the Inverter IGBT current is Additional Tools
greater than 800 amps for 0.05 MS or the motor • Basic hand tools
cable is short. • ASTM Class 0 electrical insulating rubber gloves
• FMI 14 is set when motor torque commanded is with leather protectors J48603
zero and current is reported by the Inverter. • Lockout bracket J48506
• Red “Stop Hybrid” light illuminates. • Digital Volt/Ohm Meter J46708
diesel-only mode.

Fault Code 113 - Inverter Current | Fault Isolation Procedures TRTS1000
C A
F F
C A
E D E D
B
High-Voltage AC Motor/Gen Connector View

High-Voltage AC Harness Connector View
(Amphenol Connector)
(Amphenol Connector)
Inverter Motor/
Generator
Phase 3 C C Phase 3
Phase 2 B B Phase 2
Phase 1 A A Phase 1

Fault Code 113 - Inverter Current

Purpose: Verify FMIs present. Purpose: Verify integrity of AC cable.
A B
1. Review and follow the “Warnings & Cautions” on 1. Visually inspect the AC cable for signs of abrasion,
page 1. cuts or exposed wiring.
2. Retrieve Active fault codes and FMIs with Ser- 2. Remove the AC High-Voltage Cable at the
viceRanger using the 9-Way Diagnostic Connector. Motor/Generator and Inverter.
! Warning: See “High-Voltage Service Shutdown and 3. Measure the resistance between the following AC
Power-Up Procedure” on page 4. Follow the proce- High-Voltage Cable Pins:
dures to avoid shock, burn or death from improp- - A-B
erly handled high-voltage. - B-C
3. Key off. - C-A
4. Which FMIs are present? Note: An auto-ranging digital Volt/Ohm Meter

must be used.
• If resistance between each phase is 5M or
greater, go to Step C.
go to Step D.
• If resistance is outside of range, replace the AC
High-Voltage Harness, then go to Step V.
Pin A to Pin B
Pin B to Pin C
Pin C to Pin A

Fault Code 113 - Inverter Current | Fault Isolation Procedures TRTS1000
Purpose: Verify continuity of AC Cable to ground. Purpose: Verify continuity of Inverter to

C D Motor/Generator connections of the AC Cable.
1. Measure the resistance of each AC High-Voltage 1. Remove the AC High-Voltage Cable from the
Cable Pin to ground. Inverter and Motor/Generator.
• If resistance between each pin and ground 2. Measure the resistance of the AC High-Voltage
is 5M or greater, replace the Inverter, then Cable from the Inverter Connector to the
go to Step V. Motor/Generator Connector on each of the
following pins:
AC high-voltage cable, then go to Step V. - A-A
- B-B
- C-C
Note: An auto ranging digital Volt/Ohm Meter
must be used.
Pin A to ground
• If resistance is less than 1 ohm on each circuit,
Pin B to ground replace the Motor/Generator, then
go to Step V.
Pin C to ground • If resistance is outside of range, replace the
AC High-Voltage Harness, then go to Step V.
Pin A to Pin A
Pin B to Pin B
Pin C to Pin C


V
1. Key off.
battery cable.
3. Key on.
go to Step A.

Fault Code 114 - Inverter Power Supply | Fault Isolation Procedures TRTS1000
Fault Code 114 - Inverter Power Supply

J1939: SA 239 SPN 520261 FMI 3, 4

The Inverter assembly uses a 12-volt supply provided from Only Inactive faults can be cleared from the TECU or HCM
the HCM to power the internal control board. The HCM history using ServiceRanger. The TECU automatically clears
provides ignition power after it completes the power-up self faults from history after 200 hours. The HCM automatically
check. clears a fault from history after the fault has been Inactive
for 200 hours.
Detection
less than 16 volts. - Inverter
The following conditions must be met to set the fault - HCM
code Active: - Inverter
• FMI 3 is set when the Inverter ignition voltage is - Power Supply Harness from HCM to Inverter
greater than 16 volts for 0.5 seconds.
• FMI 4 is set when the Inverter ignition voltage is Additional Tools
less than 7 volts for 0.1 seconds. • Basic hand tools
Fallback • ASTM Class 0 electrical insulating rubber gloves
When Fault Code 114 is set the following conditions occur: with leather protectors J48603
• Amber “Check Hybrid” light illuminates. • Lockout bracket J48506
• Fault is stored in HCM memory. • Lockout tags
• Electric Motor/Generator Assist and Regeneration • Eaton® Test Adapter Kit J43318
are disabled; however, high-voltage relays remain • Digital Volt/Ohm Meter J46708
powered. • ServiceRanger
diesel-only mode.

TRTS1000 Fault Isolation Procedures | Fault Code 114 - Inverter Power Supply
Front Harness View Delphi 56-Way Mating Connector View

(HCM - Hybrid System Interface Connector) (Inverter - Low Voltage Connector) 1
29 34
23 28 14
28
15
37 38
13 22
42 29
35 36
56
7 12
6 43
1
HCM Inverter
1 Ground 1
2 Ground 2

Fault Code 114 - Inverter Power Supply | Fault Isolation Procedures TRTS1000
Fault Code 114 - Inverter Power Supply

Purpose: Check for Active or Inactive fault code Purpose: Verify voltage present at Inverter.
A status and perform Electrical Pretest. C
page 1.
3. Connect a multimeter to the Inverter 56-Way
4. Place multi meter where it can be viewed while
standing next to the truck.
5. Key on.
go to Step B.
Pretest, test is complete. Go to Step V. Note: Gently flex the Inverter 56-Way Connector
Harness near the connector while monitoring
the voltage reading.
• If voltage is 11–13 volts, replace the Inverter,
then go to Step V.
• If voltage is greater than 16 volts, repair the
vehicle 12-volt charging system. Refer to the
Purpose: Verify FMI present. OEM for repair procedure.
B • If voltage is outside of range, go to Step D.
1. Retrieve Active fault codes and FMIs

with ServiceRanger using the 9-Way Diagnostic Connection Measurement
Connector.
2. Key off. Pin 15 to Pin 1

• If Fault Code 114 FMI 3 or 4 is listed,
go to Step C.
• If Fault Code 114 is not present, test is
complete. Go to Step V.

TRTS1000 Fault Isolation Procedures | Fault Code 114 - Inverter Power Supply
Purpose: Verify continuity of circuits between HCM Purpose: Verify repair.

D Harness and Inverter. V
2. Disconnect the negative battery cable. 2. Reconnect all connectors and the negative
battery cable.
3. Disconnect the HCM System Harness
38-way connector. 3. Key on.
4. Measure resistance from the following: 4. Clear codes, see “Clear Inactive Faults” on page 13.
- Inverter 56-Way Connector Pin 15 to HCM 5. Drive the vehicle and attempt to reset the code.
38-Way Connector Pin 2.
- Inverter 56-Way Connector Pin 1 to ground. 6. Check for codes, see “View Active and Inactive
• If resistance from Pin 15 to Pin 2 is 0 to 0.3
ohms and resistance from Pin 1 to ground is • If no codes, test is complete.
0 to 0.3 ohms, replace the Hybrid Control • If Fault Code 114 appears, find error in testing,
Module (HCM). Go to Step V. go to Step A.
• If resistance is outside of range, repair the • If a code other than 114 appears, go to “Fault
open in the Power or Ground Harness, then Code Isolation Procedure Index” on page 14.
go to Step V.
56-Way Pin 15 to
38-Way Pin 2
56-Way Pin 1 to
ground

Fault Code 115 - Inverter Temperature | Fault Isolation Procedures TRTS1000
Fault Code 115 - Inverter Temperature

J1939: SA 239 SPN 520223 FMI 0

The Inverter Temperature Sensor is a thermistor located Only Inactive faults can be cleared from the TECU or HCM
inside the Inverter that changes in value based on the history using ServiceRanger. The TECU automatically clears
temperature. The Inverter supplies a 5-volt reference faults from history after 200 hours. The HCM automatically
voltage to the sensor and measures the volt drop in the clears a fault from history after that fault has been Inactive
circuit. When the Inverter temperature is warm the sensor for 200 hours.
resistance is low and the Inverter detects a low-voltage (0.1
volts equals 260 °F [127 °C]). When the Motor/Generator is Possible Causes
cold the sensor resistance is high and the Inverter detects a This fault code can be caused by any of the following:
high-voltage (4.0 volts equal -68 °F [-56 °C]). • FMI 0
Detection - Inverter
The following preconditions must be met before the system - Liquid cooling system (low coolant, no coolant
will detect the fault: flow, Coolant Pump, Radiator, Radiator Fan,
• The Inverter ignition voltage is greater than 7 volts Reservoir)
and less than 16 volts.
Additional Tools
• FMI 0 is set with the Inverter temperature is greater • Lockout bracket J48506
than 206 °F (97 °C) for 100 MS or sensor broken.
• Lockout tags
Fallback • Eaton® Test Adapter Kit J43318
powered.
diesel-only mode.

TRTS1000 Fault Isolation Procedures | Fault Code 115 - Inverter Temperature

Fault Code 115 - Inverter Temperature

Purpose: Verify Inverter temperature. Purpose: Verify Hybrid System coolant level.
A B
page 1.
2. Retrieve Active fault codes and FMIs with Ser- cooled to see if it is filled to the proper level:
• If the coolant is within the recommend limits,
! Warning: See “High-Voltage Service Shutdown and go to Step C.
procedure, then go to Step V.
3. Key on.
4. Select the Data Monitor 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
Purpose: Verify integrity of Hybrid Cooling System
from the first to second reading, go to Step B.
C components.
• If PID 120 “Inverter Temperature” remained
constant, replace the Inverter, then
1. Visually inspect the Hybrid Liquid Cooling System
go to Step V.
Radiator for debris or obstruction to airflow and
inspect the coolant lines for sharp bends:
Parameter Reading • If the radiator is free of debris and the coolant
lines are not kinked, go to Step D.
PID 120 “Inverter • If the radiator is full of debris, the airflow is
Temperature” obstructed or the coolant lines are kinked.
initial reading Repair the concern, then go to Step V.
PID 120 “Inverter

Temperature”
after 20 minutes

TRTS1000 Fault Isolation Procedures | Fault Code 115 - Inverter Temperature
Purpose: Verify hybrid system Coolant Pump Purpose: Verify voltage at Hybrid System Coolant
D operation. F Pump.

2. Connect ServiceRanger to the 9-Way Connector in 2. Disconnect the Coolant Pump 2-Way Connector.
the cab.
3. Select the Advanced Product Functions option and select the “Cooling Pump” option.
select the “Cooling Pump” option.
4. Enable the Cooling Pump option.
4. Enable the Cooling Pump option:
5. Measure the voltage at the 2-Way Connector from
• If the Coolant Pump turns on, go to Step E. Pin A to Pin B.
• If the Coolant Pump fails to turn on, • If voltage between Pins A and B is ±0.2 volts of
go to Step F. battery voltage, refer to OEM for Coolant Pump
concern.
range, refer to OEM for Cooing Pump Power
Harness repair procedure.
Purpose: Verify Hybrid System Heat Exchanger Fan
E operation.
Pin A to Pin B

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, then
go to Step V.
• If the Heat Exchanger Fan fails to turns on,
go to Step G.

Purpose: Verify voltage at Hybrid System Heat Purpose: Verify repair.

G Exchanger Fan. V
2. Disconnect the Heat Exchanger Fan 2-Way 2. Reconnect all connectors and negative
Connector. battery cable.
3. Select the Advanced Product Functions option and 3. Key on.
4. Enable the Heat Exchanger Fan option.
5. Measure the voltage at the 2-Way Connector from
Pin A to Pin B:
• If voltage between Pins A and B is ±0.2 volts of
battery voltage, refer to OEM for Heat
Exchanger Fan concern. • If Fault Code 115 appears, find error in testing,
go to Step A.
range, refer to OEM for Heat Exchanger Fan • If a code other than 115 appears, go to “Fault
Power Harness repair procedure. Code Isolation Procedure Index” on page 14.
Pin A to Pin B

TRTS1000 Fault Isolation Procedures | Fault Code 116 - High Voltage Relays
Fault Code 116 - High Voltage Relays

J1939: SA 239 SPN 520224 FMI 10, 14

The High-Voltage Relays are located inside the Power Only Inactive faults can be cleared from the TECU or HCM
Electronics Carrier (PEC) in the Relay Box unit. There is 1 history using ServiceRanger. The TECU automatically clears
precharge relay on the positive side, an additional relay on faults from history after 200 hours. The HCM automatically
the positive, and 1 on the negative for a total of 3. These clears a fault from history after that fault has been Inactive
relays are normally open when the system is off. The relays for 200 hours.
are controlled through the Inverter.
Possible Causes
detects the fault:
- PEC
less than 16 volts. - APG
- Inverter
Conditions to Set Fault Code Active - DC high-voltage cable
code Active: - DC cable interlock loops
• FMI 10 is set when the Inverter detects the input - Inertia Switch
voltage measured at the capacitor is less than 210 - Service Switch
volts within 3 seconds after the sub-relay closed in
• FMI 14
the Relay Box.
- Inverter
• FMI 14 is set when only the negative relay in the
Relay Box is on and capacitor voltage decreases - PEC
less than 10 volts/5 seconds when initial capacitor
voltage was greater than 200 volts and motor Additional Tools
speed less than 500 min-1, or there is a detect • Basic hand tools
error in the initial check.
Fallback with leather protectors J48603
When Fault Code 116 is set the following conditions occur: • Lockout bracket J48506
• Amber “Check Hybrid” light blinks for FMI 10 and • Lockout tags
remains solid for FMI 14. • Eaton® Test Adapter Kit J43318
• Fault is stored in HCM memory. • Digital Volt/Ohm Meter J46708
• Inverter shuts high-voltage system off. • ServiceRanger
diesel-only mode.

Fault Code 116 - High Voltage Relays | Fault Isolation Procedures TRTS1000
1 High Voltage DC Connector View 2
Delphi 56-Way Mating Connector View 1 (Yazaki Connector)
14
28
15
42 29
56
43
Mating Connector View DC(-)

DC(+)
(Deutsch 19 - Way)
19 8 9
18 7 10
2
17 6 1 3 11
16 5 4 12
15 14 13
Inverter PEC
340-Volt Neg (High Voltage) DC (-) DC (-) 340-Volt Neg (High Voltage)
340-Volt Pos (High Voltage) DC (+) DC (+) 340-Volt Pos (High Voltage)
Interlock positive 1 1 Interlock positive
Interlock negative 2 2 Interlock negative
Precharge Plus 29 17 Precharge Plus
Main Plus Plus 30 9 Main Plus Plus
Main Minus Plus 31 13 Main Minus Plus
Main Plus Minus 35 11 Main Plus Minus
Main Minus Minus 36 15 Main Minus Minus
Precharge Minus 37 19 Precharge Minus
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.

Fault Code 116 - High Voltage Relays

Purpose: Verify FMIs present. Purpose: Verify continuity of Inverter connector
A C circuits.

page 1.
2. If the vehicle is not equipped with a DC/DC
2. Retrieve Active fault codes and FMIs with Ser- Converter or APG, skip this step.
3. Using ASTM Class 0 electrical insulating rubber
! Warning: See “High-Voltage Service Shutdown and gloves with leather protectors, disconnect the DC
Power-Up Procedure” on page 4. Follow the proce- cable for the DC/DC Converter and APG at the PEC.
4. With the key off, temporarily remove the Lockout
Bracket and pull the Service Switch out.
3. Which FMIs are present? 5. Key on.
• If Fault Code 116 FMI 14 is listed, go to Step I. 6. Is Fault Code 116 FMI 10 still Active in
• If Fault Code 116 FMI 10 is listed, ServiceRanger?
go to Step B. • If Fault Code 116 FMI 10 is Active with the
• If no Fault Codes are listed, The Service Switch DC/DC Converter and APG disconnected,
was pushed in. Go to Step V. go to Step D.
• If Fault Code 116 FMI 10 is no longer Active
with the DC/DC Converter and APG
disconnected, key off and reinstall the Lockout
Bracket on the PEC. Replace the Power
Purpose: Verify Data Monitor parameters.

B
1. Key on.
3. Select the “Data Monitor” option.
4. View the Battery Pack Voltage (BCU1) PID 118 in
the high- voltage Battery list:
• If the Battery Pack Voltage (BCU1) PID 118 is
greater than 200 volts, go to Step C.
• If the Battery Pack Voltage (BCU1) PID 118 is
less than 200 volts, replace the Power

Purpose: Verify continuity of PEC connector Purpose: Verify continuity of Inverter connector
D circuits to ground. E circuits to ground.

2. Disconnect the PEC 19-Way Connector. 2. Reconnect the PEC 19-Way Connector.
3. Temporarily remove the Lockout Bracket and pull 3. Disconnect the Inverter 56-Way Connector.
the Service Switch out.
4. Inspect the connector pins for damaged, corroded
Note: Ensure the Key Switch is off. and/or loose wires.
4. Measure resistance at the PEC 19-Way Connector 5. Measure resistance between the Inverter 56-Way
Terminal at the following pins: Connector at the following pins:
- Pin 17 to Pin 19 - Pin 29 to Pin 37
• If the resistance between Pins 17 and Pin 19 is Note: Gently flex the Inverter 56-Way
112–122 ohms and the resistance from Pin 9 Connector Harness near the Connector
to Pin 11 and Pin 13 to Pin 15 are each 33–37 while monitoring the resistance values.
ohms, go to Step E.
• If resistance is out of range, go to Step F. 112–122 ohms and the resistance from Pin 30
to Pin 35 and Pin 31 to Pin 36 are each 33–37
ohms, push the Service Switch on the PEC and
Connection Measurement reinstall the Lockout Bracket. Go to Step H.
• If resistance is out of range, repair the Hybrid
Pin 17 to Pin 19 Harness between the PEC and Inverter, then go
to Step V.
Pin 9 to Pin 11
Pin 13 to Pin 15 Connection Measurement
Pin 29 to Pin 37
Pin 30 to Pin 35
Pin 31 to Pin 36

Purpose: Verify continuity of PEC connector Purpose: Verify continuity of Inverter connector
F circuits. G circuits.

2. Remove the Air Filter Cover and Air Filter from the 2. Disconnect the DC High-Voltage Cable at the
PEC. Refer to TRSM1000 for procedures.* PEC Bulkhead and at the Inverter Bulkhead.
3. An Inertia Switch is located at the front of the 3. Measure resistance between the Low-Voltage
PEC inside the box and viewable when the Air Filter Interlock Pins on the PEC side of the DC
is removed. High-Voltage Cable:
4. Using ASTM Class 0 electrical insulating rubber Note: The Interlock Pins are the two small spade
gloves with leather protectors, press the button on terminals located in the same opening.
the top of the Inertia Switch until heard or felt a
click. This switch must be depressed a set distance • If the resistance is 0–0.3 ohms between
to reset the switch.** the Interlock Loop Pins, replace the
Power Electronics Carrier (PEC), then
5. Measure resistance at the PEC 19-Way Connector go to Step V.
Terminal at the following pins:
• If resistance is out of range, replace the DC
- Pin 17 to Pin 19
high-voltage cable, then go to Step V.
- Pin 9 to Pin 11
- Pin 13 to Pin 15
• If the resistance between Pin 17 and Pin 19 is Connection Measurement
112–122 ohms and the resistance from Pin 9
to Pin 11 and Pin 13 to Pin 15 are each 33–37 Low-Voltage Interlock
ohms, the Inertia Switch was tripped. Test is Pins on PEC side of cable
complete. Go to Step V.
• If resistance is out of range, push in the
Service Switch on the PEC and reinstall the
Lockout Bracket, then go to Step G.
• * See Air Filter

• ** See Resetting PEC Inertia Switch.
Pin 17 to Pin 19
Pin 9 to Pin 11
Pin 13 to Pin 15

Purpose: Verify continuity of DC Cable from PEC to Purpose: Verify Data Monitor parameters.
H Inverter Connector circuits. I
1. Key off. 1. Connect ServiceRanger to the 9-Way Diagnostic
2. Disconnect the DC High-Voltage Cable at the
PEC Bulkhead and the Inverter Bulkhead. 2. Select the “Data Monitor” option.
3. Measure the resistance of each high-voltage circuit 3. View the following parameters in the High-Voltage
on the cable: Battery list.
• If the resistance of each high-voltage circuit in - Battery Pack Voltage (BCU1) PID 118
the cable is 1 ohm or less, replace the Inverter, - Battery Voltage PID 116
then go to Step V. • If the voltage readings on PID 116 and PID 118
• If resistance is out of range, replace the are within 10 volts of each other, replace the
DC High-Voltage Cable, then go to Step V. Power Electronics Carrier (PEC), then
go to Step V.
• If the voltage readings on PID 116 and PID 118
Connection Measurement are greater than 10 volts of each other, replace
the Inverter, then go to Step V.
Each high-voltage Parameter Reading

circuit on the DC
Cable from PEC to
PID 118 “Battery Pack
Inverter
Voltage”
PID 116 “Battery Voltage”


V
1. Key off.
battery cable.
3. Key on.
• If Fault Code 116 appears, contact Eaton at
1-800-826-HELP (4357). Repeat this
Step (Step V).

Fault Code 117 - BCU Relay Cut Request | Fault Isolation Procedures TRTS1000
Fault Code 117 - BCU Relay Cut Request

J1939: SA 239 SPN 520251 FMI 3, 14

The high-voltage relays are located inside the Power Only Inactive faults can be cleared from the TECU or HCM
Electronics Carrier (PEC) in the Relay Box unit. These relays history using ServiceRanger. The TECU automatically clears
are normally open when the system is off. The relays are faults from history after 200 hours. The HCM automatically
controlled through the Inverter and monitored through a clears a fault from history after that fault has been Inactive
5-volt input from the Inverter. If the relays are open the for 200 hours.
voltage is around 5 volts and when the relays are closed the
voltage is around 1 volt. Possible Causes
Detection • FMI 3
detect the fault: - PEC

less than 16 volts. - Low-voltage wire harness between PEC
and Inverter
• FMI 14
code Active: - PEC
• FMI 3 is set when Battery Control Unit (BCU) Relay
Ready CAN Flag is Active and the Relay Off signal is
Additional Tools
set high for 0.02 seconds. • Basic hand tools
• FMI 14 is set when the Relay Cut request of the • ASTM Class 0 electrical insulating rubber gloves
BCU is set over the CAN data link. with leather protectors J48603
Fallback
• Lockout tags
• ServiceRanger
diesel-only mode.

TRTS1000 Fault Isolation Procedures | Fault Code 117 - BCU Relay Cut Request

14
19 8 9
28
15 18 7 2 10
17 6 1 3 11
16 5 4 12
42 29
15 14 13
56
43
Inverter PEC
Relay Off 43 5
49
48
47
Relay Off

Fault Code 117 - BCU Relay Cut Request

Purpose: Verify FMIs present. Purpose: Verify continuity between PEC Connector
A C and Inverter Connector.

page 1.
4. Measure the resistance from the PEC 19-Way
3. Key off.
Connector Pin 5 to the Inverter 56-Way Connector
! Warning: See “High-Voltage Service Shutdown and Pin 43.
Harness near the Connector while
monitoring the resistance readings.
• If Fault Code 117 FMI 14 is listed, test 0–0.3 ohms, go to Step D.
is complete. FMI 14 requires no action
or replacement.
HCM Low-Voltage Harness between the PEC
• If Fault Code 117 FMI 3 is listed, go to Step B. and Inverter, then go to Step V.
19-Way Pin 5 to
56-Way Pin 43
Purpose: Verify fault codes present.

B
1. View Active faults to see if any of the following are
listed: 76, 77, 78, 79, 82, 86, 101, 102, 103, 104,
105, 106, 107, 108, 109:
• 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 Fault Code
117 FMI 3, go to Step C.

TRTS1000 Fault Isolation Procedures | Fault Code 117 - BCU Relay Cut Request
Purpose: Verify continuity of Vehicle Harness and Purpose: Measure the resistance of the DC
D ground. E Interlock Low-Voltage Loop.

2. Measure the resistance between the Inverter 56-Pin ! Warning: See “High-Voltage Service Shutdown and
Connector Pin 48 to Pin 49, and Pin 47 to ground. Power-Up Procedure” on page 4. Follow the proce-
0–0.3 ohms and resistance from Pin 47 to
ground is 0–0.5 ohms, go to Step E. 2. Disconnect the DC High-Voltage Cable at the
• If resistance is outside of range, replace the Inverter and the PEC.
HCM Low-Voltage Harness between the PEC 3. Measure the resistance between the Low-Voltage
and Inverter, then go to Step V. Interlock Pins in the DC Connector on the
Inverter end.
• If resistance between the low-voltage Interlock
Pins is 0–0.3 ohms, replace the Inverter, then
go to Step V.
Pin 48 to Pin 49
• If resistance is outside of range, replace
Pin 47 to ground the DC Interlock Low-Voltage Loop, then
go to Step V.
Low-voltage
Interlock circuit


V
1. Key off.
battery cable.
3. Key on.
go to Step A.

TRTS1000 Fault Isolation Procedures | Fault Code 118 - Auxiliary High-Voltage Relay Control Circuit
Fault Code 118 - Auxiliary High-Voltage Relay Control Circuit

J1939: SA 239 SPN 520252 FMI 3, 4, 5

The Auxiliary High-Voltage Relays located in the Power Only Inactive faults can be cleared from the TECU or HCM
Electronics Carrier (PEC) are controlled by the Hybrid history using ServiceRanger. The TECU automatically clears
Control Module (HCM). At key on, high-voltage power is faults from history after 200 hours. The HCM automatically
supplied from the relay box to the Auxiliary High-Voltage clears a fault from history after that fault has been Inactive
Relays. When the ePTO option is selected on the Push for 200 hours.
Button Shift Control, the HCM energizes the control circuits
for the main positive and main negative relays. The power Possible Causes
then flows through the Auxiliary High-Voltage Relays to the This fault code can be caused by any of the following:
DC/DC Converter. • FMI 3, 4, 5
Detection - PEC
The following preconditions must be met before the system - Hybrid System Harness
detects the fault: - DC Cable High-Voltage Loop
• HCM ignition voltage is greater than 7 volts and - DC/DC Converter
less than 16 volts.
Additional Tools
code Active: • ASTM Class 0 electrical insulating rubber gloves
battery in the coil circuit of the Auxiliary • Lockout bracket J48506
High-Voltage Relay. • Lockout tags
• FMI 4 is set when the HCM detects a short to • Eaton® Test Adapter Kit J43318
ground in the coil circuit of the Auxiliary • Digital Volt/Ohm Meter J46708
High-Voltage Relay.
• ServiceRanger
• FMI 5 is set when the HCM detects an open in the
coil circuit of the Auxiliary High-Voltage Relay.
Fallback
• The DC/DC Converter does not operate because the
HCM de-energizes the auxiliary high-voltage relay
circuit.

Fault Code 118 - Auxiliary High-Voltage Relay Control Circuit | Fault Isolation Procedures TRTS1000

Fault Code 118 - Auxiliary High-Voltage Relay Control Circuit

Purpose: Check for Active or Inactive fault code Purpose: Measure voltage of HCM Harness to
A status and FMIs present. B ground.

page 1.
2. Disconnect the negative battery cable.
4. Key on.
3. Key off.
5. Measure voltage from Pin 33 to ground.
Power-Up Procedure” on page 4. Follow the proce- • If the voltage from Pin 33 to ground is 0 volts,
dures to avoid shock, burn or death from improp- replace the Hybrid Control Module (HCM)
erly handled high-voltage. (only if Fault Code is Active), then
go to Step V.
• If the voltage from Pin 33 to ground is
• If FMI 3 is listed, go to Step B. 11–13 volts, repair the Hybrid System Harness
• If FMI 4 or 5 are listed, go to Step C. for a short to battery, then go to Step V.
Pin 33 to ground

Purpose: Measure resistance of the HCM Harness Purpose: Measure resistance of Bulkhead Terminal
C circuit to ground. D to ground.

2. Measure the resistance from the HCM System 2. Disconnect the PEC 19-Way Connector.
Harness 38-Way Connector on the following pins:
3. Measure the resistance between the PEC 19-Way
- Pin 33 to Pin 5 Bulkhead Terminal at the following pins:
- Pin 33 to ground - Pin 8 to Pin 10
• If the resistance between Pin 33 and Pin 5 is - Pin 8 to ground
12–22 ohms and the resistance between Pin
33 and ground is 10K ohms or greater, replace
12–22 ohms and resistance from Pin 8 to
the Hybrid Control Module (HCM) (only if
ground is 10K ohms or greater, replace the
Fault Code is Active). Go to Step V.
Hybrid Harness between the HCM and the PEC
• If resistance is outside of range, go to Step D. for a short to ground or open.
Go to Step V.
• If resistance is outside of range, go to Step E.
Pin 33 to ground Pin 8 to Pin 10
Pin 8 to ground

Purpose: Measure resistance from DC/DC Purpose: Measure resistance from DC/DC
E Converter to ground. F Converter to ground.

2. Disconnect the DC/DC Converter High-Voltage 2. Disconnect the DC/DC Converter High-Voltage
Connector at the PEC. Connector at the DC/DC Converter.
3. Measure resistance between the DC/DC Converter 3. Measure the resistance between the DC/DC
Cable 2-Way Connector at the following pins: Converter Terminal at the following pins:
- Pin 1 to ground - Pin 1 to ground
• If resistance between Pin 1 and Pin 2 is 0–0.3 • If resistance between Pin 1 and Pin 2 is
ohms and resistance from Pin 1 to ground is 0–0.3 ohms and resistance from Pin 1 to
10K ohms or greater, replace the Power ground is 10K ohms or greater, replace the
Electronics Carrier (PEC), then go to Step V. DC/DC Converter High-Voltage Cable, then
go to Step V.
• If resistance is outside of range, go to Step F.
DC/DC Converter, then go to Step V.
Pin 1 to ground Pin 1 to Pin 2
Pin 1 to ground


V
1. Key off.
battery cable.
3. Key on.
go to Step A.

TRTS1000 Fault Isolation Procedures | Fault Code 120 - APG Unit 1 AC Voltage
Fault Code 120 - APG Unit 1 AC Voltage

J1939: SA 239 SPN 520275 FMI 3, 4

Eaton hybrid electric vehicle system. It generates 60 Hz faults from history after 100 hours. The HCM automatically
single-phase 120 volts AC power for utility applications. clears a fault from history after that fault has been Inactive
for 200 hours.
Detection
• APG Inverter needs to be operating. • FMI 3
- APG
The following conditions must be met to set the fault • FMI 4
code Active: - Short phase to neutral in harness
• FMI 3 is set when output voltage is detected to be - Power Panel
greater than or equal to 145 volts AC power. - APG
• FMI 4 is set when output voltage is detected to be - Potential of output device like motor
less than or equal to 75 volts AC power. causing surge
Fallback Additional Tools
• APG shuts down. with leather protectors J48603
• Lockout tags
• ServiceRanger

Fault Code 120 - APG Unit 1 AC Voltage | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 120 - APG Unit 1 AC Voltage
Fault Code 120 - APG Unit 1 AC Voltage

A status and FMIs present. V
page 1.
viceRanger using the 9-Way Diagnostic Connector. ! Warning: See “High-Voltage Service Shutdown and
3. Key off. dures to avoid shock, burn or death from improp-
Power-Up Procedure” on page 4. Follow the proce- 3. Key on.
• If Fault Code 120 FMI 3 is Active, replace the
then go to Step V. • If Fault Code 120 appears, find error in testing,
go to Step A.
• If Fault Code 120 FMI 4 is Active, go to Step B.
Purpose: Verify integrity of APG.

B
1. Key off
2. Remove all loads from the APG.
3. Restart APG.
• APG restarts, component external to APG
is causing fault. Find faulty component, then
go to Step V.
• APG does not restart, replace the Inverter,
then go to Step V.

Fault Code 122 - APG UNIT 1 Output | Fault Isolation Procedures TRTS1000
Fault Code 122 - APG UNIT 1 Output

J1939: SA 3 SPN 520277 FMI 6, 14, 15

Inverter connected to the high voltage DC bus of the Eaton history using ServiceRanger. The TECU automatically clears
Hybrid electric vehicle system. It generates 60 Hz faults from history after 200 hours. The HCM automatically
single-phase 120V AC power for utility applications. clears a fault from history after that fault has been Inactive
for 200 hours.
Detection
• APG Inverter needs to be operating. • FMI 6, 15
- Short phase to ground in harness
- Output device causing surge
code Active: - Power Panel
• FMI 6 is set when multiple over current events - APG
are detected. • FMI 14
• FMI 14 is set when the UPS has detected
- Component drawing excessive current
abnormally low impedance placed on its output.
• FMI 15 is set when the UPS output current limit Additional Tools
(calculated or measure) has been exceeded for the
longer than allowed by the internal time limit.
Fallback with leather protectors J48603
When FMI 6, 14, or 15 is set the following conditions occur: • Lockout bracket J48506
• Amber “Check Hybrid” light illuminates • Lockout tags
• Fault is stored in HCM memory. • Digital Volt/Ohm Meter J46708
• APG shuts down. • ServiceRanger

TRTS1000 Fault Isolation Procedures | Fault Code 122 - APG UNIT 1 Output
4 3
2 6 1
5
5 2
6 1
E 4 3
APG 6-way Low-Voltage

Connector View
APG 7-way High-Voltage
AC Connector View

Fault Code 122 - APG UNIT 1 Output

Purpose: Check for Active or Inactive fault code Purpose: Measure resistance from APG circuit to
A status and FMIs present. B ground.
1. Review and follow the “Warnings & Cautions” on 1. Remove the 7-Way Connector at the APG.
page 1.
2. Measure the resistance from the AC High-Voltage
2. Retrieve Active fault codes and FMIs with Ser- Cable on the following pins.
viceRanger using the 9-Way Diagnostic Connector. - Pin 1 to ground
3. Key off. - Pin 2 to ground
- Pin 3 to ground
- Pin 4 to ground
dures to avoid shock, burn or death from improp- - Pin 5 to ground
erly handled high-voltage. - Pin 6 to ground
4. Which FMIs are present? • If the resistance is 10K ohms or greater,

go to Step C.
• If Fault Code 122, FMI 6 or 15 are Active,
go to Step B. • If the resistance is less than 10K ohms,
go to Step D.
• If Fault Code 122 FMI 14 is Active, remove
output devices, then go to Step V.
Pin 1 to ground
Pin 2 to ground
Pin 3 to ground
Pin 4 to ground
Pin 5 to ground
Pin 6 to ground

TRTS1000 Fault Isolation Procedures | Fault Code 122 - APG UNIT 1 Output
Purpose: Measure resistance of APG circuit short Purpose: Measure resistance of APG circuit short
C to ground. D to ground.
1. Remove the 6-Way APG to Power Panel Connector 1. Remove the 7-Way Connector at the Power Panel.
from the APG.
2. Measure the resistance from the AC High-Voltage
2. Measure the resistance from the APG 6-Way Cable on the following pins:
Connector on the following pins: - Pin 1 to ground
• If the resistance is 10K ohms or greater, - Pin 4 to ground
replace the Auxiliary Power Generator (APG) - Pin 5 to ground
Inverter, then go to Step V. - Pin 6 to ground
• If the resistance is less than 10K ohms, • If the resistance is 10K ohms or greater,
go to Step E. replace the APG Power Panel, then
go to Step V.
• If the resistance is less than 10K ohms,
replace the AC High-Voltage Harness, then
go to Step V.
Pin 1 to ground
Pin 2 to ground Connection Measurement
Pin 1 to ground
Pin 2 to ground
Pin 3 to ground
Pin 4 to ground
Pin 5 to ground
Pin 6 to ground

Purpose: Measure resistance of APG circuit short Purpose: Verify repair.

E to ground. V
1. Remove the 6-Way APG to Power Panel Connector 1. Key off.
from the Power Panel.
2. Measure the resistance from the APG 6-Way
3. Key on.
Connector on the following pins:
- Pin 1 to ground 4. Clear Codes, see “Clear Inactive Faults” on page 13.
- Pin 2 to ground 5. Operate the APG and attempt to reset the code.
• If the resistance is 10K ohms or greater, 6. Check for codes, see “View Active and Inactive
replace the APG Power Panel, then Faults” on page 13.
go to Step V.
• If the resistance is less than 10K ohms,
replace the 6-Way Harness, then go to Step V. • If Fault Code 122 FMI 6 or 15 appears, go to
Step B.
• If Fault Code 122 FMI 14 appears, find error in
Connection Measurement testing, go to Step A.
Pin 1 to ground Code Isolation Procedure Index” on page 14.
Pin 2 to ground

TRTS1000 Fault Isolation Procedures | Fault Code 123 - APG Unit 1 High Voltage Battery
Fault Code 123 - APG Unit 1 High Voltage Battery

J1939: SA 239 SPN 520278 FMI 3, 4, 14

Inverter connected to the high voltage DC bus of the Eaton history using ServiceRanger. The TECU automatically clears
hybrid electric vehicle system. It generates 60 Hz faults from history after 200 hours. The HCM automatically
single-phase 120-volt AC power for utility applications. clears a fault from history after that fault has been Inactive
for 200 hours.
Detection
• FMI 3, 4: APG Inverter needs to be operating. • FMI 3
• FMI 14: APG Inverter needs to be in pre-charge - APG
phase. • FMI 4, 14
Conditions to Set Fault Code Active - APG
The following conditions must be met to set the fault - PEC
code Active: - High-Voltage DC Cable
• FMI 3 is set when high voltage DC has been
detected to surpass an upper limit. Additional Tools
• FMI 4 is set when high voltage DC has been • Basic hand tools
detected to drop below a lower limit. • ASTM Class 0 electrical insulating rubber gloves
• FMI 14 is set when the APG cannot stabilize high with leather protectors J48603
voltage DC during the pre-charge phase. • Lockout bracket J48506
• APG shuts down if operating.

Fault Code 123 - APG Unit 1 High Voltage Battery | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 123 - APG Unit 1 High Voltage Battery
Fault Code 123 - APG Unit 1 High Voltage Battery

Purpose: Check for Active and Inactive fault code Purpose: Verify repair.
A status. V
page 1.
• If Fault Code 123 FMI 3, 4, or 14 is Active with
an Active hybrid system fault, troubleshoot
Active hybrid fault, then go to Step V. • If Fault Code 123 appears, find error in testing,
go to Step A.
• If Fault Code 123 FMI 3, 4, or 14 is Active
without an Active hybrid system fault, replace • If a code other than 123 appears, go to “Fault
the Auxiliary Power Generator (APG) Code Isolation Procedure Index” on page 14.

Fault Code 125 - APG Unit 1 Over Temperature | Fault Isolation Procedures TRTS1000
Fault Code 125 - APG Unit 1 Over Temperature

J1939: SA 239 SPN 520280 FMI 0

single-phase 120-volt AC power for utility applications. The clears a fault from history after that fault has been Inactive
heat sink temperature (IGBT case temperature) exceeds the for 200 hours.
upper temperature limit for normal operation.
Possible Causes
detects the fault:
- Cooling system
• APG Inverter needs to be operating.
- APG Temperature Sensor fault in range
• FMI 0 is set when the heat sink temperature at an • ASTM Class 0 electrical insulating rubber gloves
unspecified module exceeds the upper temperature with leather protectors J48603
limit for normal operation. • Lockout bracket J48506
• APG shuts down if operating.

TRTS1000 Fault Isolation Procedures | Fault Code 125 - APG Unit 1 Over Temperature

Fault Code 125 - APG Unit 1 Over Temperature | Fault Isolation Procedures TRTS1000
Fault Code 125 - APG Unit 1 Over Temperature

Purpose: Check for Active and Inactive fault code Purpose: Verify repair.
A status. V
page 1.
• If FMI 0 is Active, go to Step B.
go to Step A.
Purpose: Verify proper coolant level.

B
cooled to see if it is filled to the proper level.
• If the coolant is within the recommended
limits, replace the Auxiliary Power Generator
(APG) Inverter, then go to Step V.

TRTS1000 Fault Isolation Procedures | Fault Code 126 - APG Unit 1 Configuration
Fault Code 126 - APG Unit 1 Configuration

J1939: SA 239 SPN 520281 FMI 22–27

Inverter that is connected to the high-voltage DC bus of the history using ServiceRanger. The TECU automatically clears
single-phase 120V AC power for utility applications. clears a fault from history after that fault has been Inactive
for 200 hours.
Detection
detect the fault: This fault code can be caused by any of the following:
• APG Inverter needs to be operating. • FMI 22–27: APG

code Active: • ASTM Class 0 electrical insulating rubber gloves
• FMI 22 is set when a control board self test with leather protectors J48603
has failed. • Lockout bracket J48506
• FMI 23 is set when a nonvolatile data checksum • Lockout tags
failure has occurred.
• FMI 24 is set when software incompatibility has
been detected. • ServiceRanger
• FMI 25 is set when a blown fuse is detected.

• FMI 26 is set when the internal fan speed is
detected to be low.
• FMI 27 is set when there is an Inverter fault.
Fallback
When FMI 22–27 is set the following conditions occur:
• APG does not start.

Fault Code 126 - APG Unit 1 Configuration | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 126 - APG Unit 1 Configuration
Fault Code 126 - APG Unit 1 Configuration

A status and FMIs present. V
page 1.
3. Key on.
3. Key off.
dures to avoid shock, burn or death from improp- • If no codes, test is complete.
4. Which FMIs are present? go to Step A.
• If FMI 22–27 are present, replace the • If a code other than 126 appears, go to “Fault
Auxiliary Power Generator (APG) Inverter, Code Isolation Procedure Index” on page 14.
then go to Step V.

Fault Code 127 - APG Unit 1 Ambient Air Over Temperature | Fault Isolation Procedures TRTS1000
Fault Code 127 - APG Unit 1 Ambient Air Over Temperature

J1939: SA 239 SPN 520282 FMI 0

single-phase 120-volt AC power for utility applications. The clears a fault from history after that fault has been Inactive
ambient air temperature is measured with an internal for 200 hours.
sensor and sets a fault when the temperature reaches 140
°F (60 °C). Possible Causes
Detection • FMI 0
detects the fault: - Faulty Sensor
• HCM is powered and ignition voltage is greater - Ambient case temperature too high
than 7 volts and less than 16 volts.
Additional Tools
• FMI 0 is set when the ambient temperature inside • Lockout bracket J48506
of the APG Inverter case reaches 140 °F (60 °C).
• Lockout tags
When FMI 0 is set the following conditions occur: • ServiceRanger
• The APG powers down.

TRTS1000 Fault Isolation Procedures | Fault Code 127 - APG Unit 1 Ambient Air Over Temperature

Fault Code 127 - APG Unit 1 Ambient Air Over Temperature | Fault Isolation Procedures TRTS1000
Fault Code 127 - APG Unit 1 Ambient Air Over Temperature

A status. V
page 1.
• If FMI 0 is present, go to Step B.
go to Step A.
Purpose: Verify proper coolant level.

B
1. Ensure that the Inverter cabinet is not exposed to
external heat source.
cooled to see if it is filled to the proper level.
• If the coolant is within the recommend limits,
replace the Auxiliary Power Generator (APG)

TRTS1000 Fault Isolation Procedures | Fault Code 128 - APG Unit 1 Ambient Air Temperature Sensor
Fault Code 128 - APG Unit 1 Ambient Air Temperature Sensor

J1939: SA 239 SPN 520322 FMI 3

Inverter that is connected to the high-voltage DC bus of the history using ServiceRanger. The TECU automatically clears
single-phase 120V AC power for utility applications. Fault clears a fault from history after that fault has been Inactive
Code 128 indicates that the Ambient Air Temperature for 200 hours.
Sensor has been detected as faulty.
Possible Causes
The following preconditions must be met before the system • FMI 3: Faulty sensor
detect the fault:
• HCM is powered and ignition voltage is greater Additional Tools
than 7 volts and less than 16 volts. • Basic hand tools
Conditions to Set Fault Code Active • ASTM Class 0 electrical insulating rubber gloves
The following conditions must be met to set the fault with leather protectors J48603
code Active: • Lockout bracket J48506
• FMI 3 is set when the Ambient Air Temperature • Lockout tags
Sensor has been detected out of range. • Digital Volt/Ohm Meter J46708
When Fault Code 128 FMI 3 is set the following conditions
occur:
• APG shuts down and attempts a restart after 30
seconds.

Fault Code 128 - APG Unit 1 Ambient Air Temperature Sensor | Fault Isolation Procedures TRTS1000

TRTS1000 Fault Isolation Procedures | Fault Code 128 - APG Unit 1 Ambient Air Temperature Sensor
Fault Code 128 - APG Unit 1 Ambient Air Temperature Sensor

A status. V
page 1.
3. Key on.
3. Key off.
dures to avoid shock, burn or death from improp- • If no codes, test is complete.
4. Which FMIs are present? go to Step A.
• If FMI 3 is present, replace the • If a code other than 128 appears, go to “Fault
Auxiliary Power Generator (APG) Inverter, Code Isolation Procedure Index” on page 14.
then go to Step V.

Fault Code 129 - APG Unit 1 Communication | Fault Isolation Procedures TRTS1000
Fault Code 129 - APG Unit 1 Communication

J1939: SA 239 SPN 520323 FMI 9

single-phase 120-volt AC power for utility applications. The clears a fault from history after 200 hours of the fault
Controller Area Network (CAN) is a high-speed twisted pair staying Inactive.
500K proprietary data link that connects the HCM to the
Electric Clutch Actuator (ECA), Battery Control Module, Possible Causes
Inverter and APG. The link contains one 120 ohm resistor at This fault code can be caused by any of the following:
each end. The link is used to transmit information specific • FMI 9
to clutch position and power electronics operations.
- APG
Detection - HCM
The following preconditions must be met before the system - CAN Data Link
detects the fault:
than 7 volts and less than 16 volts. • Basic hand tools
Conditions to Set Fault Code Active • ASTM Class 0 electrical insulating rubber gloves
The following conditions must be met to set the fault with leather protectors J48603
code Active: • Lockout bracket J48506
• FMI 9: Communication with the HCM has not • Lockout tags
occurred for more than 2 seconds. • Digital Volt/Ohm Meter J46708
• If the fault sets during operation the APG shuts off.

TRTS1000 Fault Isolation Procedures | Fault Code 129 - APG Unit 1 Communication
E D
8 1
C
7 2 A B
F
6 3
5 4
G J
H

connector view
9-way diagnostic connector

Fault Code 129 - APG Unit 1 Communication | Fault Isolation Procedures TRTS1000
Fault Code 129 - APG Unit 1 Communication

Purpose: Verify Active and Inactive fault code Purpose: Verify resistance on APG CAN Harness.
A status and FMIs present. B
1. Review and follow the “Warnings & Cautions” on 1. Measure the resistance between the following:
page 1. - Diagnostic 9-Way Connector Pin H and Pin J
2. Retrieve Active fault codes and FMIs with Ser- - 2-Way Connector Pin 1 and Pin 2
viceRanger using the 9-Way Diagnostic Connector. - 3-Way Connector Pin A and Pin B
3. Key off. Note: The 3-Way and 2-Way Data Link
Connectors are located next to the
9-Way Diagnostic Connector.
dures to avoid shock, burn or death from improp- Note: Make sure the Volt/Ohm Meter is on the
4. Which FMIs are present? • If the resistance between Pin H and Pin J,
Pin A and Pin B, or Pin 1 and Pin 2 is between
• If FMI 9 is present, go to Step B.
50–70 ohms, go to Step C.
• If the resistance is more than 70 ohms, one
or more of the terminating resistors on the
CAN Data Link Harness is either missing or
out of range, or there is an open in the link.
Repair the OEM CAN Data Link Harness, then
go to Step V.
• If the resistance is less than 50 ohms, there
is an additional terminating resistor present.
Repair the CAN Data Link Harness, then
go to Step V.
9-Way Pin H to
9-Way Pin J
2-Way Pin 1 to
2-Way Pin 2
3-Way Pin A to
3-Way Pin B

TRTS1000 Fault Isolation Procedures | Fault Code 129 - APG Unit 1 Communication
Purpose: Verify resistance on APG CAN Harness. Purpose: Verify repair.

C V
2. Disconnect the negative battery cable. 2. Reconnect all connectors.
3. Disconnect the APG 8-Way Connector at the APG. 3. Key on.
4. Measure the resistance between APG 8-Way 4. Operate the APG and attempt to reset the code.
Note: Make sure the Volt/Ohm Meter is on the Faults” on page 13.
• If the resistance between Pin 4 and Pin 5 is • If Fault Code 129 appears, find error in testing,
between 110–130 ohms, replace the go to Step A.
then go to Step V. • If a code other than 129 appears, go to “Fault
• If the resistance is outside the range, repair the
Pin 4 to Pin 5

Fault Code 131 - APG Unit 1 Configuration Error | Fault Isolation Procedures TRTS1000
Fault Code 131 - APG Unit 1 Configuration Error

J1939: SA 239 SPN 520320 FMI 13

single-phase 120V AC power for utility applications. The clears a fault from history after that fault has been Inactive
Hybrid Controller Module (HCM) can be configured for up for 200 hours.
to two (2) APG units.
Possible Causes
The following preconditions must be met before the system • FMI 13: HCM configuration
detects the fault:
than 7 volts and less than 16 volts. • ServiceRanger
code Active:
• FMI 13 is set when the number of APGs responding
on the link is different than the number of APGs
configured in the HCM.
Fallback

TRTS1000 Fault Isolation Procedures | Fault Code 131 - APG Unit 1 Configuration Error
8 1
7 2
6 3
5 4

connector view

Fault Code 131 - APG Unit 1 Configuration Error | Fault Isolation Procedures TRTS1000
Fault Code 131 - APG Unit 1 Configuration Error

Purpose: Check for Active or Inactive fault code Purpose: Verify resistance of APG CAN Harness.
A status and FMIs present. C
page 1.
! Warning: Disconnect the APG 8-Way Connector at
the APG.
3. Key off.
3. Measure the resistance between APG 8-Way
! Warning: See “High-Voltage Service Shutdown and Connector Pin 4 and Pin 5:
dures to avoid shock, burn or death from improp- Note: Make sure the Volt/Ohm Meter is on the
4. Which FMIs are present? • If resistance between Pin 4 and Pin 5 is

between 50– 70 ohms, replace the Auxiliary
• If Fault Code 131 FMI 13 is Active, Power Generator (APG) Inverter, then
go to Step B. go to Step V.
Purpose: Verify APG configurations. Pin 4 to Pin 5

B
1. Does APG configuration match the number of
installed APG units?
• Yes, go to Step C.
• No, set configuration equal to number of
installed APG units, then go to Step V.

TRTS1000 Fault Isolation Procedures | Fault Code 131 - APG Unit 1 Configuration Error

V
1. Key off.

3. Key on.
go to Step A.

Front Box Test | Symptom Procedures TRTS1000
Front Box Test

Overview
This symptom-driven test is performed if a dash “-” or
flashing gear is displayed on the gear display, and there are
no Active or Inactive codes. Turn key on and watch the gear
display. If the gear display shows a dash “-” constantly, the
Transmission Electronic Control Unit (TECU) 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

directed here from the Diagnostic Procedure and
there are no Active fault codes.
Detection
The following symptoms may have been experienced:
• Power up no crank and gear display shows a dash
“-”.
• Transmission does not engage a gear from neutral
(flashing gear number is gear display).
Fallback
There is no fallback mode for this symptom; however, the
vehicle may do either of the following: not crank if the dash
“-” is present or not engage a gear if the flashing gear is
present when a non-neutral gear is selected.
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
Additional Tools
• ServiceRanger

TRTS1000 Symptom Procedures | Front Box Test
Note: The picture above shows the Shift Forks in neutral position.

Front Box Test | Symptom Procedures TRTS1000
Front Box Test

Purpose: Visually observe the gear display after Purpose: Visually observe the gear display when
A power up. C placing the transmission into Drive.
1. Only perform this symptom test if sent here from 1. Key off.
the Diagnostic Procedure and there are no Active
2. Attempt to remove any type of torque lock on the
fault codes.
drivetrain through one of the following methods:
2. Key on. - Remove the driveshaft
3. Press “N” on the Push Button Shift Control. - Lift the drive wheels off the ground
- Roll the vehicle in neutral
4. Observe gear display:
3. Key on.
• If gear display shows: “N”, go to Step B.
• If gear display shows: “-”, go to Step C.
• If gear display shows a solid “N”,
go to Step B.
Parameter Reading • If gear display still shows a solid dash “-”,
go to Step D.
Gear Display
Parameter Reading
Gear Display
Purpose: Visually observe the Gear Display when

B placing the transmission into Drive.
1. Press service brake and select D.

Purpose: Perform Electrical Pretest.
D
• If Gear Display shows a solid gear, test
is complete.
• If gear display shows a flashing gear with no Pretest” on page 25):
arrows, go to Step C.
go to Step E.
Parameter Reading • If issue was repaired during the Electrical

Pretest, go to Step A.
Gear Display

TRTS1000 Symptom Procedures | Front Box Test
Purpose: Verify Electric Shifter performs a Purpose: Verify repair.

E calibration sweep. V
2. Listen for noise from the Electric Shifter 2. Reconnect all connectors.
calibrating/actuating then turn the key off and listen
3. Place Shift Control into neutral.
for the same noise again:
4. Key on.
• If the Electric Shifter can be heard
calibrating/actuating, go to Step F. • If gear display displays a solid “N”, test
is complete.
• If the Electric Shifter can not be heard
calibrating, go to Step F. • If gear display does not display a solid “N”,
find error in testing, go to Step A.
Parameter Reading
Gear Display
Purpose: Remove Electric Shifter from the Shift

F Bar Housing and inspect the mechanical
transmission.
1. Key off.
- Shift ails move into each gear position
- Electric Shifter is free from any excessive lube
same time
• If no problem found, and the Electric Shifter
actuation was not heard in the previous step,
replace the Transmission Electronic Control
Unit (TECU), then go to Step V.
• If no problem found, and the Electric Shifter
actuation was heard in the previous step,
replace the Electric Shifter, then go to Step V.
go to Step V.
• * See Electric Shifter.

Engine Crank Test | Symptom Procedures TRTS1000
Engine Crank Test

J1939: SA 3 SPN FMI
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 does not crank.
The Hybrid Control Module (HCM) receives the input to

crank from Pin 20 on the HCM 38-Way 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 uses the standard 12-Volt
Starter by energizing the 12-Volt Cranking Relay. This relay
then provides battery power to Pin 30 of the Start Enable
Relay, which then powers the Starter Solenoid.

directed here from the Diagnostic Procedure and
Detection
• Vehicle does not crank or there is a solid “N” in the
Gear Display.
Fallback
No fallback options are associated with this fault.
Possible Causes
• 12-Volt Cranking Relay
• Start Enable Relay
• Vehicle Harness
• Engine Starter
• 12-volt batteries
• Key Switch input to Pin 20 of the HCM
Additional Tools
• ServiceRanger

TRTS1000 Symptom Procedures | Engine Crank Test

1 29
6 34
7 23
12 28
36 35 37 38
22 13
13 22
38 37 35 36
28 23 7 12
34 29 1 6
Starter solenoid
TECU
87 Typical Relay Switch
Start Enable Latch 26 86 Start Enable

Relay
Start Enable Plus 32 85
30
Start Enable Minus 4
30
87
HCM 86
86
12V Cranking
85 87
Crank Enable Latch 26 Relay
85
Crank Enable Plus 32
30
Crank Enable Minus 4
Engine Crank Request 20

12V Plus
Key Switch
Off
Ignition 12V Truck
Crank Battery

Engine Crank Test | Symptom Procedures TRTS1000
Engine Crank Test

Purpose: Visually observe the Gear Display after Purpose: Verify Crank Request parameter.
A power up. B
1. Perform this symptom test if only if directed to do 1. Key on.
so by the Symptom-Driven Diagnostic Index and
Connector.
2. Key on.
3. Select the “Data Monitor” option and view the
3. Press N on the Push Button Shift Control: “Crank Request” parameter:
Note: The ePTO light must be off when using the • If Crank Request reads 1 (Crank),
Key Switch to start the vehicle. go to Step C.
• If “N” is present on the gear display, • If Crank Request reads 0 (No Crank),
go to Step B. go to Step E.
• If “N” is not present on the gear display, refer

to the “Hybrid Diagnostic Procedure” on Parameter Reading
page 8 for the correct symptom-based test
“Crank Request”
to perform.
Parameter Reading
Gear Display
Purpose: Verify integrity of the Cranking Relay.

C
1. Substitute a different start enable and 12-Volt
Cranking Relay.
2. Attempt to crank engine:
• If engine cranks, pinpoint which of the 2 relays
was at fault and replace it. Go to Step V.
• If engine does not crank, go to Step D.

TRTS1000 Symptom Procedures | Engine Crank Test
Purpose: Verify power to the Start Enable Relay. Purpose: Verify repair.
D V
2. Engine may crank. 2. Reconnect all connectors.
3. Jumper Pin 87 of the Start Enable Relay Connector 3. Place Shift Control into neutral.
to battery power:
4. Key on:
• If engine cranks, repair open circuit between
• If engine starts, test is complete.
Pin 87 of the Start Enable Relay and battery.
Refer to OEM for repair procedures. • If engine does not start, find error in testing,
go to Step A.
• If engine does not crank, concern is with
Starter Solenoid or Power Harness to
Solenoid. Refer to OEM for repair procedures.
Purpose: Verify voltage to ground on HCM

E Harness.
1. Key off.
4. Key in start position.
5. Measure voltage from HCM Harness 38-Way
Connector Pin 20 to ground.
• If voltage is 11–13 volts, replace the Hybrid
• If voltage is below 11 volts, repair the Vehicle
Pin 20 to ground

Hybrid Performance Test | Symptom Procedures TRTS1000
Hybrid Performance Test

J1939: SA 3 SPN FMI
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: This symptom-based test should only be performed

when directed by the Symptom-Driven Diagnostics
Index and there are no Active fault codes.
Detection
• Vehicle acceleration performance is not acceptable.
Fallback
Some faults codes affect the amount of torque available
from the Motor/Generator and will be noticeable to
the driver.
Possible Causes
• Hybrid liquid cooling system
• PEC air cooling system restriction or poor air flow
• Reduce engine power
• Truckload capacity above the rated amount
Additional Tools
• ServiceRanger

TRTS1000 Symptom Procedures | Hybrid Performance Test
Note: No schematic for this test.

Hybrid Performance Test | Symptom Procedures TRTS1000
Hybrid Performance Test

Purpose: Verify engine torque. Purpose: Verify battery temperature.
A B
1. Key on. 1. Select the “Data Monitor” option and view the
following parameter:
Connector in the cab and view the following “Data - Battery Temperature PID 115
Monitor” parameters under the hybrid (Engine and • If Battery temperature is below 104 °F (40 °C),
Brake) list: refer to OEM for engine power concern, then
- SPN 513 Actual Engine Torque go to Step V.
- SPN 518 Requested Engine Torque • If temperature is above 104 °F (40 °C), inspect
• If actual torque is equal to requested torque, the battery cooling system for plugged intake
go to Step B. or exhaust ports, restricted or plugged Air
Filter, and failed Battery Cooling Fan. Refer to
• If actual torque is less than requested torque, OEM for procedures and specifications.
refer to OEM for engine power concern.
Go to Step V. • After making repairs, go to Step V.
Parameter Reading Parameter Reading
SPN 513 Actual PID 115 Battery

Engine Torque Temperature
SPN 518 Requested

Engine Torque

V
1. Key off.
4. Key on.
• If vehicle exhibits normal amount of power,
test is complete.
• If vehicle seems to produce lack power,
find error in testing, go to Step A.

TRTS1000 Symptom Procedures | ServiceRanger Test
ServiceRanger Test
J1939: SA 3 SPN FMI
Overview
The service tool ServiceRanger communicates with both
the Hybrid Control Module (HCM) and the Transmission
Electronic Control Unit (TECU) for all diagnostic information
over the J1587 and J1939 Data Links. The tool connects to
the standard 9-Way Diagnostic Connector in the cab.
Note: All Hybrid systems require the new ServiceRanger

Midas along with the Nexiq USB Communication Box.
when directed by the Symptom-Driven Diagnostic
Index.
Detection
• ServiceRanger does not communicate with vehicle.
Fallback
No fallback condition exists for this symptom.
Possible Causes
• Incorrect ServiceRanger software version
• Incompatible Communication Box
• J1939 or J1587 Data Link
• 9-Way Diagnostic Connector power or ground
• HCM
• TECU
Additional Tools
• ServiceRanger

ServiceRanger Test | Symptom Procedures TRTS1000

1 29
6 34
7 23
12 28
36 35 37 38
22 13
13 22
38 37 35 36
28 23 7 12
34 29 1 6
9 Pin Diagnostic Connector
E D
C
F A B
TECU
G J
H
J1587 Plus 10
J1587 Minus 11
J1939 Low TECU 2
9 Pin Diagnostic
J1939 High TECU 3 Connector
A Ground
B 12V Batt
C J1939 High
HCM
D J1939 Low
J1587 Plus 10
E
J1587 Minus 11
F J1587 Plus
J1939 Low 2
G J1587 Minus
J1939 High 3
H CAN High
J CAN Low

ServiceRanger Test
Purpose: Verify ServiceRanger connects. Purpose: Verify both HCM and TECU available on
A C J-1587 and J-1939.
1. You should only perform this symptom test when 1. View the Vehicle Components selection in
directed by the Symptom-Driven Diagnostic Index. ServiceRanger and note if the HCM and TECU are
both listed on J1587 and J1939:
Connector in the cab. • If the TECU and HCM both appear on the list
twice, ServiceRanger is communicating with
3. Select the green “Connect” tab:
the vehicle and has full functions available to
• If the ServiceRanger screen comes up, it. Go to Step V.
go to Step B.
• If the TECU or HCM are missing from the list
• If ServiceRanger shows a “Failed to Connect” but the other modules are listed, go to Step G.
error message, go to Step D.
Purpose: Verify voltage at 9-Way Diagnostic

Purpose: Verify both J-1587 and J-1939 are D Connector.
B available.
1. Key on.
1. View the J1587 and J1939 connection icons at the
2. Disconnect ServiceRanger from the 9-Way
bottom of the ServiceRanger screen:
Diagnostic Connector.
• If both data link lights are highlighted green,
3. Measure voltage at the 9-Way Diagnostic
go to Step C.
Connector from Pin A to Pin B:
• If either data link light is highlighted red,
• If voltage is 11–13 volts, concern is with the
go to Step E.
Communication Box or Cable. Try another
Communication Box and Cable. Go to Step V.
• If voltage is out of range, repair the Power
Supply to the 9-Way connection, then
go to Step A.
Pin A to Pin B

ServiceRanger Test | Symptom Procedures TRTS1000
Purpose: Verify J-1587 continuity at 9-Way Purpose: Verify J-1939 continuity at 9-Way
E Diagnostic Connector. F Diagnostic Connector.

2. Measure resistance between the following pins at 2. Measure resistance between the following pins at
the 9-Way Diagnostic Connector: the 9-Way Diagnostic Connector:
- F to G - C to D
- F to ground - C to ground
• If resistance from Pin F to Pin G is 1.8K–2.5K • If resistance from Pin C to Pin D is 50–60
ohms and resistance from Pin F to ground is ohms and resistance from Pin C to ground is
10k ohms or greater, go to Step F. 10k ohms or greater, concern is with one of
the following areas:
- PC
Vehicle Harness, then go to Step V.
- Communication Box
- Cables
• Refer to the “Diagnostic Tools” section for
Pin F to Pin G list of compatible diagnostic tools. If
concern is still present, contact Eaton at
Pin F to ground 1-800-826-HELP (4357).
OEM Vehicle Harness, then go to Step V.
Pin C to Pin D
Pin C to ground

Purpose: Verify powers and grounds. Purpose: Verify J-1587 continuity at TECU 38-Way
G I Connector.
1. Perform the Electric Pretest: 1. Key off.

• If the Electrical Pretest passes, and there is no 2. Disconnect negative battery cable.
communication with the HCM, go to Step H.
3. Disconnect TECU Harness 38-Way Connector.
• If the Electrical Pretest passes, and there is no
4. Measure resistance between TECU Harness
communication with the TECU, go to Step I.
• If the Electrical Pretest finds an issue, repair
the concern and go to Step A.
between 0–0.3 ohms, replace Transmission
Electronic Control Unit (TECU), then go to
Step V.
Data Link Harness between HCM and closest
Purpose: Verify J-1939 continuity at HCM 38-Way
H Connector.
connector, then go to Step V.
1. Key off.
Pin 10 to Pin 11
V
1. Key off.
Data Link Harness between HCM and closest 2. Reconnect all connectors.
connector, then go to Step V. 3. Place Shift Control into neutral.
4. Key on:
• If ServiceRanger communicates with both the
Pin 2 to Pin 3 HCM and the TECU, test is complete.
• If ServiceRanger fails to communicate with
the HCM and TECU, go to Step A. Find error
in testing.

Gear Engagement Test | Symptom Procedures TRTS1000
Gear Engagement Test

J1939: SA 3 SPN FMI
Overview
The Hybrid Control Module (HCM) normally commands the
different gears shifts which are carried out through the
Transmission Electronic Control Unit (TECU). The HCM also
controls the Electric Clutch Actuator (ECA), which changes
the position of the clutch.

directed by the Symptom-Driven Diagnostic Index
and there are no Active fault codes.
Detection
• Transmission does not engage a gear from
neutral and a warning tone sounds (Solid “N” in
gear display).
• Transmission does not engage a gear from Neutral
(flashing gear in gear display). This symptom is
addressed in the Front Box Symptom test.
• Transmission does not move from a stop (solid
gear number in gear display).
Fallback
Possible Causes
• Transmission
• Service Brake Switch
• Boom/Outrigger Switch
Additional Tools
• ServiceRanger

TRTS1000 Symptom Procedures | Gear Engagement Test
Messages from the Body Controller to the HCM

Parameter Signal Value Meaning Description
0 Allow Driving Body Controller is requesting the HCM not

520355 Prohibit Driving
1 Prohibit Driving allow gear engagement from neutral.
Messages from the Engine, Chassis, or Body

Controller to the TECU
0 Not Applied The ECU is confirming the current state of

597 Brake Switch
1 Applied the Service Brake Switch.

Gear Engagement Test | Symptom Procedures TRTS1000
Gear Engagement Test

Purpose: Visually observe the gear display after Purpose: Confirm the proper parameter
A power up. C configuration to prohibit driving.
1. Perform this symptom test only if directed by the 1. Key on.

Symptom-Driven Diagnostic Index and there are no
2. Connect ServiceRanger and view the following Data
Active fault codes.
Monitor parameter PID 154 “Prohibit Driving.”
2. Press N on the Push Button Shift Control:
• Prohibit Driving reads 0 (Allow Driving),
• If “N” is present on the Gear Display, contact Eaton at 1-800-826-HELP [4357].
go to Step B.
• Prohibit Driving reads 1 (Prohibit Driving),
• If “N” is not present on the Gear Display, ensure boom and outriggers are fully
refer to the “Hybrid Diagnostic Procedure” on retracted. Contact the OEM for
page 8 for the correct symptom-based test repair procedures.
to perform.
Parameter Reading
PID 154 “Prohibit Driving”
Purpose: Visually observe the Gear Display when

B placing the transmission into Drive.
1. Key on.
2. Start engine.
3. Press 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” on page 418.
• If gear display shows a solid gear, but vehicle
does not move, go to Step C.

TRTS1000 Symptom Procedures | Gear Engagement Test
Purpose: Verify proper brake status signal.

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 pressed
when applying the brakes, contact Eaton at
1-800-826-HELP [4357].
• If the Service Brake Switch does not change
status, repair Service Brake wiring or Switch.
Contact the OEM for repair procedures.
Parameter Reading
SPN 597 “Service Brake

Status”

V
1. Key off.
4. Key on.
• If the transmission engages a gear and moves
from a stop, test is complete.
• If the transmission neither engages a gear nor
moves from a stop, go to Step A. Find error
in testing.

ePTO Test | Symptom Procedures TRTS1000
ePTO Test
J1939: SA 3 SPN FMI

The ePTO feature allows the diesel engine to remain off for This fault code can be caused by any of the following:
extended periods of time during PTO usage. The DC/DC • Transmission not in neutral
Converter is energized only in ePTO mode so it can charge
the 12-volt battery system. The Hybrid Control Module • HCM system fault
(HCM) operates the Motor/Generator to power the • TECU system fault
transmission mounted PTO. • PTO Pump
If the high-voltage batteries are low, the HCM will start the • HCM
engine with the Motor/Generator or the standard 12-volt • Body hydraulic pressure and demand switches
system. To select the ePTO mode press the Mode button on
the Push Button Shift Control. • Boom or Outrigger switches
• Hybrid System Harness
Some applications use a Chassis or Body Controller to
control the PTO and send information to the HCM. Other • Hood Switch
applications use the HCM to control and confirm • PTO Ball Switch
engagement of the PTO. The Body Controlled option is • TECU
referred to as the J1939 option and the HCM controlled is
referred to as the Analog option. • PBSC
Note: To determine which module is controlling the PTO Additional Tools

connect ServiceRanger and select “Roadranger • Basic hand tools
Configurations.” Under the “Hybrid Control Module”
option is a list for PTO Feedback— Analog Controlled • Eaton® Test Adapter Kit J43318
(HCM), or J1939 Controlled (Body Controller). • Digital Volt/Ohm Meter J46708
Note: This symptom-based test should only be performed • ServiceRanger
as directed by a Diagnostic Procedure and there are
no Active fault codes.
Detection
The following symptoms may be experienced:
• ePTO light does not illuminate when mode
is selected.
• ePTO light flashes and the push button
tone sounds.
• ePTO light is illuminated, but the hydraulic lift does
not operate when the controls are used.
• ePTO light is illuminated, but the PTO Pump fails to
turn off after PTO usage.
• ePTO light is illuminated, but the diesel engine runs
frequently or all the time.
Fallback

TRTS1000 Symptom Procedures | ePTO Test
Messages from the Body Controller to the HCM

0 No OK Body Controller will allow the Hybrid HCM

520354 OK to Crank to automatically start the engine in ePTO if
1 OK necessary.
0 Disengaged Body Controller is confirming the PTO is

520365 PTO Engaged
1 Engaged engaged.
0 No Request Body Controller is requesting the HCM to

520353 Request Engine Run
1 Request start the engine.
0 No Demand Body Controller is requesting the Hybrid to

520352 Hydraulic Demand (PTO) turn the transmission and provide PTO
1 Demand power.
0 False
520351 PTO Engaged Command TECU is sending the request to the HCM
1 True
0 False
520350 PTO Engaged Feedback HCM is confirming it received the message
1 True

ePTO Test
Purpose: Verify “ePTO” light operates. Purpose: Determine the run time appropriate for
A C application and verify PTO Pump shuts down.
1. Only perform this symptom test if directed by the 1. Release the controls on the Hydraulic Lift and let
Symptom-Driven Diagnostic Index and there are no the vehicle set:
Active fault codes.
Note: The run time may vary depending on the type
2. Key on. of system and size of accumulators that need
to be charged.
3. Press ePTO on the Push Button Shift Control:
• If ePTO light is lit on the Push Button Shift • If PTO Pump shuts off, go to Step D.
Control, go to Step B. • If PTO Pump continues to operate,
• If ePTO light is not lit on the Push Button Shift go to Step L.
Control, replace the Push Button Shift Control
(see Shift Control). Make sure the following
fault codes are not Active 16, 35, 24, 48, or 59.
Go to Step V.
• If ePTO light is flashing on the Push
Button Shift Control and the tone sounds,
go to Step F.
Purpose: Verify Hydraulic Lift operation.

B
1. Use the controls to operate the Hydraulic Lift.
• Hydraulic Lift operates, go to Step C.
• Hydraulic Lift does not operate, go to Step K.

Purpose: Verify the State of Charge and verify that Purpose: Confirm “Request Engine Run” signal is
D diesel engine turns on and shuts down. E present at low State Of Charge.
1. Operate the Hydraulic controls until the diesel 1. Connect ServiceRanger to the 9-Way Diagnostic
engine turns on. Connector.
2. Connect ServiceRanger and select the Data 2. View the Data Monitor parameter PID 152 “Request
Monitor option. Engine Run”:
3. View the high-voltage battery list and view the • If PID 152 “Request Engine Run” reads 0 (No
PID 133 “Battery State Of Charge (SOC)”: Request) and PID 133 “Battery SOC” is less
than 68%, the current power usage is enough
• If diesel engine cycles on for some time
to require the engine to remain on so the
then shuts back down, test is complete.
system can deliver the power demands. If the
Go to Step V.
power demands are reduced the engine should
• If diesel engine never cycles on and PID 133 shut down because the SOC will go over 68%.
“Battery SOC” is less than 23%, concern with
• If the PID 152 “Request Engine Run” reads 0
engine. The hybrid system will attempt to start
(No Request) and PID 133 “Battery SOC” is
the engine when the SOC goes below 23%.
greater than 68%, contact Eaton at
1-800-826-HELP (4357).
• If diesel engine never cycles on and PID 133
• If PID 152 “Request Engine Run” reads 1
“Battery SOC” is greater than 23%, battery
(Request), the Body Controller is requesting
SOC must be below 23% before the hybrid
the engine to remain on. This may be a leak in
system will request the engine to start.
the air system or a low 12-volt system.
Continue to operate the hydraulic controls until
Contact the OEM for repair procedure.
the engine comes on.
• If Diesel engine cycles on and never shuts Parameter Reading
down, and PID 133 “Battery SOC” is less than
68%, go to Step E. PID 152 “Request
Engine Run”
• If diesel engine cycles on and never shuts
down, and PID 133 “Battery SOC” is greater PID 133 “Battery SOC”
than 68%, go to Step E.
Parameter Reading

Purpose: Visually observe the Gear Display after Purpose: Confirm "ePTO Mode Confirmation"
F power up. H signal.
1. Observe the Gear Display: 1. Connect ServiceRanger to the 9-Way

Diagnostic Connector.
• If gear display shows a solid “N” or number,
go to Step G. 2. View the Data Monitor parameter PID 164 “ePTO
Mode Confirmation”:
• If gear display shows a “PD”, the vehicle is in a
diagnostic mode. To exit this mode, turn key • If PID 164 “ePTO Mode Confirmation” reads 1
off for 2 minutes and then turn key back on. (True), go to Step I.
Go to Step F.
• If PID 164 “ePTO Mode Confirmation” reads 0
(False), go to Step M.
Parameter Reading
Parameter Reading
Gear Display PID 164 “ePTO
Mode Confirmation”
Purpose: Verify the Neutral light is operational.

G Purpose: Confirm "PTO Engaged" signal.
I
1. Press the N on the Push Button and observe the
light: 1. View the Data Monitor parameter PID 149
“PTO Engaged”:
• Light is displayed solid, go to Step H.
• If PID 149 “PTO Engaged” reads 1 (Engaged),
• Light is flashing, repair the concern with the
go to Step J.
transmission not achieving neutral. Go to the
“Hybrid Diagnostic Procedure” on page 8. • If PID 149 “PTO Engaged” reads 0
(Disengaged), contact Eaton at
1-800-826-HELP (4357).
Parameter Reading
PID 149 “PTO Engaged”

Purpose: Confirm “ePTO Request” signal. Purpose: Verify "Hydraulic Demand" and "Battery
J K SOC" status during hydraulic operation.
1. View the Data Monitor parameter PID 163 1. Operate the Hydraulic Lift while monitoring the
“ePTO Request”: Data Monitor parameters:
• If PID 163 “ePTO Request” reads 1 (True), - PID 151 “Hydraulic Demand” located in the
contact Eaton at 1-800-826-HELP (4357). “ePTO” list
- PID 133 “Battery SOC” located in the “HV
• If PID 163 “ePTO Request” reads 0 (False), Battery” list
concern is with mechanical problem to the
PTO, electrical power to PTO circuit, air • If PID 151 “Hydraulic Demand” reads 1
pressure, or signal wire from PTO. Contact the (Demand) and PID 133 “Battery SOC” is
OEM for repair procedures. greater than 23%, concern is with the PTO
Pump. Contact the OEM for repair procedure.
Parameter Reading • If PID 151 “Hydraulic Demand” reads 1
(Demand) and PID 133 “Battery SOC” is less
PID 163 “ePTO Request” than 23%, concern is engine not starting to
recharge the hybrid System. The hybrid
system will request the engine to start when
the SOC is less than 23%. Contact the OEM for
repair procedures.
• If PID 151 “Hydraulic Demand” reads 0 (No
Demand), concern is with lack of hydraulic
demand on the HCM from the Body Controller
which can be caused by a faulty pressure
switch/transducer. Contact the OEM for repair
procedure.
Parameter Reading
PID 151 “Hydraulic

Demand”

Purpose: Confirm "Hyrdulic Demand" signal. Purpose: Verify no output speed, transmission. is
L N in neutral and no gear is requested.
1. Release the hydraulic controls. 1. View the following Data Monitor parameters from
the “Hybrid Transmission” list and make sure they
2. Connect ServiceRanger and select the Data
match the required values:
Monitor option.
- PID 191 Output Shaft Speed = 0 RPM
3. View PID 151 “Hydraulic Demand” under the - SPN 524 Select Gear = 0
ePTO list:
- SPN 523 Current Gear = 0
• If PID 151 “Hydraulic Demand” reads 1
• If all the parameters on ServiceRanger match
(Demand), concern with the constant
the values shown, go to Step O.
Hydraulic demand from the Body Controller.
Contact the OEM for repair procedures. • If the parameters on ServiceRanger do not
match the values shown, turn the ignition key
• If PID 151 “Hydraulic Demand” reads 0
off for two minutes then power back up and
(No Demand), contact Eaton at
read the values again. If the values still do
1-800-826-HELP (4357).
not match, contact Eaton at
1-800-826-HELP (4357).
Parameter Reading
PID 151 “Hydraulic Parameter Reading

Demand”
PID 191 “Output Shaft
Speed”
SPN 524 “Select Gear”
SPN 523 “Current Gear”
Purpose: Verify no Active fault codes.

M
1. Key on.
Connector.
3. Ensure there are no TECU or HCM fault codes 66,
87, 18, 97, or 8.
• If no fault codes present, go to Step N.
• If fault codes are present, go to the “Hybrid
Diagnostic Procedure” on page 8.

Purpose: Confirm "OK to Crank" status. Purpose: Verify repair.

O V
1. View the following Data Monitor parameters from 1. Key off.
the “Hybrid ePTO” list and make sure they match
the required values:
- PID 153 “OK to Crank” = 1 3. Key on.
• If PID 153 “OK to Crank” reads "1", contact 4. Place Shift Control into ePTO Mode:
Eaton at 1-800-826-HELP (4357). • If PTO system operates, test is complete.
• If PID 153 “OK to Crank” reads "0", concern is • If PTO system does not operate, find error in
with the Hood Switch reading an open or the testing, go to Step A.
Parking Brake Switch reading not applied.
Parameter Reading
PID 153 “OK to Crank”

Wiring Diagrams | Appendix TRTS1000
Wiring Diagrams

TRTS1000 Appendix | Wiring Diagrams

Wiring Diagrams | Appendix TRTS1000
Hybrid Transmission ECU System

Harness
Transmission ECU
For Transmission
18
Diagnostics 19
A
B
C
Rail select
20
sensor
10
11
A
B Gear select
C
12 sensor
B A 7 A
B
8
Input shaft
C D speed sensor
23 A
B
24
Output shaft
speed sensor
B 17
C 31
A 25
Rail select
motor
4-way 35
37
B - Service Bat. + 36 Electric

38
C - Service Bat. - shifter
Gear select
A - Service Ignition +
motor

Connector Pin Descriptions | Appendix TRTS1000
Connector Pin Descriptions

Hybrid and Transmission Connector Pins
HCM - Hybrid System Interface Connector
HCM - Vehicle Interface Connector
TECU - Vehicle Interface Connector
TECU and HCM Connectors

Terminal Side - Harness Connector Terminal Side - Harness Connector
(HCM - Hybrid System Interface Connector) (HCM - Vehicle Interface Connector)
29 34 29 34
23 23 28
28
37 38 37 38
13 22 13 22
35 36 35 36
12 7 12
7
6 1 6
1
Terminal Side - Harness Connector

6
7
12
36 35
22 13
38 37
28 23
34 29
Caution: Please note the location and orientation of the HCM and TECU connectors.
! The backshell should always face down on the harness connectors.

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
Ignition TECU 35 10A Fused Switched Power 12 GXL or
from Ignition Bus 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

TRTS1000 Appendix | Connector Pin Descriptions
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
12v Cranking Relay Minus HCM 4 12v 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 Light HCM 23 4-Way Service Connector D 18 TXL
PTO Request (Non J1939 BCU) HCM 24 BCU 18 TXL
Not Used 25 Plug
12v Cranking Relay Latch HCM 26 12v 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
12v Cranking Relay Plus HCM 32 12v Cranking Relay 86 18 TXL
Not Used 33 Plug
Not Used 34 Plug
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

Hybrid Controller 38-Way (Hybrid System Interface Connector)

Not Used 1 Plug
Inverter Enable HCM 2 Fuse 5A 15 18 TXL
Not Used 3 Plug
Coolant Pump & Battery Fan Relay Minus HCM 4 Coolant Pump Relay & Battery 85 18 TXL
Fan Relay
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
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

Inverter connectors
High Voltage AC Amphenol Connector

Phase U Phase W
Ground Strap
Bracket
Phase V Mounting Bracket Ground Strap

Capscrews (M5 0.8 - 6H)
High Voltage DC Yazaki Connector

DC (+) DC (-)

Delphi 56-Way Connector View
14 1
28 15
42 29
56 43

Inverter 56-Way Connector

Gnd 1 Inverter 1 Chassis Ground 18
Gnd 2 Inverter 2 Chassis Ground 18
CAN High 1 Inverter 13 HEV Backbone A 18
CAN High 2 Inverter 14 PEC 1 18
Inverter Enable Inverter 15 HCM 2 18
Relay Box Enable Inverter 16 PEC 6 18
CAN Low 1 Inverter 27 HEV Backbone B 18
CAN Low 2 Inverter 28 PEC 2 18
PreChg + Inverter 29 PEC 17 18
Main (+) + Inverter 30 PEC 9 18
Main (-) + Inverter 31 PEC 13 18
Gnd B Inverter 34 PEC 7 18
Main (+) - Inverter 35 PEC 11 18
Main (-) - Inverter 36 PEC 15 18
Prechg - Inverter 37 PEC 19 18
TMGnd Inverter 38 Temp Sender 2 18
RBSw(+) Inverter 48 Inverter 49 18
RlyOff (B1) Inverter 43 PEC 5 18
RlyOff (O) Inverter 47 Chassis Gnd 18
TM Inverter 50 Temp Sender 1 18
REZ_S4 Inverter 51 Resolver 4 18
REZ_Minus Inverter 55 Resolver 5 18
REZ_Plus Inverter 56 Resolver 6 18

Power Electronics Carrier (PEC) Connectors
Low Voltage Deutsch

19 - Way Connector
High Voltage DC/DC Connector

(Yazaki Connector)
High Voltage DC Connector
High Voltage DC Connector (Yazaki Connector)
(Yazaki Connector)
Mating Connector View

Caution: The PEC 19-way low-voltage connector (Deutsch 19 - Way)
needs to have the back shell and strain
relief such that the unit will not allow
water entry from direct spray.
19 8 9
18 7 10
2
17 6 1 3 11
16 5 4 12
15 14 13

PEC 19-Way Connector

CAN High PEC 1 Inverter 14 18
CAN Low PEC 2 Inverter 28 18
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 87 12
Cooling Relay
Battery Fan Minus PEC 14 Battery Negative - 12
PEC High-Voltage (DC) Connector to Inverter

Description From Pin# To Pin# Wire Diameter
DC + PEC A Inverter A 15 mm²
DC - PEC B Inverter B 15 mm²
Loose Disconnect PEC 1 PEC 2 0.8 mm² (18 AWG)
PEC High-Voltage (DC) Connector to DC/DC Converter

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 mm² (18 AWG)
Loose Disconnect PEC 2 DC/DC Converter 2 0.8 mm² (18 AWG)
Inverter High-Voltage (AC) Connector

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
Inverter High-Voltage (DC) Connector

DC + Inverter A PEC A 15 mm²
DC - Inverter B PEC B 15 mm²
Loose Disconnect Inverter 1 Inverter 2 0.8 mm² (18 AWG)

Electric Clutch Actuator (ECA) Connectors

HCM
Engine Flywheel Speed Sensor

(Eaton Supplied)
30 AMP fuse
G
F
G
F
13
28 A A
27 B B Battery power
(Non-switched power)
run to the Battery
A
B
C
Metri-Pack 8-Way Connector
Metri-Pack 3-Way Connector
E F G H
A B
D C C
B A
ECA 3-Way Connector

Ignition ECA A Not Used Plug
Battery Minus ECA B Chassis Ground Battery - 12
Battery Plus ECA C Fused 30 amp from Vbatt Battery + 12
ECA 8-Way Connector

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

Motor/Generator Connectors
High Voltage AC
Ampenol Connector
Low Voltage Yazaki

Temperature Sensor
Connector
Resolver Connector
Terminal Side - Harness Connector Terminal Side - Harness Connector

Temperature Sensor Resolver
(Yazaki 2-pin connector) (Yazaki 6-pin connector)
Views looking into connectors with wires exiting the opposite side.
Ground Strap
Ground Strap
Bracket
Bottom View

Motor/Generator Resolver Connector

Resolver Signal 3 Motor/Gen 1 EPS Inverter 53 18
Resolver - Motor/Gen 5 EPS Inverter 55 18
Resolver + Motor/Gen 6 EPS Inverter 56 18
Motor/Generator Temperature Sensor Connector

Motor Temp Motor/Gen 1 EPS Inverter 50 18
Motor Temp Gnd Motor/Gen 2 EPS Inverter 38 18
Motor/Generator High-Voltage (AC) Connector

Phase 1 Motor/Gen A Inverter A 4 AWG
Phase 2 Motor/Gen B Inverter B 4 AWG
Phase 3 Motor/Gen C Inverter C 4 AWG

Typical DC/DC Converter Circuit

High Voltage DC
Yazaki Connector DC(-)
Test Port Connection
DC(+) (Not Used)
OEM Connection
12V DC(-)
12V DC(+)
Deutsch 4-Way OEM Connector
! Warning: Remove the 12-volt battery cables prior to work-

ing on the DC/DC Converter.

DC/DC Converter 4-Way Deutsch OEM Connector

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
Converter High-Voltage (DC) Connector

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
Converter 12-Volt Studs

12volt + DC/DC A Battery Positive Post A 2
12volt - DC/DC B Battery Negative Post B 2

Copyright Eaton, 2015.
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 modifications. THIS
INFORMATION IS NOT INTENDED FOR
SALE OR RESALE, AND THIS NOTICE
MUST REMAIN ON ALL COPIES.
Note: Features and specifications 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 spec’ing or service assistance,

call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.
Roadranger: Eaton and trusted partners

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

Eaton Fault Code 21

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Troubleshooting Guide

Eaton Hybrid Drive Systems MY08

© 2015 Eaton. All rights reserved

Fault Isolation Procedures - continued

2015.10.19 © 2015 Eaton. All rights reserved ii

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

iii © 2015 Eaton. All rights reserved 2015.10.19

Warnings & Cautions

! Caution: Follow the specified procedures in the indicated

! Caution: Do not release the parking brake or attempt to

! Caution: To avoid damage to the transmission during

2015.10.19 © 2015 Eaton. All rights reserved 1

2 © 2015 Eaton. All rights reserved 2015.10.19

Insulated Rubber Glove Test and High-Voltage Work Area

Insulated Rubber Glove Test High-Voltage Work Area Requirements

2015.10.19 © 2015 Eaton. All rights reserved 3

High-Voltage Service Shutdown and Power-Up Procedure

A buffer zone must be set up and ASTM Class 0 electrical

The rubber-insulated gloves that must be worn while

Before inspecting or working on any high-voltage cables or

The lockout tagout devices should only be removed by the

ASTM Class 0 electrical insulating rubber gloves with

High-voltage cables and wiring are orange and contain a

4 © 2015 Eaton. All rights reserved 2015.10.19

2015.10.19 © 2015 Eaton. All rights reserved 5

Diagnostic Tools/Service Publications

ServiceRanger version 3 ServiceRanger PC based Diagnostic Tool

J48605 Hybrid Safety Cones (set of 4)

J48506 Lockout Switch Plate

J48906 Lockout Tags (per 25)

J48605 Hybrid Safety Cones (set of 4)

J48506 Lockout Switch Plate

J48906 Lockout Tags (per 25)

J48907 Orange Magnetic Sign

J48608 Hybrid Non-Conductive Safety Pole

J48908 Glove Bag

6 © 2015 Eaton. All rights reserved 2015.10.19

Misc. Service Tools Items listed below are ordered separately

J48624 Nexiq USB-Link Communication Adapter

J43318-A* Pin Adapter Kit - Interface Harness Diagnostics

J48735* Alignment Pins - Hybrid Motor/Gen to Transmission Main Case

AMB-45* Digital Megohmmeter - High-Voltage Leakage Detection

J49111* Clutch Alignment Tool

J46708* Fluke Digital Multimeter

J48505 Input Shaft Turning Socket

J48507 Lifting Fixture - Power Electronics Carrier

J48502 Jack Adapter Plate - Hybrid Drive Unit

5019 Transmission Jack - Low Lift

5078 Transmission Jack - High Lift

J48577 Engine/Transmission Stand Adapter Plate - Hybrid Drive Unit

J29109-A Engine/Transmission Stand - 6000 lb. Rating

TRSM0110 Service Manual (covers internal transmission repairs only)

TRTS1000 Troubleshooting Guide

TRDR1000 Drivers Instructions

TRDR1110 First Responder Guide

CLMT-0365 Eaton 365 mm Clutch Installation Procedure

2015.10.19 © 2015 Eaton. All rights reserved 7

Hybrid Diagnostic Procedure

Is Red "Stop Hybrid" or Go to “Hybrid Light and

Go to "Fault Code Isolation Procedure